Segmented Sports Shoe Shell Joined by Heat Welding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current sports shoe shell manufacturing techniques are limited by material rigidity, restricting design flexibility and material choice, especially when using recycled materials, as they require specific forming techniques that hinder the use of high rigidity materials and limit shape and thickness options.

Innovation Solution

A sports shoe shell composed of two separately formed portions that can be joined using heat welding, allowing for the use of materials with varying rigidity and thickness without the need for elastic deformation during forming, and enabling the incorporation of films or functional elements with desired characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a shell is formed as a single piece by injection molding with low rigidity material, then the shell can be removed from the punch by elastic deformation, but the choice of material is limited to low rigidity materials and the shell cannot achieve high mechanical strength

Engineering Contradiction:

Improveshell forming processVSAvoidshell mechanical strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The shell is divided into multiple separate portions that are formed independently without requiring elastic deformation for removal. Each portion can be formed with high rigidity materials using standard injection molding techniques, and the portions are subsequently joined together to form the complete shell structure.

Inventive Principle:

Principle #1Segmentation

2Strength

If materials with high rigidity are used for the shell, then the shell provides high mechanical strength, but the shell cannot be deformed to remove it from the punch without inducing deformation

Engineering Contradiction:

Improveshell rigidityVSAvoidshell forming process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The shell is segmented into multiple portions that are formed separately. This segmentation allows each portion to be manufactured using conventional injection molding processes with high rigidity materials, eliminating the need for elastic deformation during removal from the mold.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical deformation process is replaced by a joining process. Instead of deforming the shell to remove it from the mold, the separate portions are joined together after formation, substituting the mechanical deformation step with a joining operation that allows use of high rigidity materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If the thickness of the walls of the shell is increased to improve strength, then the rigidity of the shell increases and hinders the removal thereof from the punch

Engineering Contradiction:

Improveshell wall thicknessVSAvoidshell removal from mold

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The shell is divided into multiple portions that are formed separately. This allows each portion to have optimized wall thickness for strength without creating removal difficulties, as the portions are not required to be elastically deformed for mold removal.

Inventive Principle:

Principle #1Segmentation

4Strength

If the shell has a shape with a relatively wide opening to allow removal without deformation, then the shell can be made with high rigidity material, but the shape of the shell is limited at the design stage

Engineering Contradiction:

Improvematerial rigidity choiceVSAvoidshell shape design flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The shell is segmented into multiple portions that can be formed with various shapes and then joined together. This segmentation removes the constraint of requiring a wide opening for removal, allowing greater design flexibility in the shape of each portion while still enabling the use of high rigidity materials.

Inventive Principle:

Principle #1Segmentation

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 approach allows for a versatile design with durable and structurally stable shells that can utilize a wide range of materials, including recycled ones, without protruding joints, ensuring adequate mechanical strength and aesthetic appeal.

Implementation Method 1

the first shell portion and the second shell portion are joined together through joining portions which are adapted to be fixed to each other by means of heat welding

Methodology Applied

Scientific EffectHeat welding: Welding

Data Source

PatentUS11786004B2Sports shoe and method of construction thereof

Publication Date: 2023.10.17 CALZATURIFICIO DAL BELLO

AI summary

A sports shoe includes a shell formed of a first shell portion and of a second shell portion, distinct from each other and adapted to be assembled together. The first shell portion includes a first peripheral rim edge and the second shell portion includes a second peripheral rim edge including, respectively, a first joining rim portion and a second joining rim portion adapted to be coupled together. Specifically, the first joining rim portion includes at least a joining channel adapted to cooperate with a corresponding at least a joining projection included in the second joining rim portion. The joining channel and the corresponding joining projection are fixable to each other by means of heat welding.