Heat-Activated Remoldable Insole Resolving Curing and Leakage Issues
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Solution Overview
Problem
Conventional methods for making custom insoles using expandable uncured resins face issues such as one-time curing, sensitivity to moisture, short shelf life, potential allergic reactions, inability to remold, and leakage of curing agents, leading to discomfort and unusability.
Innovation Solution
A heat-activated and remoldable resin composition is used, which locks a foam into a shape until reactivated, allowing the insole to be reshaped multiple times by heating, and is impregnated into an open cell foam with an inflating agent for improved support and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If expandable uncured resin is used to make custom insoles, then the insole can be molded to fit individual foot shapes, but the insole cannot be remolded after curing and has short shelf life
Solution Approach 1:
The patent uses a resin composition that changes its physical state based on temperature parameters. The resin is in a soft, moldable state at elevated temperatures and transitions to a cured, stable state at lower temperatures. This parameter-based state change enables multiple molding cycles while maintaining long shelf life, as the resin remains stable during storage and only activates when heated during use.
2Ease of manufacture
If expandable uncured resin with moisture catalyst is used, then the resin can be activated to cure the insole, but the resin is sensitive to moisture and has toxic components
Solution Approach 1:
The patent replaces the chemical moisture-based curing mechanism with a thermal activation mechanism. Instead of using moisture-sensitive catalysts that trigger curing upon contact with water, the invention uses heat-activated resin composition that requires thermal energy to initiate curing. This substitution eliminates moisture sensitivity and associated toxicity issues while maintaining ease of manufacture through simple heating during the molding process.
3Ease of manufacture
If conventional curing agents are injected into the insole, then the resin can be cured, but the curing agent spills out and makes the insole unusable
Solution Approach 1:
The patent extracts and eliminates the separate curing agent component from the traditional two-part resin system. Instead of injecting a separate curing agent that can leak and cause problems, the invention uses a self-contained heat-activated resin composition where the curing mechanism is integrated into the resin itself. This extraction of the separate curing agent eliminates spillage issues while maintaining the curing function through thermal activation.
4Adaptability or versatility
If heat moldable insoles are used, then the insole can be reshaped, but the insole collapses under body weight and cannot support feet
Solution Approach 1:
The patent creates a dynamic system where the insole transitions between two functional states: a soft, moldable state when heated for customization, and a firm, supportive state when cooled for use. This dynamic state change allows the insole to be reshaped during manufacturing and then maintain structural integrity during wear, resolving the contradiction between reshapability and foot support capability.
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 customizable, reusable, and comfortable insoles that can be molded to fit individual foot shapes without the risks associated with traditional methods, offering firm support and avoiding allergic reactions.
Implementation Method 1
A heat-activated and remoldable resin composition is used, which locks a foam into a shape until reactivated, allowing the insole to be reshaped multiple times by heating
Implementation Method 2
impregnated into an open cell foam with an inflating agent for improved support and stability
Data Source
AI summary
An apparatus including means for being remoldable with application of heat at a predetermined temperature, means for absorbing the remoldable means, and means for enclosing the absorbing means, wherein the enclosing means comprises a substantially sealed enclosing means configured to resist a leakage of the absorbing means saturated with the remoldable means. The apparatus further include a insole implement, in which the insole implement having an insole section and an arch pad area, wherein the arch pad area is operable for accepting the enclosing means, wherein the insole implement is operable for maintaining a molded shape as the heat activated and remoldable resin composition in the sealed chamber implement cools in temperature, and wherein the insole implement is further configured to be operable for being remolded to a different shape by reheating the enclosing means containing the absorbing means saturated with the remoldable means.