Metallic Surface Layer on Sports Shoe Shell
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Solution Overview
Problem
Conventional sports shoe shells for gliding boards face challenges such as rapid wear and increased weight due to insufficient mechanical properties and aesthetics when interacting with binding devices, and existing solutions either complicate manufacturing or result in an uncomfortable, heavy, and aesthetically poor product.
Innovation Solution
A sports shoe shell with a metallic surface layer applied via metallization on connecting surfaces, such as sidewalks, to enhance wear resistance without altering the shoe's structure, using processes like vacuum or electrolysis metallization, which is cost-effective and compatible with existing manufacturing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bi-injected rigid upper with comfort liner is used, then rigidity and surface hardness at connecting surfaces are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies composite materials by combining a plastic upper material with a metallic surface layer. The metallic layer is deposited onto the plastic surface through vacuum metallization or electrolysis, creating a composite structure that provides the hardness and wear resistance of metal while retaining the flexibility and comfort of the plastic base material. This resolves the contradiction by achieving high surface hardness without requiring complex bi-injection molding processes.
Solution Approach 2:
The metallic surface layer is applied selectively to specific zones of the upper that require enhanced hardness, such as the front and rear curbs that contact the binding device. This localized application provides high surface hardness where needed while maintaining the original plastic material properties in other areas, avoiding the need for complex multi-material injection molding throughout the entire upper structure.
2Strength
If plastic material of high hardness is used in connecting zones, then surface hardness is improved, but wear resistance deteriorates
Solution Approach 1:
The patent uses a composite material system where a metallic layer is deposited onto the plastic upper surface. The metal layer provides both the required surface hardness and superior wear resistance that plastic materials alone cannot achieve. This composite approach resolves the contradiction by combining the advantages of both materials: the plastic provides flexibility and comfort while the metallic coating provides hardness and wear resistance.
Solution Approach 2:
The patent changes the surface properties of the plastic material by applying a metallic coating through vacuum metallization or electrolysis. This parameter change transforms the surface characteristics from plastic-dominated to metal-dominated, achieving the hardness and wear resistance of metal without compromising the underlying plastic material's flexibility and comfort properties.
3Strength
If metal reinforcement is added to plastic structure, then rigidity is improved, but weight increases
Solution Approach 1:
The metallic surface layer is applied only to specific zones of the upper where rigidity and contact with the binding device are required, such as the front and rear curbs. This localized metal coating provides the necessary rigidity in critical areas while keeping the rest of the upper lightweight and flexible, thus resolving the contradiction between rigidity and weight.
Solution Approach 2:
The patent uses a thin metallic film or layer deposited on the plastic upper surface. This thin film provides the required rigidity and surface properties without adding significant weight, as the metallic layer is applied as a surface coating rather than a thick structural reinforcement. The base plastic material remains flexible and lightweight while the thin metal layer provides enhanced surface properties.
4Strength
If large amount of metal is used in shell, then surface hardness is improved, but comfort and thermal properties deteriorate
Solution Approach 1:
The metallic surface layer is applied selectively only to the zones requiring high surface hardness, such as the front and rear curbs that contact the binding device. The majority of the upper structure remains made of flexible plastic material that provides comfort and flexibility. This localized approach resolves the contradiction by providing metal hardness only where needed while maintaining comfort properties in the contact areas with the foot.
Solution Approach 2:
The patent creates a composite structure where a thin metallic layer is combined with a plastic base material. The plastic material provides flexibility, comfort, and thermal insulation properties, while the thin metal layer provides surface hardness and wear resistance. This composite approach resolves the contradiction by combining the advantages of both materials without the disadvantages of using large amounts of metal.
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 solution provides effective surface resistance and attractive aesthetics while maintaining minimal weight and simplicity, significantly reducing premature wear and enhancing mechanical properties without increasing the shoe's complexity or weight.
Implementation Method 1
a metallic surface layer is applied, in particular on its connecting surfaces, to a sports shoe shell by a metallization process
Implementation Method 2
using processes like vacuum or electrolysis metallization
Implementation Method 3
using processes like vacuum or electrolysis metallization
Data Source
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AI summary
The sport shoe shell (2) for a gliding board e.g. skiboard, comprises a plastic material part and a connection surface to co-operate with a fixation device of the gliding board. The plastic material part is covered by a fine layer of metallic surface on a front (4) or rear platform (3). The metallic surface layer is obtained by bonding at a level of the connection surface, has a thickness between few nanometers and few micrometers, and presents a physical, mechanical or chemical attachment on the plastic material surface. The platform has a horizontal zone to receive a machinery support. The sport shoe shell (2) for a gliding board e.g. skiboard, comprises a plastic material part and a connection surface to co-operate with a fixation device of the gliding board. The plastic material part is covered by a fine layer of metallic surface on a front (4) or rear platform (3). The metallic surface layer is obtained by bonding at a level of the connection surface, has a thickness between few nanometers and few micrometers, and presents a physical, mechanical or chemical attachment on the plastic material surface. The platform has a horizontal zone to receive a machinery support of the fixation device. The metallic surface layer vertically extends on above and below the horizontal zone of the platform. Independent claims are included for: (1) a sport shoe; and (2) a process for manufacturing a sport shoe shell.