3D-Printed Anisotropic Midsole for Cushioning and Forward Propulsion
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Solution Overview
Problem
Existing footwear fails to effectively cushion and support the foot, leading to discomfort, fatigue, and increased risk of injury due to inadequate impact absorption and energy transfer, particularly during everyday and performance activities.
Innovation Solution
A three-dimensional mesh midsole with anisotropic lattice structures is designed to provide customized mechanical properties, including varying lattice shear moduli in different directions, enhancing cushioning, propulsion, and stability through additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional footwear soles are used, then manufacturing is simple and cost-effective, but cushioning and impact absorption are inadequate
Solution Approach 1:
The patent employs a three-dimensionally printed mesh structure with porous characteristics that provides superior cushioning and impact absorption compared to traditional solid or foam soles. The porous mesh architecture allows for energy dissipation through deformation while maintaining structural integrity, directly addressing the inadequate cushioning performance of conventional footwear soles.
Solution Approach 2:
The invention combines the three-dimensionally printed mesh structure with adhesive layers and outsole materials to create a composite sole assembly. This composite approach integrates multiple functional layers (cushioning mesh, adhesive bonding layer, traction outsole) to achieve both improved cushioning performance and structural complexity in a unified design.
2Adaptability or versatility
If the midsole uses uniform structure, then manufacturing is easier, but mechanical properties cannot be customized for different directions
Solution Approach 1:
The patent implements local quality by varying the mesh structure characteristics (such as cell size, wall thickness, or pattern density) in different regions of the midsole to provide directionally specific mechanical properties. This allows the sole to exhibit different stiffness, cushioning, or energy return characteristics in different directions or zones, enabling customization for specific performance requirements while using additive manufacturing to achieve complex spatial variations.
Solution Approach 2:
The invention utilizes parameter changes in the three-dimensionally printed mesh structure, such as varying lattice geometry, material composition, or porosity parameters across different regions or orientations. These parameter variations enable the midsole to achieve customized mechanical properties in different directions, optimizing performance for specific activities while leveraging additive manufacturing capabilities to produce the complex geometry.
3Reliability
If adequate cushioning is provided, then foot protection improves, but weight of the footwear increases
Solution Approach 1:
The three-dimensionally printed mesh structure provides adequate cushioning and foot protection through its porous architecture that dissipates impact forces efficiently. The open-cell or controlled-porosity design allows for energy absorption and rebound without requiring dense, heavy materials, thus maintaining lightweight construction while achieving superior impact protection compared to traditional solid cushioning materials.
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 anisotropic midsole efficiently converts vertical forces into forward motion, improving efficiency and reducing energy expenditure during activities like running, while providing enhanced comfort and injury protection.
Implementation Method 1
A sole for an article of footwear may include a three-dimensionally (3D) printed mesh having an anisotropic structure that predisposes the sole to deform forward when the sole contacts a surface
Implementation Method 2
the anisotropic structure may include a lattice framework populated with a combination of soft and stiff subcells
Data Source
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AI summary
The present disclosure relates to a sole for an article of footwear, the sole comprising: a three-dimensional mesh comprising: a plurality of interconnected unit cells, each interconnected unit cell comprising a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more struts are connected; and a mechanically anisotropic region comprising: a first lattice shear modulus measured in a forward direction, and a second lattice shear modulus measured in a rearward direction opposite the forward direction and greater than the first lattice shear modulus.