UV Curable Material Bonded to Textile Footwear

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Solution Overview

Problem

Conventional footwear manufacturing processes require high temperatures and pressures for vulcanization, which can damage textiles and necessitate the use of toxic adhesives and primers, limiting the development of durable and comfortable footwear models.

Innovation Solution

The use of ultraviolet (UV) radiation curable materials that can be shaped and bonded to textiles without the need for elevated temperatures or toxic adhesives, using a method involving heat, pressure, and UV curing to form durable outsoles and other components directly on the textile surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high temperatures and pressures are used for bonding materials to textiles, then bond strength is improved, but the textile is damaged

Engineering Contradiction:

Improvebond strengthVSAvoidtextile damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the bonding parameters from high temperature and pressure to low temperature and atmospheric pressure by using UV radiation as the curing mechanism. The UV curable material is applied to the textile at ambient conditions and then cured using UV light, achieving strong bonds without thermal or mechanical damage to the textile fibers.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical bonding system (heat and pressure) with a photochemical bonding system (UV radiation). Instead of using thermal energy to activate the bonding process, the invention uses UV light to initiate polymerization of the curable material, creating a strong bond without mechanical stress on the textile.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If high temperatures and pressures are used for bonding materials, then bond strength is improved, but toxic adhesives are required

Engineering Contradiction:

Improvebond strengthVSAvoidtoxic adhesives

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The UV curable material is self-adhering and self-curing. It is applied in an uncured state to the textile surface, then undergoes polymerization when exposed to UV radiation, forming a strong bond without requiring separate adhesive applications or toxic bonding agents. The material serves both as the bonding agent and the structural component.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent extracts the harmful adhesive component from the bonding process by using the UV curable material itself as the bonding medium. The material contains all necessary bonding properties and cures in place, eliminating the need for separate toxic adhesive substances that would contaminate the bonding interface.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If conventional bonding processes are used, then manufacturing simplicity is maintained, but production costs increase

Engineering Contradiction:

Improveprocess simplicityVSAvoidproduction costs

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent replaces energy-intensive thermal and mechanical bonding systems with a photochemical curing process. UV radiation requires significantly less energy than high-temperature ovens or pressing equipment, reducing production costs while maintaining manufacturing simplicity. The process can be completed in seconds without complex heating or pressure equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for the creation of durable footwear components with enhanced bond strength and reduced environmental impact, eliminating the need for toxic solvents and expensive tooling, while enabling the direct bonding of materials to textiles without exposing them to high temperatures.

Implementation Method 1

exposing at least a portion of the shaped UV radiation curable material to ultraviolet (UV) radiation, thereby curing at least a portion of the shaped UV radiation curable material

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentEP4042894A1Article with UV radiation curable material adhered to textile and method of making the same

Publication Date: 2022.08.17 NIKE INNOVATE CV

Figure 1A~1C
Figure 1D~1E
Figure 2A~2B

AI summary

An article of apparel, sporting equipment, or footwear incorporates a component formed of a UV radiation curable material. In the case of an article of footwear, the UV radiation curable material may be formed into an outsole. The method of manufacturing such articles includes shaping one or more pieces of an ultraviolet (UV) radiation curable material; placing the shaped UV radiation curable material in direct contact with a surface of a textile; using heat or pressure or both to adhere the shaped UV radiation curable material to the surface of the textile, and curing at least a portion of the shaped UV radiation curable material adhered to the surface of the textile by exposing the shaped UV radiation curable material to ultraviolet (UV) radiation, thereby forming an article comprising UV radiation cured material bonded to the surface of the textile.