Knitted Fabric Sole Structure with Fused Thermoplastic Elastomer
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Solution Overview
Problem
Existing methods for making shoe soles with compressible elastomers are limited in color and pattern variations, and when using knitted fabrics for both the upper and sole, the sole can detach during vigorous exercise, leading to damage.
Innovation Solution
A method involving a knitted fabric with a thermoplastic filling material, sealed and molded to create a sole structure with a compressible elastomer, where the knitting texture is fused with the surface of the elastomer, allowing for varied colors and patterns and increased structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a knitted fabric is used for both the upper and sole to achieve fine visual changes, then the visual appeal is improved, but the structural strength deteriorates causing the sole to detach during vigorous exercise
Solution Approach 1:
The patent combines knitted fabric with thermoplastic filling material to create a composite sole structure. The knitted fabric provides the knitting texture and visual appeal, while the thermoplastic material provides structural strength and compression resistance. This composite approach allows the sole to maintain both aesthetic qualities and mechanical integrity during vigorous exercise.
Solution Approach 2:
The patent utilizes thermoplastic material that changes its physical properties with temperature. During molding, the thermoplastic material is heated to become pliable and fuse with the knitted fabric, then cooled to become rigid and provide structural support. This parameter change allows the same material to serve both manufacturing and structural functions.
2Reliability
If compressible elastomer is used for the sole to provide compression, then the comfort is improved, but the color and pattern variations are limited to single color or monotonous patterns
Solution Approach 1:
The patent applies different materials to different regions of the sole. The thermoplastic filling material provides compression functionality in the bulk, while the knitted fabric surface layer provides color and pattern variations. This local differentiation allows each material to excel at its specific function without compromising the other.
Solution Approach 2:
The patent adds a dimensional layering approach where the knitted fabric serves as a surface layer with visual properties, while the thermoplastic material forms the bulk structure with compression properties. This multi-layer dimensional structure enables both compression function and color/pattern versatility to coexist.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the creation of a visually appealing sole with unique patterns and enhanced durability by integrating a compressible elastomer with a knitting texture, reducing the likelihood of damage during use.
Implementation Method 1
applying a heating temperature to melt the thermoplastic filling material of the knitted fabric
Implementation Method 2
applying a heating temperature to melt the thermoplastic filling material of the knitted fabric
Implementation Method 3
placing the knitted fabric with the opening sealed into a mold, applying a heating temperature to melt the thermoplastic filling material of the knitted fabric, and restricting a shape of the knitted fabric via the mold
Data Source
AI summary
The present invention provides a method for making a sole structure with a knitted fabric and a sole structure. The method comprises steps of: placing a thermoplastic filling material in a knitted fabric, sealing an opening of the knitted fabric, placing the knitted fabric with the opening sealed in a mold, applying a heating temperature to melt the thermoplastic filling material of the knitted fabric, and restricting a shape of the knitted fabric via the mold to make a sole structure. The sole structure includes a compressible elastomer and a knitting texture wrapped around the compressible elastomer and fused with a surface of the compressible elastomer. The compressible elastomer is formed from the thermoplastic filling material after being melted and cooled. The knitting texture is formed from the knitted fabric and is capable of being directly observed from an appearance of the sole structure.