Laser-Patterned Footwear Surfaces Without Complex Molds
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Solution Overview
Problem
Traditional methods for incorporating structural features and decorative designs into footwear are complex, costly, and time-consuming, often requiring expensive multi-component molds and labor-intensive processes, making it difficult to manufacture customized athletic footwear efficiently.
Innovation Solution
The use of laser technology to create precise structural and aesthetic features on footwear surfaces, such as midsoles, without the need for complex molds or additional materials, by marking or engraving patterns and colors using UV or CO2 lasers, and applying masking mediums and fluids to support the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-component molds and manual processing are used to create structural features and decorative designs, then manufacturing precision and customization capability are improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical molding processes with laser technology. Lasers directly write structural features and decorative designs onto the footwear surface through ablation or melting, eliminating the need for complex multi-component molds and manual processing steps while maintaining high precision.
Solution Approach 2:
The patent changes the physical state and properties of the footwear material through controlled laser parameters (energy density, pulse duration, wavelength). By adjusting these parameters, the laser can create different structural features and decorative effects without changing the fundamental material composition, thereby simplifying the manufacturing process.
2Adaptability or versatility
If traditional manufacturing processes are used to create customized footwear, then structural features and decorative designs can be achieved, but productivity decreases due to time-consuming manual processing
Solution Approach 1:
The laser system enables automated direct writing of structural features and decorative designs, replacing time-consuming manual processing. The laser can rapidly create customized patterns and structures by simply changing the digital design file, dramatically improving productivity while maintaining full customization capability.
Solution Approach 2:
The patent implements a dynamic manufacturing process where laser parameters (power, speed, pulse frequency) can be adjusted in real-time during processing. This allows the system to adapt to different material types, feature complexities, and customization requirements without stopping the manufacturing process, thereby maintaining high productivity.
3Manufacturing precision
If complex multi-component molds are used to manufacture footwear with structural features, then manufacturing precision is improved, but loss of substance increases due to material waste from multiple components
Solution Approach 1:
The patent merges multiple separate manufacturing operations into a single laser processing step. The laser can create both structural features and decorative designs in one pass, eliminating the need for multiple components and assembly steps, thereby reducing material waste while maintaining precision.
Solution Approach 2:
By replacing mechanical molding with laser direct writing, the patent eliminates material waste associated with mold release agents, parting lines, and flash from multi-component molding. The laser ablates or melts material precisely where needed without generating excess waste material.
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 method allows for the cost-effective and efficient creation of customized, personalized footwear with optimized performance and aesthetic characteristics, reducing manufacturing complexity and costs while enabling precise control over structural and decorative features.
Implementation Method 1
directing a laser beam from the laser to the surface of the object to mark or engrave at least a portion of the surface of the object
Implementation Method 2
Marking the surface of the object may include changing a color of at least a portion of the surface of the object without removing material therefrom
Data Source
AI summary
The invention relates to footwear and portions thereof having structural features and decorative designs thereon, and related systems and methods for manufacturing same. An exemplary method for providing a feature on a surface of an object includes positioning a laser proximate the surface of the object, directing a laser beam from the laser to the surface of the object to mark or engrave at least a portion of the surface of the object, and moving at least one of the laser and the object to create a pattern on the surface of the object, the pattern providing at least one of an aesthetic and a structural feature on the surface of the object.