Integrated Plastic Shell Skate One-Step Injection Molding

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Solution Overview

Problem

The traditional manufacturing process of ice skates and roller skates is cumbersome, inefficient, and environmentally harmful, with complex inner sleeve production, inaccurate glue application, and health risks due to harmful materials.

Innovation Solution

An integrated plastic shell skate design where the shoe inner sleeve and plastic shoe shell are formed as a whole through one-step injection molding, eliminating the need for stitching and glue application, and allowing for interchangeable inserts to produce different skate styles in the same mold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing process with separate inner sleeve and plastic shell is used, then production flexibility is maintained, but manufacturing complexity increases and production efficiency decreases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the inner sleeve and plastic shell into a single integrated structure formed by one-step injection molding. The inner sleeve is first formed in the mold cavity, then plastic material is injected to form the shell around it, creating a unified structure that eliminates separate manufacturing and assembly steps, thereby improving productivity and reducing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a universal mold structure that can produce different styles of skates by simply changing the insert components. The base mold remains the same, but different inserts (such as blade inserts, roller inserts, or hockey stick inserts) can be swapped to create various skate types, enabling multi-functionality and flexibility in production while maintaining simplified manufacturing processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If traditional stitching and glue application methods are used, then assembly flexibility is maintained, but manufacturing time increases and quality consistency decreases

Engineering Contradiction:

Improveconnection accuracyVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces the mechanical assembly processes of stitching and glue application with a single injection molding process. The plastic material is injected under pressure to form the shell that is inherently connected to the inner sleeve, eliminating the need for separate mechanical fastening operations. This substitution achieves precise connection accuracy while significantly reducing production time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If harmful glue materials are used for assembly, then bonding strength is achieved, but health safety deteriorates and environmental harm increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidhealth and environmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and eliminates the harmful glue materials from the manufacturing process entirely. By using one-step injection molding, the connection between the inner sleeve and plastic shell is achieved through the molded structure itself rather than through chemical adhesives. This removal of harmful substances maintains connection reliability while eliminating health and environmental hazards.

Inventive Principle:

Principle #2Taking out (Extraction)

4Manufacturing precision

If manual glue application by workers is used, then positioning flexibility is maintained, but manufacturing precision decreases and labor intensity increases

Engineering Contradiction:

Improveglue positioning accuracyVSAvoidoperational difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent implements a self-positioning mechanism through the mold design itself. The mold cavity is configured to automatically position the inner sleeve and guide the plastic material flow during injection, ensuring precise connection without requiring manual intervention for positioning. This self-service approach eliminates the need for workers to manually apply glue and position components, thereby improving manufacturing precision and reducing operational difficulty.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20220022593A1Integrated plastic shell skate

Publication Date: 2022.01.27 JIANG FENG

AI summary

An integrated plastic shell skate is provided, including ice skates and roller skates, which includes a shoe inner sleeve, a plastic shoe shell and a shoe rack assembly, the shoe rack assembly is fixedly installed at the bottom of the plastic shoe shell, the shoe inner sleeve is formed by pressing once in the inner sleeve cold pressing die after pre-heating, and the plastic shoe shell is formed on the outer side of the shoe inner sleeve through the shoe shell mold, so that the plastic shoe shell and the shoe inner sleeve are integrated formed as a whole. The present disclosure has the characteristics of portability, comfort, safety, environmental protection, firmness and durability.