Laser Partial Vulcanization of Rubber Shoe Soles
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Solution Overview
Problem
The conventional method of manufacturing shoe soles is time-consuming and costly due to the need for multiple molds for various sizes and designs, limiting flexibility and increasing production costs.
Innovation Solution
A method involving partial vulcanization of uncured rubber using laser irradiation to pattern and shape the rubber, allowing for customization before full vulcanization, eliminating the need for molds and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional vulcanization method with molds is used, then shoe soles can be produced with fixed shapes and patterns, but production time increases and manufacturing cost increases due to need for multiple molds
Solution Approach 1:
The patent applies preliminary action by partially vulcanizing the rubber sheet before final molding. The rubber is pre-treated with peroxide and heated to initiate partial vulcanization, creating a base structure that can then be efficiently molded. This preliminary preparation reduces the complexity and time required for the final molding process.
Solution Approach 2:
The vulcanization process is segmented into two distinct stages: partial vulcanization using peroxide and heat treatment, followed by complete vulcanization during molding. This segmentation allows each stage to be optimized independently, reducing overall production time while maintaining shape accuracy.
2Adaptability or versatility
If multiple molds are made for various shoe sizes and designs, then different shoe sole specifications can be produced, but manufacturing cost increases significantly
Solution Approach 1:
The patent creates a universal partially vulcanized rubber sheet that can serve multiple purposes. Instead of creating specialized molds for each design, the same base rubber sheet can be molded into different shapes and sizes, making the manufacturing process more versatile and cost-effective.
Solution Approach 2:
The patent changes the physical and chemical parameters of the rubber through partial vulcanization, transforming it from a completely uncured state to a partially cured state with specific mechanical properties. This parameter change enables the rubber to be more easily shaped and molded while reducing the need for multiple specialized molds.
3Stability of the object's composition
If uncured rubber is completely vulcanized in mold, then outsole shape and pattern are fixed, but additional cut or scribe processes are needed to modify shapes or patterns
Solution Approach 1:
The patent performs preliminary partial vulcanization before molding, creating a stable base structure that maintains its composition while still allowing for efficient final shaping. This preliminary action prevents the need for additional cutting or scribing operations after complete vulcanization.
Solution Approach 2:
The patent applies partial vulcanization rather than complete vulcanization in the initial stage. This partial action is sufficient to stabilize the rubber's composition and enable efficient molding, eliminating the need for additional post-processing steps while maintaining complete vulcanization in the final product.
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 production time and costs by enabling easier customization and assembly, providing a more efficient and cost-effective method for manufacturing shoe soles without the need for molds, while maintaining quality and design variability.
Implementation Method 1
laser beam is applied to irradiate a portion of the uncured rubber sheet in order to pattern the uncured rubber sheet and partially vulcanize the uncured rubber sheet at the same time
Implementation Method 2
partially vulcanize the uncured rubber sheet
Data Source
AI summary
Disclosed herein is a novel method of preparing shoe sole. The method of preparing shoe sole includes irradiating an uncured rubber sheet by laser beam to pattern and vulcanize a portion of the uncured rubber, tailoring the partially patterned vulcanized rubber into a shoe shape, and afterward fully vulcanizing the partially patterned vulcanized rubber sheet to form a shoe sole. An additional step of assembling the upper panel of shoe sole on the partially vulcanized rubber sheet is also performed.