Carbon Fiber Deflection Plate for Footwear Shock Attenuation
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Solution Overview
Problem
Conventional footwear cushioning methods relying on compression result in high energy loss and rapid degradation, losing up to 30% of cushioning capability within the first 200 miles of use.
Innovation Solution
A deflection-based cushioning system utilizing a carbon fiber plate in the heel of the shoe that absorbs shock through deflection, similar to a trampoline, with a void underneath to allow bending and a central post for support, minimizing energy loss and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If compression-based cushioning materials (foam) are used in footwear, then shock absorption is provided, but energy loss is high and cushioning capability degrades rapidly
Solution Approach 1:
The patent changes the fundamental cushioning mechanism from compression to deflection. The carbon fiber plate utilizes elastic deflection rather than compressive deformation, fundamentally altering the physical parameter of how shock is absorbed. This enables the system to maintain cushioning capability while reducing energy loss, as the plate returns to its original shape after each deflection cycle rather than undergoing permanent compression set.
Solution Approach 2:
The patent employs carbon fiber composite material for the deflection plate, combining high strength, stiffness, and elastic properties. The carbon fiber composite provides the necessary structural integrity to withstand repeated deflection cycles while maintaining energy return characteristics, solving both the energy loss and durability issues associated with conventional foam materials.
2Duration of action of stationary object
If conventional foam cushioning is used, then shock absorption is achieved, but the material deforms quickly and loses cushioning capability within 200 miles of use
Solution Approach 1:
The patent transitions from compressive deformation to elastic deflection as the primary cushioning mechanism. The carbon fiber plate deflects elastically under load and returns to its original shape, avoiding the permanent deformation that occurs in foam materials. This parameter change enables the system to maintain shape stability and service life far exceeding the 200-mile limitation of conventional foam.
3Power
If a rigid plate is used for shock attenuation, then energy return is increased, but the plate may undergo catastrophic damage (plastic deformation)
Solution Approach 1:
The patent optimizes the plate's structural parameters including thickness, curvature, and material properties to achieve the desired balance between energy return and damage resistance. The carbon fiber plate is designed with specific geometric parameters that enable elastic deflection within safe limits, preventing plastic deformation while maximizing energy return. The post support structure further controls the deflection parameters to prevent catastrophic failure.
Solution Approach 2:
The patent incorporates a post support structure positioned beneath the deflection plate to prevent excessive deflection that could lead to plastic deformation or catastrophic failure. This preliminary support structure acts as a safety mechanism that limits the maximum deflection amplitude, ensuring the plate remains within its elastic regime even under extreme loading conditions.
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 system provides superior cushioning and energy return with reduced energy loss and increased durability, maintaining performance over time and accommodating various weight loads and activities.
Implementation Method 1
an elastic plate that is inserted into grooves of a thermoplastic housing
Implementation Method 2
A deflection-based cushioning system utilizing a carbon fiber plate in the heel of the shoe that absorbs shock through deflection, similar to a trampoline
Data Source
AI summary
The footwear cushioning invention includes a floating elastic plate that stores and returns elastic energy to provide cushioning through deflection of the elastic plate. Cushioning is by energy return rather than the compression of a foam. Footwear cushioning utilizes a deflection plate integrated into the heel of the shoe for providing shock attenuation and energy absorption when a wearer impacts a hard surface with the shoe. The deflection plate can be carbon fiber because it increases energy return and minimizes energy loss. A cavity can be formed in a midsole of the shoe underneath the deflection plate to allow the plate to flex into the cavity when pressed down upon by a wearer's heel, thereby accepting the energy of a downward step. A post can be located in the center of the cavity underneath the deflection plate that allows support and minimizes excessive deflection of the deflection plate.