Skate Boot Graphical Element Laminate Design
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Solution Overview
Problem
Conventional skate boot manufacturing methods are labor-intensive and costly, prone to aesthetic damage from impacts and abrasions, and discourage new designs due to complex assembly and material limitations, such as cracking plastic and fraying seams.
Innovation Solution
A graphical element laminate for skate boots featuring a thermoplastic outer layer with printed and translucent regions, allowing woven or non-woven fabric patterns to be interspersed with printed elements, reducing manufacturing complexity and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If decorative pieces of leather, fabric or plastic are arranged and joined together to produce aesthetically pleasing skate boots, then the appearance and design variety are improved, but the manufacturing process becomes labor intensive and more costly
Solution Approach 1:
The patent merges multiple decorative pieces into a single integrated laminate layer that combines different materials (leather, fabric, plastic) and patterns into one unified component. This eliminates the need to assemble multiple separate decorative pieces, reducing labor intensity and manufacturing complexity while maintaining aesthetic variety.
Solution Approach 2:
The patent uses composite materials by laminating different materials (leather, fabric, plastic) together in a single layer. This allows the skate boot to display multiple patterns and textures simultaneously without requiring separate assembly of decorative pieces, thereby simplifying the manufacturing process.
2Shape
If numerous seams or joints are used to join decorative pieces, then design variety is improved, but the seams become prone to fraying or loosening over time
Solution Approach 1:
The patent merges multiple decorative pieces into a single integrated laminate layer, eliminating seams and joints between pieces. This unified structure removes the source of fraying and loosening while maintaining design variety through the integrated patterns and material combinations.
3Shape
If plastic material is used for the outer layer to provide different textures, then texture variety is improved, but applying different colors to different areas becomes difficult and prone to cracking
Solution Approach 1:
The patent segments the outer layer into multiple laminate layers, each capable of displaying different colors and textures. This segmentation allows independent color application and pattern integration in each layer, making it easier to achieve varied color schemes without the cracking issues associated with single-layer plastic.
Solution Approach 2:
The patent uses composite materials by combining plastic with other materials (leather, fabric) in laminated layers. This composite structure provides texture variety while allowing different colors to be applied to different materials in different layers, reducing cracking and improving ease of manufacture.
4Shape
If plastic outer surfaces have colors applied to them, then aesthetic appeal is improved, but the colors are prone to cracking, denting and chipping under impact and abrasion
Solution Approach 1:
The patent uses composite materials by laminating plastic with more durable materials (leather, fabric) to create a multi-layer structure. This composite construction provides aesthetic appeal through color and texture variety while the underlying materials protect against cracking, denting, and chipping from impacts and abrasion.
Solution Approach 2:
The patent provides beforehand cushioning by creating a multi-layer laminate structure where underlying layers protect the outer decorative layers from impact damage. This protective structure prevents cracking and chipping before they occur during use.
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 simplifies manufacturing, enhances aesthetic appeal, and improves durability by allowing intricate designs without increased costs, while protecting the underlying material from damage, making it suitable for competitive skating.
Implementation Method 1
a first thermoplastic layer laminated on the base layer outer side of the base layer
Data Source
AI summary
A method of manufacturing a skate boot, including providing a first sheet of thermoplastic material, the thermoplastic material being at least one of translucent and transparent, printing a graphic element on the first side of the first sheet of thermoplastic material, providing a second sheet of base layer material with a first side of the second sheet of base layer material having a design element, positioning the first side of the first sheet onto the first side of the second sheet such that the graphic image is disposed between the first side of the first sheet and the first side of the second sheet, and joining the first sheet and the second sheet together to form a graphic element laminate. The graphic element laminate is affixed to an outer surface of a skate boot core.