Published Technical Disclosure Archive

Advanced Molded Component Insert Manufacturing Tech

Publication ID: 24-11857025_0006_PTD
Published: October 27, 2025
Category:Direct Improvements & Enhancements

Legal Citation

pr1or.art Inc., “Advanced Molded Component Insert Manufacturing Tech,” Published Technical Disclosure No. 24-11857025_0006_PTD, Published October 27, 2025, available at https://archive.pr1or.art/24-11857025_0006_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 disclosed a system and method for forming molded components with inserts, but it had limitations in terms of durability, production speed, and unwanted molding material in critical features. This new invention aims to overcome these limitations by introducing innovative solutions that enhance the overall performance of the molded components.

Novelty and Inventive Step

The new claims introduce novel solutions that are not obvious from the original patent, including the use of removable plugging materials, protective coatings, and advanced molding machines. These innovations provide a significant improvement over the original patent, enabling the production of higher-quality molded components with inserts.

Alternative Embodiments and Variations

Alternative embodiments of the invention could include using different types of removable plugging materials, applying the protective coating using various methods, or modifying the molding machine to accommodate different insert designs. Additionally, the invention could be adapted for use in various industries, such as aerospace, automotive, or medical devices.

Potential Commercial Applications and Market

The invention has significant commercial potential in various industries, including footwear, aerospace, automotive, and medical devices. The improved efficiency, durability, and quality of the molded components with inserts could lead to increased market share and revenue for companies that adopt this technology.

CPC Classifications

SectionClassGroup
A A43 A43B13/04
B B29 B29D35/0018
B B29 B29D35/122
B B29 B29D35/14
B B29 B29D35/142

Field of Art

Molding and manufacturing technologies, specifically focused on insert molding techniques for complex component fabrication, with expertise in materials science, injection molding processes, and precision manufacturing techniques

Person of Ordinary Skill (PHOSITA) Profile

A skilled manufacturing engineer with advanced knowledge of injection molding, materials properties, tooling design, and process optimization, typically holding a bachelor's or master's degree in mechanical engineering or materials science

Obviousness Rationale

A person having ordinary skill would recognize that the PTD's variations represent predictable extensions of the source patent's core molding methodology, introducing incremental improvements in insert preparation, material selection, and post-molding processing that would be readily apparent to an experienced manufacturing engineer

Obvious Combinations & Variations

Source Patent Element
Disposing a plug within a receptacle of an insert with an engagement feature
PTD Variation
Using a removable plugging material with a lower melting point that can be evacuated after molding
Obviousness Reasoning
A PHOSITA would recognize this as a standard design optimization technique for managing insert geometry during molding, representing a predictable variation of known insert preparation methods
Source Patent Element
Molding a plug using heat and pressure to cover an engagement feature
PTD Variation
Applying a protective coating to critical insert features prior to molding and removing post-process
Obviousness Reasoning
Surface treatment and protective masking are well-established techniques in precision manufacturing, representing a known approach to managing complex geometric features during molding processes
Source Patent Element
Insert with a bushing and laterally extending flange
PTD Variation
Creating a rigid and durable attachment point for peripheral items through modified insert design
Obviousness Reasoning
Adapting insert geometry for enhanced functional performance is a routine design modification that would be obvious to a skilled engineer seeking to optimize component integration
Source Patent Element
Elastomer-based molding process for insert components
PTD Variation
Implementing advanced molding machines configured to rapidly evacuate plugging materials
Obviousness Reasoning
Process automation and efficiency improvements are standard engineering practices, representing predictable technological progression in manufacturing technologies
Source Patent Element
Method of forming a molded article with an insert
PTD Variation
Developing a system for reducing unwanted molding material in critical insert features
Obviousness Reasoning
Minimizing manufacturing defects and optimizing geometric precision are fundamental goals in precision manufacturing, making such variations obvious to a skilled practitioner
35 U.S.C. § 103 Summary: Pursuant to 35 U.S.C. ยง 103, the variations disclosed in this Published Technical Disclosure would be considered obvious to a person having ordinary skill in the art when viewed in light of US Patent 11857025, as the claimed innovations represent predictable technological extensions employing known manufacturing techniques, material selections, and process optimizations within the established technological framework of insert molding methodologies

Original Patent Information

Patent NumberUS 11,857,025
TitleSystem and method for forming a molded component with an insert
Assignee(s)NIKE, Inc.