Co-Molded 3D Sole Support Elements With Rotatable Joints

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Solution Overview

Problem

Existing shoe sole reinforcing and support elements are typically integrally molded from a single base material, limiting flexibility and deformation properties, and the number of functions they can provide.

Innovation Solution

A support element for shoe soles comprising a first partial member and a second partial member, mechanically joined in a connection region to allow rotation or sliding, using chemically incompatible plastic materials to create a rotatable and slidable connection without a chemical bond, manufactured through injection molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If reinforcing elements are integrally molded from a single base material, then manufacturing simplicity is maintained, but flexibility and deformation properties are limited

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidflexibility and deformation properties

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The support element is divided into multiple partial members (first partial member, second partial member, etc.) that can be formed from different materials or have different properties. These segmented parts are connected through connection regions, allowing each segment to contribute different flexibility or deformation characteristics while maintaining manufacturing efficiency through integrated molding processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the support element can have different material properties, flexibility, or deformation characteristics by using different materials for different partial members or by creating varying densities and structures in different zones. This allows optimization of specific areas for particular functions while maintaining overall structural integrity.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If additional functional elements are added to selectively influence sole properties, then functionality is enhanced, but device complexity increases

Engineering Contradiction:

ImprovefunctionalityVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple functional elements are merged into a single integrated support element structure. The first partial member, second partial member, and connection regions form one cohesive component that can be manufactured in a single injection molding process, eliminating the need for separate assembly steps while providing multiple functions through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support element is designed to perform multiple functions simultaneously - providing structural reinforcement, enabling controlled flexibility, allowing deformation in specific directions, and potentially incorporating damping or energy return properties. This multi-functionality is achieved through the combined structure of different partial members working together.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If chemically incompatible materials are used to create rotatable connections, then flexibility is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improverotational and sliding capabilityVSAvoidconnection region precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The injection molding process itself creates the connection regions between partial members with the necessary precision. The chemically incompatible materials prevent bonding at the interface, naturally forming defined connection regions with appropriate tolerances for rotation and sliding without requiring additional precision machining or assembly steps.

Inventive Principle:

Principle #25Self-service

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

Enhances the ability to influence sole properties locally, allowing independent control of flexibility and deformation in different regions, improving stability and comfort by enabling rotatable and slidable connections without additional manufacturing steps.

Implementation Method 1

manufactured through injection molding

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS12575639B2Co-molded 3D elements

Publication Date: 2026.03.17 ADIDAS AG

AI summary

Describes are support elements for a sole of a shoe, in particular a sports shoe, a sole and a shoe with such a support element, as well as a method for the manufacture of a support element. As examples, the support element includes a first partial member formed of a first material, and a second partial member formed of a second material. The first partial member is mechanically joined to the second partial member in a connection region, wherein the connection region is configured to allow the first partial member to rotate or slide relative to the second partial member. The first partial member, the second partial member, and the connection region can be co-molded and joined together in a single fabricating step.