Insert-Molded Lace Guide Flanges for Weldable Closure Attachment
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Solution Overview
Problem
Conventional closure systems for articles, such as footwear, are often expensive and complicated to manufacture, making it difficult for manufacturers to integrate reel-based mechanisms, leading to a need for simpler and more cost-effective coupling methods for tightening mechanisms.
Innovation Solution
The development of insert molded components made from thermoplastic materials with integrated lace guides and flange members, allowing for easy attachment to articles like shoes, using thermoplastic elastomers with lower melting temperatures for direct coupling and bonding, and methods like RF welding for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional reel-based closure systems are integrated into footwear, then tightening functionality is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The closure system is divided into separate functional components: a reel mechanism for tightening, a lace guide for routing, and a flange member for attachment. These segments can be manufactured independently and assembled, reducing overall manufacturing complexity while maintaining tightening functionality.
Solution Approach 2:
The flange member serves multiple functions: it provides attachment to the footwear article, supports the reel mechanism, and integrates the lace guide. This multi-functionality reduces the number of separate components needed, simplifying manufacturing while preserving the tightening function.
2Reliability
If conventional reel-based closure systems are integrated into footwear, then tightening functionality is achieved, but manufacturing cost increases
Solution Approach 1:
The lace guide and flange member are merged into a single integrated component that can be molded as one piece. This consolidation reduces the number of parts to manufacture, assemble, and inventory, thereby lowering manufacturing costs while maintaining the necessary tightening functionality.
Solution Approach 2:
The material selection (thermoplastic elastomer with lower melting temperature) enables new manufacturing methods like RF welding and insert molding, which are more cost-effective than traditional assembly methods for conventional closure systems.
3Ease of manufacture
If thermoplastic elastomer flange member is used with lower melting temperature, then direct coupling to article is enabled, but material selection is constrained
Solution Approach 1:
Different parts of the closure system use materials with different properties: the flange member uses thermoplastic elastomer for ease of coupling, while the reel housing uses a different thermoplastic material for structural requirements. This local differentiation allows each component to be optimized for its specific function.
Solution Approach 2:
The system combines different thermoplastic materials (elastomer for flange, other thermoplastic for housing) to achieve both ease of manufacture through direct coupling and the necessary structural properties for the reel mechanism.
4Productivity
If insert molding process is used for assembly, then coupling speed increases, but process complexity increases
Solution Approach 1:
The flange member is pre-formed with integrated lace guides and attachment features before the insert molding process. This preliminary preparation simplifies the actual coupling operation, allowing quick insertion and molding without complex in-process operations.
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
Enables quick and convenient coupling of tightening mechanisms to articles, reducing manufacturing costs and complexity while providing customizable and adjustable lacing systems that enhance fit and comfort.
Implementation Method 1
methods like RF welding for secure fastening
Implementation Method 2
using thermoplastic elastomers with lower melting temperatures for direct coupling and bonding
Data Source
AI summary
According to an embodiment, a component for attachment to an article includes an upper component that is made of a thermoplastic material having a first melting temperature and a flange member that is molded onto the upper component and made of a thermoplastic elastomer material having a second melting temperature that is lower than the first melting temperature of the upper component. The flange member extends laterally from a bottom end of the upper component so that a bottom surface of the flange member is flush with or positioned axially below a bottom surface of the upper component. The melting temperature of the thermoplastic elastomer material enables the flange member to be directly coupled to the article via heat welding and the like without substantially affecting the upper component.