Advanced Molded Component Insert Manufacturing Method

Publication ID: 24-11857025_0001_PTD

Published: October 27, 2025

Category:Direct Improvements & Enhancements

Legal Citation

pr1or.art Inc., “Advanced Molded Component Insert Manufacturing Method,” Published Technical Disclosure No. 24-11857025_0001_PTD, Published October 27, 2025, available at https://archive.pr1or.art/24-11857025_0001_PTD

This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,025.

Background and Problem Solved

The original patent, 'System and method for forming a molded component with an insert,' disclosed a method for forming molded articles with inserts, but had inherent limitations in terms of quality control, material selection, and process efficiency. The present invention addresses these limitations by introducing direct improvements and enhancements to the original patent, providing a more reliable, efficient, and cost-effective solution for forming molded components with inserts.

Novelty and Inventive Step

The present invention's novelty lies in the introduction of a temperature control system, a removable plugging material, a hybrid molding process, a vacuum chamber, and a surface treatment, which collectively provide a non-obvious solution to the limitations of the original patent. The inventive step resides in the combination and integration of these novel features, which result in a more efficient, reliable, and cost-effective method for forming molded components with inserts.

Alternative Embodiments and Variations

Alternative embodiments of the present invention may include variations in the design of the molding machine, the composition of the plugging material, the configuration of the hybrid molding process, and the implementation of the vacuum chamber and surface treatment. These variations can be adapted to suit specific industry requirements, material properties, and manufacturing constraints, ensuring broad conceptual coverage and applicability.

Potential Commercial Applications and Market

The present invention has significant commercial potential in the footwear industry, particularly in the manufacturing of high-performance athletic shoes, as well as in other industries requiring precision-molded components with inserts, such as automotive, aerospace, and medical devices. The invention's ability to improve quality, reduce waste, and increase efficiency is expected to appeal to manufacturers seeking to enhance their production processes and product offerings.

CPC Classifications

Section	Class	Group
A	A43	A43B13/04
B	B29	B29D35/0018
B	B29	B29D35/122
B	B29	B29D35/14
B	B29	B29D35/142

Section 103 Obviousness Analysis (PHOSITA)

▼

Field of Art

Molding technologies for manufacturing components with insert features, specifically focusing on footwear and precision manufacturing techniques involving elastomeric materials and insert molding processes

Person of Ordinary Skill (PHOSITA) Profile

A mechanical engineer or manufacturing specialist with expertise in injection molding, materials science, and insert molding techniques, possessing knowledge of thermoplastic and elastomeric material behaviors under heat and pressure

Obviousness Rationale

A PHOSITA would recognize that the PTD's variations represent incremental improvements to the source patent's fundamental insert molding method, utilizing standard engineering problem-solving techniques and known manufacturing optimization strategies that would be apparent to someone skilled in precision molding technologies.

Obvious Combinations & Variations

Source Patent Element

Disposing a plug within a receptacle of an insert with an engagement feature

PTD Variation

Adding a temperature control system to optimize molding process parameters

Obviousness Reasoning

Temperature management is a predictable and routine optimization technique in injection molding, representing a known method to improve material flow and component quality

Source Patent Element

Molding a plug including an elastomer material within a receptacle

PTD Variation

Implementing a hybrid molding process combining injection and compression molding techniques

Obviousness Reasoning

Combining molding techniques is a standard design choice for achieving more precise component geometries and material distributions

Source Patent Element

Insert with a bushing and laterally extending flange

PTD Variation

Applying surface treatments to reduce material adhesion in critical insert features

Obviousness Reasoning

Surface modification techniques are well-known in manufacturing for controlling material interactions and are a predictable solution to potential molding challenges

Source Patent Element

Method of forming a molded article with an insert

PTD Variation

Using a vacuum chamber for rapid evacuation of plugging materials

Obviousness Reasoning

Vacuum-assisted material removal is a standard engineering technique for improving manufacturing precision and efficiency

35 U.S.C. § 103 Summary: Based on the teachings of US Patent 11857025, a person having ordinary skill in the art would find the variations disclosed in this publication to represent obvious extensions of the prior art, employing standard engineering techniques and predictable modifications to the fundamental insert molding method. The disclosed innovations represent routine optimization strategies that would be apparent to a skilled practitioner in precision manufacturing technologies.

Original Patent Information

Patent Number	US 11,857,025
Title	System and method for forming a molded component with an insert
Assignee(s)	NIKE, Inc.