Athletic Shoe Traction Element Coring Process
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Solution Overview
Problem
Conventional methods for manufacturing traction elements for athletic shoes are time-consuming and material-wasteful, requiring additional steps like boring or drilling to remove excess material, which also necessitates frequent tool sharpening or replacement.
Innovation Solution
A coring process is used to manufacture traction elements, where a metal insert is cast into the stud body, forming an interior cavity, reducing weight and cooling time while maintaining performance and shape specifications, and incorporating a bulbous portion for structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If boring or drilling is used to remove excess material from the stud body, then the interior cavity is formed, but the manufacturing time increases and material waste occurs
Solution Approach 1:
The core is inserted into the mold cavity before the stud body material is injected or pressed in. This preliminary placement of the core allows the interior cavity to be formed during the main manufacturing process itself, rather than requiring a separate subsequent boring or drilling operation to remove material.
Solution Approach 2:
Instead of forming the stud body as a solid piece and then removing material to create the cavity, the invention extracts the approach by using a removable core that defines the cavity space from the beginning. The core is taken out after the stud body is formed, leaving the desired hollow interior cavity without requiring material removal operations.
2Volume of moving object
If boring or drilling is used to remove excess material, then the interior cavity is formed, but material waste increases
Solution Approach 1:
The core is positioned in the mold before the stud body material is added, allowing the cavity to be formed during the primary manufacturing process. This eliminates the need for subsequent material removal operations that would generate waste.
Solution Approach 2:
The invention uses a core that is inserted and then removed after forming the cavity, rather than cutting or drilling away material. This extraction approach preserves all the material that is intentionally placed in the mold, eliminating waste from material removal operations.
3Volume of moving object
If boring or drilling tools are used, then the interior cavity is formed, but tool maintenance frequency increases
Solution Approach 1:
The invention replaces cutting tools (borers or drills) with a simple removable core. The core is inserted into the mold, the stud body is formed around it, and then the core is extracted. This eliminates the need for complex cutting tools that require sharpening or replacement, significantly reducing tool maintenance requirements.
Solution Approach 2:
The core serves multiple functions: it defines the cavity shape, supports the stud body material during forming, and is easily removed after use. This self-contained approach eliminates the need for separate tooling operations and their associated maintenance needs.
4Ease of manufacture
If the stud body is cast solid without coring, then manufacturing is simpler, but weight increases and cooling time increases
Solution Approach 1:
The core is placed in the mold before the stud body material is injected or pressed in. This preliminary action creates the hollow interior cavity during the main manufacturing process, resulting in a lighter stud body without requiring complex subsequent operations.
5Ease of manufacture
If the stud body is cast solid without coring, then manufacturing is simpler, but cooling time increases
Solution Approach 1:
The core is positioned in the mold before the stud body material is added, creating the hollow cavity structure during the primary forming operation. This results in a lighter part with reduced thermal mass that cools faster, without requiring complex subsequent manufacturing steps.
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 coring process enhances manufacturing efficiency, reduces material waste, and provides a strong structural connection between the stud body and metal insert, meeting performance standards while minimizing weight and cooling time.
Implementation Method 1
The casting material is injected into the casting cavity and allowed to cool, forming the stud body
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
Various embodiments for a traction element used with athletic shoes having a stud body with a metal insert that extends axially from the stud body and methods for manufacturing such traction elements are disclosed.