Co-molded Flex Modifier Footwear Sole Structure
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Solution Overview
Problem
Current footwear sole structures lack customization and efficiency in providing tailored rigidity and flex characteristics for different athletic and non-athletic applications, leading to suboptimal performance and comfort.
Innovation Solution
Incorporating a co-molded flex modifier component made of fiber material and mold-compatible polymer within the outer sole component, allowing for selective modification of flex characteristics at specific locations, such as an elongated shank extending through the midfoot region, to enhance performance and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a uniform sole structure is used throughout the footwear, then manufacturing is simple and cost-effective, but the footwear cannot provide customized rigidity and flex characteristics for different athletic applications
Solution Approach 1:
The sole structure is divided into multiple components: an outer sole component and a separate flex modifier component. This segmentation allows each component to have specialized functions - the outer sole provides structural support while the flex modifier component selectively modifies rigidity and flex characteristics in specific regions, enabling customization without requiring complete redesign of the entire sole structure.
Solution Approach 2:
The flex modifier component is designed to provide localized modification of sole properties. By positioning this component at specific locations (such as the midfoot region), the footwear can have different rigidity and flex characteristics in different areas, allowing customization for specific athletic applications while maintaining simplicity in other regions.
2Adaptability or versatility
If multiple separate components are added to customize sole characteristics, then performance customization is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The flex modifier component is co-molded with the outer sole component in a single integrated manufacturing process. This combining of components that would traditionally require separate assembly steps allows performance customization through design variations in the mold rather than through complex assembly operations, maintaining manufacturing efficiency while achieving customization.
Solution Approach 2:
The co-molding process serves multiple functions simultaneously: it creates the outer sole structure, integrates the flex modifier component, and establishes the mechanical bond between them in a single operation. This multi-functionality in the manufacturing process achieves performance customization without proportionally increasing manufacturing complexity or cost.
3Strength
If traditional bonding methods are used to attach sole components, then assembly is straightforward, but the bond strength and durability are insufficient for high-performance athletic footwear
Solution Approach 1:
The bonding function is extracted from the assembly process and integrated into the molding process itself. Rather than attaching components through separate bonding operations, the flex modifier component is co-molded with the outer sole, creating an integral structure where the bond strength is inherent to the molded joint rather than dependent on external bonding agents or processes.
Solution Approach 2:
Traditional mechanical or chemical bonding systems are replaced with a molded joint system. The co-molding process creates a mechanically integrated connection between the outer sole and flex modifier component, where the bond strength derives from the molded material flow and interlocking geometry rather than from adhesives, stitches, or other external bonding mechanisms.
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
This solution provides improved rigidity and flex characteristics, enabling smooth motion and reduced buckling, while facilitating efficient and cost-effective manufacturing of footwear with player- or position-specific performance enhancements.
Implementation Method 1
a fiber-reinforced cover layer is fusion bonded with the inner surface of the sole body
Data Source
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AI summary
A sole structure (103) for an article of footwear (100) includes an outer sole component (106) with a co-molded flex modifier component (208). The outer sole component is formed of a first mold material, such as a rubber mold material. The flex modifier component includes a fiber material and a second mold material. The second mold material may be mold compatible with the first mold material. The sole structure may be formed by co-molding an outer sole component blank or pre-form (620, 621) (e.g., rubber mold material), and a flex modifier component, e.g., in a hot press molding process using a molding system having a mold cavity (606, 607) configured to form the outer sole component. The flex modifier component may be formed (e.g., cut or stamped) from a sheet of flex modifier material (301), such as a thermoplastic extruded hot melt film sandwiched between fusion bonded non-woven fiber fabric material impregnated with a styrene-coated polymer.