Waterproof Shoe Sole Insert with Adhesive Matrix Seal
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Solution Overview
Problem
Existing methods for manufacturing waterproof and vapor-permeable soles made of polymeric material face issues with material seepage during molding, leading to production rejects and limiting the choice of materials for the tread, such as vulcanized rubber, due to the difficulty in achieving a hermetic seal and maintaining vapor permeability.
Innovation Solution
A sole insert comprising a supporting layer of mesh, a vapor-permeable membrane, and an adhesive bonding matrix made of polymeric material that impregnates the supporting layer to create a seal, allowing for high adhesion and vapor permeability, while using separate components and methods like microinjection or screen printing to ensure structural strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If co-molding is used to connect the tread to the supporting layer, then adhesion strength is improved, but material choice is limited and production complexity increases
Solution Approach 1:
The invention divides the sole into separate components (tread, supporting layer with macroholes, membrane) that are manufactured independently and then assembled through adhesive bonding. This segmentation allows each component to be made from optimal materials for its specific function, including vulcanized rubber for the tread, while maintaining strong adhesion through the adhesive layer applied to the supporting layer.
2Reliability
If co-molding is used to create hermetic seal, then waterproofing is improved, but production rejects increase due to material seepage
Solution Approach 1:
The invention introduces an adhesive layer as an intermediary substance between the supporting layer and the tread. This adhesive mediator creates a hermetic seal that prevents water penetration while avoiding the material seepage problems associated with co-molding. The adhesive is applied in controlled amounts to the supporting layer before assembly, ensuring complete coverage without excess material leakage.
3Ease of manufacture
If simple adhesive bonding is used to assemble components, then manufacturing simplicity is improved, but structural strength is insufficient
Solution Approach 1:
The invention applies adhesive bonding selectively to specific areas of the supporting layer, particularly at the perimeter regions and at locations corresponding to the macroholes. This localized adhesive application ensures strong bonding where structurally critical while maintaining manufacturing simplicity. The adhesive is applied in controlled patterns rather than uniformly across all surfaces, optimizing both strength and ease of manufacture.
4Reliability
If mesh is compressed against membrane during molding, then seal effectiveness is improved, but material seepage occurs through mesh
Solution Approach 1:
The invention extracts the mesh from the molding process entirely, using it only as a supporting layer structure that receives adhesive application. By removing the mesh from the compression molding step, the harmful effect of material seepage through mesh openings is eliminated. The adhesive is applied to the mesh in a controlled manner before final assembly, ensuring proper bonding without forcing material through the mesh structure.
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 a waterproof and vapor-permeable sole with enhanced structural strength, flexibility in material choice, and reduced production rejects by ensuring a strong and durable bond between components, while maintaining a large vapor permeation area and avoiding the limitations of traditional molding processes.
Implementation Method 1
a layer of polymeric material (14) impregnating the supporting layer (11) and forming therein a matrix (15) for the adhesive bonding thereof to other parts composing the shoe
Implementation Method 2
a membrane (13) that is impermeable to water and permeable to water vapor
Data Source
Figure 1~3
Figure 4a~4b
Figure 5~6
AI summary
An insert for soles, particularly for perforated soles made of polymeric material, comprising a membrane (13) that is impermeable to water and permeable to water vapor, the insert ( 10) comprising: - a supporting layer (11) made of mesh, felt or other diffusely perforated material, - a vapor permeation component (12), which comprises the membrane (13) arranged above the supporting layer (1 1 ), - a layer of polymeric material (14) that impregnates locally the supporting layer (11), so as to form therein a matrix (15) for the adhesive bonding thereof to other components of the shoe, - a region ( 16) for sealing the supporting layer (1 1) to the vapor permeation component (12). The adhesive bonding matrix (15) affects at least the perimetric region of the supporting layer ( 1 1 ) and delimits at least one vapor-permeable portion (18) of the supporting layer (1 1), which is free from polymeric material ( 14). The sealing region (16) provides for the intimate grip of the polymeric material ( 14), which impregnates the supporting layer (1 1 ), to the membrane (13).