PU-Coated Spandex Fabric-Fused Midsole Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional midsole manufacturing processes are complex, labor-intensive, and result in midsoles with poor tear resistance, hydrolysis resistance, and wear resistance due to the use of TPU films, which are prone to deterioration and manual handling.
Innovation Solution
A polyurethane-coated spandex fabric-fused midsole manufacturing apparatus and method that automates the fusion of PU-coated spandex fabric to the midsole surface, using a rotary disc, vacuum means, and resin introduction to create a foam-molded product with improved adhesive strength and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If TPU film is adhered to the polyurethane resin before foaming to form a smooth surface, then the surface smoothness is improved, but the manufacturing process complexity and labor intensity increase significantly
Solution Approach 1:
The patent combines the TPU film application and midsole foaming processes into a single integrated operation. The TPU film is placed in the mold before the polyurethane resin is introduced, allowing both the film adhesion and midsole formation to occur simultaneously during one foaming cycle, rather than requiring separate manual film application and foaming steps
Solution Approach 2:
The TPU film is placed and positioned in the mold before the polyurethane resin is introduced and before the foaming process begins. This preliminary placement ensures the film is properly positioned and will form a smooth surface once the midsole is foamed, eliminating the need for post-foaming film application
2Ease of operation
If manual labor is used for TPU film adhesion and midsole manufacturing processes, then flexibility in handling is maintained, but time consumption and labor intensity increase
Solution Approach 1:
The system is designed so that the TPU film automatically adheres to the polyurethane resin during the foaming process itself. The expanding foam naturally pushes the film against the mold walls and bonds it in place, eliminating the need for separate manual adhesion operations while maintaining proper film positioning
Solution Approach 2:
Multiple operations (film placement, resin introduction, and foaming) are merged into a single automated sequence where the film is positioned and then the resin is introduced and foamed in one continuous process, significantly reducing the total time compared to separate manual operations
3Object-affected harmful factors
If TPU film is used to protect the midsole surface, then surface protection is achieved, but the material resistance properties (tear, hydrolysis, wear resistance) are deteriorated
Solution Approach 1:
The patent replaces the durable but problematic TPU film with a thin layer of polyurethane resin that serves the same protective function. The resin layer is applied directly during the midsole manufacturing process and provides surface protection without the deterioration issues of TPU film, effectively using the midsole material itself as the protective layer
Solution Approach 2:
The patent creates a composite structure where the polyurethane resin forms both the bulk midsole material and a protective surface layer. This integrated composite approach eliminates the interface between separate TPU film and midsole materials, preventing the deterioration problems that arise from TPU film usage while maintaining surface protection
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 automated process reduces time and labor consumption, enhances the midsole's bursting strength, tear resistance, and hydrolysis resistance, while maintaining high wear resistance and solvent resistance.
Implementation Method 1
vacuum means installed between the rotary disc and the midsole forming mold units to vacuum the inside of a midsole forming mold unit supplied with a PU-coated spandex fabric so that the PU-coated spandex fabric comes into close contact with the inner surface of the midsole forming mold unit
Implementation Method 2
the polyurethane resin is introduced into a bottom mold has at least one midsole's shape portion, and then a top mold is placed on the top of the bottom mold to close the bottom mold. Next, if the molds are heated to and maintained at a predetermined temperature for a predetermined length of time, the polyurethane resin is molded while being foamed in the molds
Data Source
AI summary
The present invention relates to a polyurethane-coated (PU-coated) spandex fabric-fused midsole, and an apparatus and method for manufacturing the same, which allow a shoe midsole to be easily and conveniently manufactured through a single automatic process, and allows a PU-coated spandex fabric to be easily fused to a surface of the midsole in the process of manufacturing the midsole.