3D-Printed Anisotropic Midsole Mesh for Cushioning and Propulsion
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Solution Overview
Problem
Existing footwear fails to adequately cushion and support the foot, leading to discomfort, fatigue, and increased risk of injury due to inadequate mechanical characteristics, particularly during everyday and performance activities.
Innovation Solution
A three-dimensional mesh sole with an anisotropic structure is designed, featuring interconnected unit cells with varying stiffness and shear moduli in different directions to provide customized cushioning, support, and propulsion characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional homogeneous foam midsoles are used, then manufacturing is simple and cost-effective, but cushioning and support characteristics are insufficient
Solution Approach 1:
The midsole is segmented into multiple unit cells arranged in a three-dimensional mesh, where each unit cell contains struts and nodes forming distinct geometric patterns. This segmentation allows different regions to provide different mechanical properties, achieving customized cushioning and support while maintaining manufacturability through modular design
Solution Approach 2:
The midsole incorporates regions with varying strut densities, orientations, and geometric configurations to create localized areas with different stiffness and cushioning characteristics. This enables tailored mechanical properties in specific zones to meet performance requirements while keeping other areas simpler
2Use of energy by moving object
If uniform density foam is used, then manufacturing is easy, but energy conversion efficiency is poor
Solution Approach 1:
The unit cells incorporate asymmetric strut arrangements and non-uniform geometric patterns that are optimized to convert vertical impact forces into forward propulsion. The asymmetric design creates favorable stress distribution and deformation patterns that enhance energy conversion efficiency while being manufacturable through additive processes
Solution Approach 2:
The midsole design varies geometric parameters such as strut thickness, length, and orientation angles across different regions to optimize energy conversion. These parameter changes are implemented through digital modeling and additive manufacturing, balancing performance optimization with manufacturing feasibility
3Ease of operation
If soft cushioning material is used throughout, then comfort is improved, but stability and support are reduced
Solution Approach 1:
The three-dimensional mesh structure creates localized regions with different mechanical properties by varying strut density and geometric configuration. Softer regions with higher comfort are positioned where cushioning is needed, while stiffer regions with greater stability are placed where structural support is required, all within a single integrated midsole component
Solution Approach 2:
The midsole effectively creates a composite structure by combining multiple unit cell designs with different mechanical properties within a single component. This allows the integration of soft cushioning regions and stiff support regions without requiring separate materials or components, achieving both comfort and stability simultaneously
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 mesh sole enhances comfort and reduces fatigue by converting vertical forces into forward motion, improving efficiency and reducing energy expenditure during activities like running, while providing tailored support and stability.
Implementation Method 1
a lattice shear modulus measured in a forward direction that is less than a lattice shear modulus measured in a rearward direction... predisposed to deform forward when the sole contacts the ground
Implementation Method 2
each unit cell having a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more struts are connected
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.