Composite Shell Cycling Shoe Sole Structure
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Solution Overview
Problem
Existing footwear sole structures lack a configuration that balances stiffness, durability, and minimal mass for efficient energy transfer during cycling, while also varying significantly based on intended use, with no disclosure of mounting hardware with flange portions over the inner surface of the sole.
Innovation Solution
A composite shell sole structure comprising a polymer matrix with fiber reinforcement and a polymer foam core, where the shell is formed from materials like epoxy with carbon fiber textiles, and the core is made from expanding polyurethane foam, providing high stiffness and durability with minimal mass, and incorporating mounting hardware for cleat attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a rigid sole structure is used for cycling shoes, then energy transfer efficiency is improved, but weight increases and comfort decreases
Solution Approach 1:
The sole structure uses a composite shell made from fiber-reinforced polymer materials (such as carbon fiber, fiberglass, or aramid fibers embedded in a polymer matrix) that provides high stiffness and strength-to-weight ratio. This composite construction delivers rigid energy transfer characteristics while maintaining minimal mass, directly resolving the contradiction between power transmission and weight.
Solution Approach 2:
The shell structure incorporates variable thickness and reinforcement patterns in specific regions (such as increased fiber density in high-stress areas like the pedal interface zone) to optimize energy transfer where needed while keeping other areas lighter, thus achieving high power efficiency without uniform weight increase across the entire sole.
2Power
If a rigid sole structure is used for cycling shoes, then energy transfer efficiency is improved, but flexibility and comfort worsen
Solution Approach 1:
The composite shell provides directional stiffness that maintains rigidity for energy transfer while allowing controlled flexibility in other directions, enabling the sole to be rigid when force is applied vertically (improving power transfer) while maintaining some degree of flexibility for foot movement and comfort.
Solution Approach 2:
The sole structure is divided into distinct functional zones with different stiffness characteristics - a rigid shell for energy transfer and a separate cushioning layer for comfort - allowing each segment to perform its specialized function without compromising the other.
3Strength
If a composite shell with fiber reinforcement is used, then tensile strength and durability are improved, but manufacturing complexity increases
Solution Approach 1:
The shell is formed as an integrated composite component using fiber-reinforced polymer materials that can be molded directly into the desired shape, achieving high tensile strength (greater than 0.60 gigapascals) while avoiding the need for separate assembly steps for reinforcement elements, thus managing manufacturing complexity.
Solution Approach 2:
The shell structure combines multiple functions (structural support, energy transfer, and mounting surface for cleats) into a single integrated component, eliminating the need for separate reinforcement plates or mounting brackets that would increase manufacturing complexity.
4Strength
If the shell is formed from composite material with high tensile strength, then durability and energy transfer are improved, but material cost increases
Solution Approach 1:
The shell uses fiber-reinforced polymer composites with tensile strength greater than 0.60 gigapascals that provide high durability and energy transfer efficiency at optimized material costs, balancing performance requirements with material expense.
Solution Approach 2:
The design optimizes fiber orientation, density, and distribution within the composite shell to achieve the minimum required tensile strength threshold (0.60 GPa) with the most cost-effective material configuration, avoiding over-engineering that would increase material costs unnecessarily.
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 configuration ensures efficient energy transfer during cycling by maximizing stiffness and durability while minimizing mass, and can be adapted for various footwear styles by varying the shell and core materials and design.
Implementation Method 1
a core formed from a polymer foam material is located within the cavity and substantially fills the cavity
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An article of footwear (10) has an upper (20) and a sole structure (30) secured to the upper. The sole structure includes a shell (40) and a core (50). The shell has a ground portion (41) and a footbed portion (42), with a periphery of the footbed portion being secured to the ground portion to define a cavity between the ground portion and the footbed portion. The core is located within the cavity. Whereas the shell may be formed from a composite material, the core may be formed from a polymer foam material.