Microwave Foaming Shoe Insole Manufacturing
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Solution Overview
Problem
Conventional injection molding methods for producing plastic/rubber molded bodies, such as shoe insoles, require high-temperature resistant molds and machines, leading to high costs and complex configurations, limiting the development of varied structures and designs.
Innovation Solution
A method involving a shoe last and upper with a foam matrix material of semi-foamed thermoplastic polyurethane granules, where microwave heating causes the granules to foam and bond with the upper, forming an integral insole without additional processing steps, allowing for varied granule sizes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional injection molding is used to manufacture plastic/rubber molded bodies, then the manufacturing process is well-established, but the equipment complexity and cost increase due to requiring high-temperature resistant molds and machines
Solution Approach 1:
The patent replaces the conventional mechanical injection molding system with a microwave heating system. The semi-foamed granules are heated by microwave radiation, causing them to expand and bond directly to the upper, eliminating the need for complex high-temperature molds and injection molding machines.
Solution Approach 2:
The patent changes the heating method from conventional thermal heating to microwave heating. This parameter change allows the material to be processed at lower temperatures without requiring high-temperature resistant equipment, thereby simplifying the manufacturing system while maintaining product quality.
2Ease of manufacture
If conventional injection molding is used, then manufacturing infrastructure is established, but the cost of production increases due to high-temperature resistant molds and machines
Solution Approach 1:
The patent replaces expensive high-temperature resistant molds and injection molding machines with a simpler microwave heating system. This substitution significantly reduces equipment investment and operating costs while maintaining the ability to produce high-quality molded bodies.
Solution Approach 2:
The patent uses semi-foamed granules that can be easily processed and disposed of after use. The granules are heated, expanded, and bonded to the upper, then the excess material is trimmed away, eliminating the need for expensive reusable molds and reducing material waste costs.
3Adaptability or versatility
If conventional injection molding is used, then production efficiency is maintained, but the ability to create varied structures and designs is limited
Solution Approach 1:
The patent uses semi-foamed granules of different sizes and configurations that can be selectively arranged and positioned on the upper before microwave heating. This segmentation allows for varied structures and designs to be created by adjusting granule distribution, while the microwave heating process maintains production efficiency through a simple, rapid transformation.
Solution Approach 2:
The patent employs a dynamic microwave heating process that can be controlled to achieve different foam expansion levels and bonding strengths. This dynamic control allows the same basic process to produce varied structures and designs, enhancing design flexibility without compromising production efficiency.
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 simplifies the manufacturing process, reduces costs, and enhances the intricacy and applicability of foam molded bodies by creating a fully integrated shoe structure with a bonded insole, offering improved microstructure retention and uniform heating.
Implementation Method 1
heating the shoe last with the upper and the foam matrix material thereon by microwave, so that the first semi-foamed granules are foamed
Implementation Method 2
the first semi-foamed granules are foamed to form an insole bonded to the upper
Data Source
AI summary
A method of manufacturing a shoe structure includes: a setting step of setting an upper on a shoe last, and distributing a foam matrix material comprising a plurality of semi-foamed granules of thermoplastic polyurethanes (TPU) along a bottom of the shoe last to position the foam matrix material between the shoe last and the upper, and a foaming step of heating the shoe last with the upper and the foam matrix material thereon by microwave, so that the semi-foamed granules are foamed to form an insole bonded to the upper, and the upper is shaped along a contour of the shoe last after cooling and removing the shoe last.