Shoe Sole E-TPU Insert Recesses Reduce Material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high production costs of shoe soles using Expanded Thermoplastic Polyurethane (E-TPU) due to its expensive nature and significant material requirements.
Innovation Solution
A method involving the creation of recesses in a first section of the sole, followed by cutting and fixing E-TPU inserts of specific shapes to minimize material usage, achieved through injection molding and punching, with gluing for fixation, allowing for a cost-effective and efficient use of E-TPU.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If E-TPU material is used in significant amount to ensure good wearing properties, then the wearing properties of the shoe are improved, but the production costs increase significantly
Solution Approach 1:
The patent applies local quality by placing E-TPU material only in specific regions of the sole (heel and forefoot areas) where cushioning and energy return are most needed, rather than using it throughout the entire sole. This localized application maintains the wearing properties in critical areas while significantly reducing the total amount of expensive E-TPU material required.
Solution Approach 2:
The sole is segmented into different material zones, with E-TPU inserts placed in discrete sections (heel and forefoot) rather than as a continuous layer. This segmentation allows the expensive material to be concentrated where it provides maximum performance benefit while reducing overall material consumption and cost.
2Reliability
If E-TPU material is used in significant amount to ensure good wearing properties, then the wearing properties of the shoe are improved, but the production costs increase
Solution Approach 1:
The manufacturing process is segmented into separate steps: producing the base sole, producing E-TPU inserts, and assembling them together. This allows each component to be optimized independently and assembled efficiently, reducing overall production costs while maintaining wearing properties.
Solution Approach 2:
The E-TPU inserts are pre-formed into specific shapes and sizes before assembly, allowing for precise material usage and reducing waste during the manufacturing process. This preliminary preparation of components streamlines the assembly process and reduces production costs.
3Loss of substance
If the shape of the insert is optimized to minimize scrape, then material waste is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The inserts are pre-cut to match the recess shapes before assembly, allowing for precise material utilization. The preliminary shaping of inserts ensures they fit perfectly into the recesses, minimizing material waste while the modular nature of the process keeps manufacturing precision requirements manageable.
Data Source
AI summary
The invention relates to a method for producing a sole for a shoe, especially for a sports shoe, wherein the sole has at least a first section which consists of a first plastic material and has at least a second section which consists of a second plastic material, wherein the second plastic material is Expanded Thermoplastic Polyurethane. To obtain good wearing properties of the shoe the method includes the steps of: a) Producing the first section of the sole, wherein in the first section at least one recess is created which has an opening at an upper side of the sole and which is at least partially closed by a bottom region at a bottom side of the sole, wherein the recess has a defined shape in a top plan view; b) Producing of a laminar sheet made of the second plastic material; c) Cutting-out of an insert of the laminar sheet produced according to step b), wherein the insert is or forms at least a part of the second section of the sole, wherein the shape of the insert corresponds to the shape of the recess; d) Fixing the insert in the recess.