Multilayer Insole Conductive Resin Design
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Solution Overview
Problem
Traditional insoles for safety footwear lack effective antistatic and conductive properties, with existing solutions being laborious to implement, prone to wear, and uncomfortable due to conductive seams or expensive conductive fabrics, while also failing to provide consistent electrical conductivity across the surface.
Innovation Solution
A multilayer insole design featuring a non-conductive fabric treated with a conductive resin on one layer and an antistatic/conductive polymeric material on another, ensuring uniform conductivity without seams, using a fabric with localized application of conductive resin for broad surface coverage and a soft cushioning layer for comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive seam made with wire is used to achieve electrical conductivity, then electrical conduction is achieved, but the implementation becomes complicated and laborious, and the seam is prone to wear and breakage
Solution Approach 1:
The patent extracts the conductive function from the complex seam construction and integrates it directly into the insole material itself. The insole is made from a conductive polymer composite material that provides electrical conductivity throughout the entire structure, eliminating the need for separate conductive seams and wires.
Solution Approach 2:
The patent uses a composite material consisting of a polymer matrix combined with conductive particles or fibers. This composite material provides both the structural integrity of the insole and the electrical conductivity function, eliminating the need for separate conductive components like seams and wires.
2Reliability
If a conductive seam is used to provide electrical conductivity, then conduction is achieved at wire locations, but the foot may be in contact with areas where conductive seaming is not present, resulting in loss of current flow
Solution Approach 1:
The patent applies conductive material throughout the entire insole structure, ensuring that every area of the insole that contacts the foot also provides electrical conductivity. This eliminates the problem of non-conductive areas between conductive seams.
Solution Approach 2:
The insole material itself performs multiple functions: it provides structural support, cushioning, and electrical conductivity simultaneously. The conductive polymer composite material serves as both the structural component and the conductive element, eliminating the need for separate conductive seams.
3Reliability
If a conductive seam made with metallic thread is used, then electrical conductivity is achieved, but the presence of the seam is not optimal for user comfort and can be annoying during prolonged wear
Solution Approach 1:
The patent removes the uncomfortable metallic seam from the insole structure and replaces it with an integrated conductive polymer material. This eliminates the foreign object sensation and discomfort caused by metallic threads while maintaining electrical conductivity.
Solution Approach 2:
The patent changes the material parameter from metallic thread to polymer composite material. This material substitution maintains electrical conductivity while significantly improving comfort by eliminating the rigid, irritating metallic elements.
4Reliability
If conductive fabrics made with antistatic wires are used, then electrical conductivity is achieved, but the production costs become extremely high and the manufacturing methods are onerous and laborious
Solution Approach 1:
The patent uses a composite material approach where conductive particles or fibers are incorporated into a polymer matrix during the manufacturing process. This integrated approach is more cost-effective and easier to manufacture compared to using expensive conductive fabrics with metallic wires.
Solution Approach 2:
The patent changes the conductive material parameter from expensive metallic wires to more affordable conductive particles or fibers embedded in a polymer matrix. This material substitution significantly reduces production costs while maintaining electrical conductivity.
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 multilayer insole achieves consistent antistatic or conductive properties across its surface, maintaining electrical connectivity with the shoe midsole regardless of foot position, offering comfort, durability, and resistance to abrasion while adhering to European standards for electrical resistance.
Implementation Method 1
an electrically conductive resin (12) is applied to said first layer (2) which penetrates and crosses said first layer (2) to allow passage, only in correspondence with at least one zone of said first layer (2), of the electric charges through the first layer (2) towards said second layer (4)
Implementation Method 2
an underlying second layer (4) which is made of antistatic and/or conductive polymeric material
Data Source
Figure 1~5
AI summary
Perfected multi-layer (1) antistatic and/or conductive for insoles (10), characterized in that it consists of an assembly of overlapping layers, said assembly comprising: - a first layer (2) of fabric which is intended to be facing and/or in contact, preferably by means of a sock, with the foot of the user wearing the shoe, inside which is inserted the insole (10) made with said multilayer (1), - a second layer (4) in antistatic and/or electrically conductive polymeric material intended to be in contact with the midsole of the shoe, inside which the insole (10) made with said multilayer (1) is inserted, and characterized in that: - said first layer (2) is in non-conductive material fiber fabric and has no surface seams in conductive material, - said second layer (4) is entirely and completely positioned below the first layer (2), and - an electrically conductive resin (12) is applied to said first layer (2) in non-conductive fiber fabric, in correspondence with at least one area of said first layer (2), which is in a different material than said second layer (4) and which penetrates and passes through said first layer (2) to allow the passage, only at at least one area of said first layer (2), of the electric charges through the first layer (2) towards said second layer (4).