Knitted Foamed-Thread Sole to Reduce Manufacturing Steps and Waste
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Solution Overview
Problem
Conventional sole structure manufacturing processes are inefficient due to the complexity and number of steps required, leading to increased time and waste material as the number of material elements increases, particularly in forming midsoles and outsoles.
Innovation Solution
A method involving the extrusion of non-foamed plastic threads, which are then knitted and undergo a foaming process to form foamed plastic threads, allowing for the creation of sole components with reduced material elements and streamlined manufacturing, such as using foamed threads in footwear soles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple material elements are incorporated into the midsole and outsole to improve sole structure functionality, then the sole structure performance is improved, but the manufacturing time and expense increase
Solution Approach 1:
The patent combines multiple material elements (foamed thread for cushioning, non-foamed plastic thread for structure, polyurethane coating for stiffness) into a single knitted sole component. This merging approach allows all functional elements to be integrated in one manufacturing process rather than assembled separately, improving sole structure performance while reducing manufacturing time and complexity.
Solution Approach 2:
The patent uses composite materials by knitting together different types of threads (foamed and non-foamed plastic) with different properties in the same fabric structure. This allows the sole to exhibit multiple functions (cushioning, structural support, stiffness) simultaneously within a single component, resolving the contradiction between performance and manufacturing efficiency.
2Reliability
If multiple material elements are incorporated into the midsole and outsole to improve sole structure functionality, then the sole structure performance is improved, but the manufacturing expense increases
Solution Approach 1:
The patent merges multiple material elements into a single knitted component that can be produced in one continuous manufacturing process. This eliminates the need for separate procurement, inventory management, cutting, and assembly operations for multiple sole components, thereby reducing manufacturing expense while maintaining enhanced sole structure performance.
Solution Approach 2:
The knitted sole component serves multiple functions simultaneously through its composite construction - foamed threads provide cushioning, non-foamed threads provide structural integrity, and polyurethane coating provides stiffness. This multi-functionality in a single component reduces the need for multiple specialized components, lowering overall manufacturing expense.
3Reliability
If multiple material elements are incorporated into the midsole and outsole to improve sole structure functionality, then the sole structure performance is improved, but waste material from cutting and stitching processes increases
Solution Approach 1:
The patent combines all necessary sole structure elements into a single knitted fabric that can be cut to final shape with minimal waste. By integrating cushioning, structural, and stiffness-providing elements into one continuous fabric before cutting, the process eliminates waste generated from assembling multiple separate components, reducing material loss while maintaining performance.
4Productivity
If the number of steps to form the midsole and outsole is decreased to improve manufacturing efficiency, then productivity increases, but manufacturing precision may be compromised
Solution Approach 1:
The patent performs preliminary action by knitting all material elements into a single integrated fabric before the cutting stage. This preliminary integration ensures that material placement precision is achieved during the knitting process itself, allowing subsequent cutting to proceed with minimal steps while maintaining high manufacturing precision. The foamed and non-foamed threads are precisely positioned in the knit structure before final cutting.
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
This approach reduces the time and material required for sole structure formation, increases manufacturing efficiency, and allows for precise material usage and varied properties in the sole components, such as enhanced stiffness and cushioning through the use of polyurethane coating and foamed threads.
Implementation Method 1
causing the non-foamed plastic thread to undergo a foaming process to form a knitted component with foamed plastic threads
Implementation Method 2
The knitted components may be coated in polyurethane to increase stiffness or rigidity
Data Source
AI summary
In one embodiment a non-foamed thread is formed by extruding a mixture with a plastic material and a blowing agent. The non-foamed thread is arranged into a sole component and then heated to activate the blowing agent and cause the threads to foam. In some cases, the non-foamed thread is knitted together.