Uncured Polymer Outsole Molding for Seamless Midsole Integration
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Solution Overview
Problem
Conventional methods for applying outsoles to sole structures in footwear often result in issues such as constriction or separation due to mismatched expansion rates between pre-formed polymeric layers, especially with injection-molded foams, leading to suboptimal performance and manufacturing challenges.
Innovation Solution
A method involving the application of an uncured outsole material to a midsole element or preform, followed by a molding process to cure and integrate the outsole, using either a cold pressing or heated compression molding technique, ensuring a seamless integration and enhanced performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-formed polymeric layers are used for outsole application, then manufacturing efficiency is improved, but constriction or separation occurs due to mismatched expansion rates
Solution Approach 1:
The patent applies parameter changes by transitioning from pre-formed polymeric layers to a liquid polymeric outsole material that is applied and then cured in-situ. This changes the physical state and application method, allowing the material to conform to the midsole shape without constriction or separation issues, while maintaining manufacturing efficiency through a streamlined single-step process.
Solution Approach 2:
The patent employs preliminary action by preparing the midsole with a receptacle or cavity that is pre-formed to receive and contain the liquid polymeric outsole material. This pre-prepared structure ensures proper integration and positioning of the outsole material before curing, preventing constriction or separation while maintaining manufacturing efficiency.
2Ease of manufacture
If conventional outsole application methods are used, then manufacturing simplicity is maintained, but performance is suboptimal due to constriction or separation
Solution Approach 1:
The patent changes the physical and chemical parameters of the outsole material from a pre-formed solid polymeric layer to a liquid polymeric material that is applied and then cured. This parameter change enables the material to flow and conform to the midsole shape during application, eliminating constriction or separation issues while maintaining manufacturing simplicity through a direct application and curing process.
Solution Approach 2:
The patent utilizes composite materials by combining the liquid polymeric outsole material with the midsole structure in a single integrated component. This composite approach ensures consistent performance by eliminating the interfaces and potential failure points between separate pre-formed layers, while maintaining ease of manufacture through a unified application and curing process.
3Manufacturing precision
If liquid polymeric outsole material is applied and cured in-situ, then integration quality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming a receptacle or cavity in the midsole that is specifically designed to receive and contain the liquid polymeric outsole material. This pre-prepared structure simplifies the overall manufacturing process by providing a ready-made container for the liquid material, eliminating the need for complex containment mechanisms during application while ensuring high integration quality.
Solution Approach 2:
The patent employs self-service by designing the liquid polymeric outsole material to automatically conform and integrate with the midsole structure through its own properties. The material's liquid state allows it to flow into and adapt to the midsole's geometry during application, then it cures in-situ to form a seamless integration, eliminating the need for complex external containment or shaping mechanisms.
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 provides a durable, traction-enhanced sole structure with improved abrasion resistance and cushioning, addressing manufacturing constraints and ensuring consistent integration of the outsole with the midsole.
Implementation Method 1
depositing an outsole material including an uncured second polymeric material upon an exterior surface of the midsole element; and molding the midsole element and the outsole material to impart an outsole profile to the outsole material and curing the outsole material
Data Source
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AI summary
A method of forming a sole structure for an article of footwear. The method includes providing a midsole element formed of a first polymeric material. The method also includes depositing an outsole material including an uncured second polymeric material upon an exterior surface of the midsole element and molding the midsole element and the outsole material to impart an outsole profile to the outsole material and curing the outsole material on the exterior surface of the midsole element.