Three-Layer Sole Injection Molding Head for Automated Shoe Production
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Solution Overview
Problem
Existing footwear manufacturing devices are poorly automated, inefficient, and require extensive angular and linear movements, leading to high costs and low productivity.
Innovation Solution
An injection molding device with a compact design and simplified actuation, featuring a head with multiple molds and movable rings, allowing for automated and efficient production of three-layer soles directly onto the shoe upper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If existing footwear manufacturing devices are used, then manufacturing capability is provided, but automation is poor and productivity is low
Solution Approach 1:
The patent combines multiple molding operations (first molding operation for outsole and first midsole layer, second molding operation for second midsole layer, third molding operation for inner tread layer) into a single integrated device. The head assembly with multiple molds and the base assembly with multiple rings work together in one automated cycle, eliminating the need for separate machines and manual transfers, thereby achieving high automation and productivity
Solution Approach 2:
The injection molding device is designed to perform multiple functions within a single machine: it can mold different layers of the sole (outsole, midsole layers, inner tread layer) using the same device. The head assembly can be positioned at different heights and the rings can be opened and closed to accommodate different molding operations, making the device universal for creating multi-layer soles without requiring multiple specialized machines
2Ease of manufacture
If existing devices are used, then molding operations can be performed, but they require extensive angular and linear movements of components
Solution Approach 1:
The device is divided into distinct functional segments: a head assembly containing the molds (first closing mold, second closing mold, third support mold) and a base assembly containing the rings (first ring, second ring). This segmentation allows each component to perform its specific function independently with minimal movement. The head assembly can be lowered and raised vertically, while the rings can be opened and closed radially, reducing the complexity of coordinated movements required
Solution Approach 2:
The patent introduces vertical movement of the head assembly as a new dimension of operation. Instead of requiring complex angular and linear movements in the horizontal plane, the head assembly can be simply lowered vertically onto the base assembly for molding operations and then raised for ejection. This vertical dimension simplifies the overall movement requirements and reduces device complexity
3Adaptability or versatility
If a component consisting of outsole and first midsole layer is produced separately, then molding flexibility is achieved, but cost increases and adhesion treatment is required
Solution Approach 1:
The patent merges the molding of the outsole and first midsole layer into a single first molding operation performed in one integrated device. The first closing mold and first ring work together to enclose the upper and mold both the outsole and first midsole layer simultaneously in one operation, eliminating the need for separate molding operations, additional adhesion treatments, and multiple component assemblies, thereby reducing manufacturing cost while maintaining flexibility
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
Significantly increases productivity and simplifies the manufacturing process by automating operations with minimal component movement, reducing costs and improving efficiency.
Implementation Method 1
A polymeric material is then injected into this cavity to form the second layer and complete the sole
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3C
AI summary
An injection molding device (1) for molding a sole (3, 4, 5) onto the upper (2) of a shoe, comprising a tread layer (3), at least one intermediate layer (4), and an inner layer (5) directly connected to the upper (2), the device (1) including a head (7) equipped with actuating means (20, 21, 22) to define a first molding cavity (17) for molding the tread layer (3), a second molding cavity (18) for molding the intermediate layer (4), and a third molding cavity (19) for molding the inner layer (5), the head (7) featuring a first closing form (8) for the first molding cavity (17), a second closing form (9) for the second molding cavity (18), a third support form (10) for the upper (2) to close the third molding cavity (19), and an articulated block (11, 12, 13) comprising a first blocking part (11) slidably supported along a fixed guide (14), a second blocking part (12) supported by the first blocking part (11) and rotatable around a first rotation axis (L), and a third blocking part (13) supported by the second blocking part (12) and rotatable around a second rotation axis (M), wherein the third blocking part (13) has a first arm (15) for securing the first form (8) and a second arm (16) for securing the second form (9), and wherein the third support form (10) is fixed to the second blocking part (12), the head (7) being angularly movable around the first and second rotation axes (L, M) to selectively align the corresponding closing form (8, 9, 10) with each molding cavity (17, 18, 19).