Method for manufacturing a polymeric component with injected, embedded ink
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Solution Overview
Problem
Existing methods for manufacturing polymeric components, such as those in footwear, often result in graphical images that are not durable and can be easily removed due to surface scuffing, as they are applied directly to the outer surface rather than being embedded within the material.
Innovation Solution
A method involving the injection of ink into polymeric components through a predetermined depth, where it is embedded between layers, ensuring the image remains intact even when the outer surface is scuffed, using a process that includes multiple layers with a barrier layer impermeable to fluids, and controlled needle insertion and ink flow to prevent damage to the barrier layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ink is applied to the outer surface of the polymeric component, then the manufacturing process is simple, but the graphical image lacks durability and can be easily removed by scuffing
Solution Approach 1:
The patent transitions from two-dimensional surface printing to three-dimensional embedded ink injection. The needle penetrates the polymeric component to inject ink at a predetermined depth, creating a graphical image that exists within the thickness of the material rather than merely on the surface, thereby achieving both durability and manufacturing feasibility
Solution Approach 2:
The ink is nested within the polymeric component structure. The graphical image is embedded inside the material layers, with the ink contained within the polymeric matrix, protecting it from external damage while maintaining the integrity of the component structure
2Reliability
If ink is injected deeply into the polymeric component to ensure durability, then the graphical image becomes resistant to scuffing, but the barrier layer may be compromised
Solution Approach 1:
The patent precisely controls the injection parameters, specifically the needle penetration depth and ink injection pressure. The needle penetrates to a predetermined depth that is sufficient to embed the ink within the polymeric component for durability but controlled to prevent puncturing through the barrier layer, thus maintaining the balance between image durability and layer integrity
Solution Approach 2:
The ink is injected at a specific local depth within the polymeric component rather than uniformly throughout. The graphical image is created in a localized region between the outer surface and the barrier layer, ensuring durability in the image area while preserving the barrier layer's impermeability
3Ease of operation
If the needle penetrates completely through the polymeric component to inject ink, then the injection process is straightforward, but the barrier layer becomes impermeable compromised
Solution Approach 1:
The needle penetration depth is predetermined and controlled before injection. The system is configured to stop needle advancement at a specific depth that prevents complete penetration through the barrier layer, while still allowing straightforward ink injection into the polymeric component at the appropriate location
Data Source
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AI summary
A method for manufacturing an article, such as an article of footwear (12), including injecting ink (34) into a polymeric component (10) through a first surface (40) and at a depth less than the thickness (T) so that the ink is embedded in at least one of the layers of the polymeric component as a graphical image, and inflating the polymeric component with a fluid.