Composite Plate Sole Assembly Energy Return
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Solution Overview
Problem
Existing sole assemblies with composite plates in footwear often delaminate, leading to impaired energy return and durability issues due to excessive cushioning and rigidity.
Innovation Solution
A sole assembly design featuring a spring plate positioned between two midsole platforms with an outsole layer directly below, allowing for direct force transmission and energy return, and a multi-radii transition portion for enhanced energy return during the gait cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plate is fully embedded in the midsole foam, then the plate is protected from rupture and buckle, but the plate can delaminate from the midsole material and excessive cushioning impairs energy return
Solution Approach 1:
The midsole is divided into two separate platforms (first and second midsole platforms) that sandwich the plate, creating distinct cushioning zones above and below the plate while preventing delamination through the platform structure
Solution Approach 2:
The first and second midsole platforms act as intermediary structures between the plate and the external environment, providing protected embedding while maintaining energy return through controlled foam deformation
2Reliability
If the plate is fully embedded in the midsole foam, then the plate is protected from impact forces, but the sole assembly becomes too rigid and inflexible
Solution Approach 1:
The foam platforms are configured with different properties in different regions: the first platform provides cushioning above the plate while the second platform provides support below, creating local variations in stiffness and flexibility throughout the sole assembly
Solution Approach 2:
The foam platforms are designed to deform dynamically during the gait cycle, allowing the sole assembly to transition from a rigid protective structure to a flexible adaptive structure that conforms to movement requirements
3Ease of operation
If intermediate foam layer is present between midsole and plate, then cushioning is provided, but force transmission to the plate is reduced
Solution Approach 1:
The foam platforms are configured to provide partial cushioning action - enough to enhance comfort but not so much as to significantly reduce force transmission to the plate, achieving an optimal balance between the two requirements
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 design increases energy return and gait efficiency by reducing energy loss at the metatarsophalangeal joint, improving performance in both short and long-distance running activities.
Implementation Method 1
The midsole foam below the plate attenuates shock and softens the impact of the footwear with the ground to disperse forces along and through the plate
Implementation Method 2
The midsole foam below the plate extending to the toes and beyond also deforms slightly to provide cushioned toe off in a wearer's gait cycle
Implementation Method 3
the plate can include an upward curving, multi-radii transition portion extending from a lowermost portion of the plate to the forward most portion of the plate. This transition portion can be configured to provide a bias so as to return energy to the wearer's foot
Data Source
AI summary
A footwear construction includes a sole assembly including a first midsole platform, a second midsole platform below the first midsole platform, a spring plate disposed between the first and second midsole platforms, and an outsole layer disposed below and joined directly with at least one of the plate, the first and the second midsole platforms. The outsole layer can be substantially the only layer below the plate in the forefoot region of the footwear so an underfoot force engaging the outsole layer is transmitted directly to the plate, which also can have an upward curving, multi-radii transition portion extending from a lowermost portion to a forward most portion of the plate so as to roll a wearer's foot forward into a next stride in a gait cycle of the wearer. The plate can define an aperture. A mounting cap can extend through the aperture and can receive a traction spike.