Food-Grade Silicone Insole with Flat Surface and Adhesive Layers
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Solution Overview
Problem
Existing silicone insoles face issues such as low material utilization, inadequate design, ease of removal, deformation of shoes, uneven surfaces reducing friction, insufficient connection to shoe soles, and non-toxic material standards not being met, leading to discomfort and performance issues.
Innovation Solution
A silicone insole design featuring a lower insole layer, polymer adhesive layer, and an upper silicone flat layer made of food-grade silicone, with a flat surface structure, using environmentally friendly glue and a coupling agent to ensure durability, comfort, and improved friction, while maintaining air permeability and non-toxicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional molding pressure is used in production, then manufacturing process is simple, but material utilization is low and cost is high
Solution Approach 1:
The patent changes the molding method from traditional high-pressure molding to a pressureless or low-pressure curing process. The silicone rubber composition is placed in a mold cavity and cured without applying significant molding pressure, which dramatically improves material utilization while maintaining manufacturing simplicity. This parameter change in the molding process resolves the contradiction between ease of manufacture and material utilization.
2Force
If the insole surface is made uneven to increase friction, then friction force should increase, but contact area with foot is reduced and gaps are formed
Solution Approach 1:
The patent changes the surface topology parameter from uneven to substantially smooth. The insole surface is designed to be substantially smooth rather than uneven, which maintains large contact area with the foot while still providing adequate friction through the material properties of the silicone rubber composition itself. This parameter change resolves the contradiction by finding an alternative mechanism for friction that doesn't sacrifice contact area.
3Ease of operation
If the insole is made soft and thick for comfort, then comfort is improved, but the insole is easy to deform and damage the shoes
Solution Approach 1:
The patent uses a composite material system consisting of silicone rubber base resin combined with specific fillers (such as silica), curing agents, and additives. This composite formulation provides both the softness and comfort required for user comfort while simultaneously delivering the structural stability and deformation resistance needed to protect the shoe. The synergistic combination of materials resolves the contradiction between comfort and structural stability.
Solution Approach 2:
The patent optimizes the crosslinking density and hardness parameters of the silicone rubber through careful selection of base resin, filler content, and curing conditions. By adjusting these parameters, the insole achieves an optimal balance between softness for comfort and sufficient structural stability to prevent deformation and shoe damage, resolving the contradiction through precise parameter control.
4Ease of manufacture
If ordinary industrial glue is used for bonding, then manufacturing cost is low, but the overall thickness increases and air permeability is affected
Solution Approach 1:
The patent reduces the thickness parameter of the adhesive layer by optimizing bonding parameters such as surface treatment, adhesive formulation, and curing conditions. This allows the use of thin adhesive layers that minimize overall insole thickness and maintain air permeability while still achieving adequate bonding strength, effectively resolving the contradiction between manufacturing cost and thickness control.
5Productivity
If the insole is made with perforations for air permeability, then air permeability is improved, but waterproof performance is lost and dampness increases
Solution Approach 1:
The patent changes the surface structure parameter from perforated to substantially smooth and non-porous. The silicone rubber insole is designed with a smooth surface that inherently provides both adequate air permeability through the material's porous structure (without visible perforations) and maintains waterproof performance. This parameter change resolves the contradiction by eliminating the harmful effect of water penetration while preserving breathability through alternative structural design.
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 design enhances durability, comfort, and performance by providing a firm connection, maintaining friction force, and ensuring non-toxicity, high temperature resistance, and improved air permeability, addressing the limitations of existing insoles and enhancing user experience.
Implementation Method 1
a polymer adhesive layer, a surface treatment agent layer and an upper silicone flat layer sequentially arranged from bottom to top in that order
Implementation Method 2
a material of the surface treatment agent layer includes a coupling agent
Data Source
AI summary
A silicone insole is provided and includes a lower insole layer, a polymer adhesive layer, a surface treatment agent layer and an upper silicone flat layer sequentially arranged from bottom to top in that order, the upper silicone flat layer is made of a food-grade silicone, and an upper end surface of the upper silicone flat layer is a flat structure without grooves and protrusions. An overall connection of the silicone insole is more solid and durable. The silicone insole can disperse pressure on foot to be more suitable for long standing or sporting under a protection of the food-grade silicone, it is suitable for shoes needing insoles to improve performance, and makes full use of advantages of silicone materials such as high friction, waterproof, slightly air permeability, better absorb moisture and perspiration, soft, environmentally protection, non-toxic, odorless, guaranteed rebound touch, quality, ageing resistance, and anti-static.