UV-Curable Elastomeric Material Bonding for Durable Footwear Assembly
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Solution Overview
Problem
Conventional methods for attaching elastomeric materials to textiles in footwear lack efficient and durable bonding techniques, leading to suboptimal durability and longevity of the footwear.
Innovation Solution
The use of ultraviolet (UV) radiation curable elastomeric materials, which can be partially or fully cured in situ on the substrate, forming chemical or physical bonds with the material, either through exposure to UV radiation or by incorporating an adhesive layer that melts and re-solidifies to create a strong bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bonding methods are used to attach elastomeric materials to textiles, then the manufacturing process is simple, but the bonding strength and durability are insufficient
Solution Approach 1:
The patent changes the physical-chemical state of the elastomeric material through UV radiation exposure, transforming it from uncured to cured state. This parameter change (chemical crosslinking) dramatically improves bonding strength between the elastomeric material and textile substrate, resolving the contradiction between simple process and strong bonding.
Solution Approach 2:
The patent replaces conventional mechanical or thermal bonding methods with UV radiation curing. This substitution introduces a new mechanism (photopolymerization) that achieves superior bonding strength without requiring complex mechanical pressing or high-temperature equipment, thus improving strength while maintaining process simplicity.
2Duration of action of stationary object
If conventional elastomeric materials are used without UV curing, then the material processing is easy, but the durability and lifespan of the footwear are reduced
Solution Approach 1:
The elastomeric material is formulated with UV-curable components before manufacturing, preparing it for subsequent UV curing treatment. This preliminary preparation enables the material to achieve enhanced durability through crosslinking while maintaining ease of manufacture during the actual production process, as the curing is accomplished through simple UV exposure rather than complex processing steps.
Solution Approach 2:
The patent uses composite elastomeric materials that combine conventional polymer components with UV-curable monomers or oligomers. This composite formulation allows the material to be easily processed during manufacturing while subsequently achieving enhanced durability and lifespan through UV-induced crosslinking, resolving the contradiction between ease of manufacture and long-term durability.
3Reliability
If UV radiation is applied to cure elastomeric materials in situ, then the bonding durability is improved, but the energy consumption increases
Solution Approach 1:
The patent replaces energy-intensive thermal curing processes with UV radiation curing. UV curing consumes less energy because it directly activates photoinitiators in the elastomeric material to trigger crosslinking, rather than requiring bulk heating of the entire material and equipment. This substitution achieves improved bonding durability while reducing overall energy consumption.
Solution Approach 2:
The UV curing process can be applied in periodic or pulsed manner, allowing the elastomeric material to be cured in stages or selectively in specific areas. This periodic application reduces total energy consumption compared to continuous high-energy exposure, while still achieving the necessary bonding durability through cumulative UV dose.
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
This method enhances the bonding strength between elastomeric materials and textiles, resulting in improved durability and extended lifespan of footwear by utilizing UV radiation to cure the elastomeric materials and create robust interfaces.
Implementation Method 1
uncured or partially cured ultraviolet (UV) radiation curable elastomeric material
Data Source
AI summary
A method of manufacturing an article that includes providing an element formed of an elastomeric material or composite; placing the surface of the element in contact with a substrate; and affixing the element to the substrate. The element includes an uncured, partially cured, or fully cured UV radiation curable elastomeric material and optionally one or more regions of an adhesive material. The element is affixed to the substrate while the surface of the element is in contact with a surface of the substrate by increasing a temperature of at least a portion of the element, applying pressure to at least a portion of the element, or exposing the uncured or partially cured UV radiation curable material to UV radiation in an amount and for a duration of time that is sufficient to partially cure the uncured material or to fully cure the partially cured material.