Domed Midsole Staged Compressive Stiffness
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Solution Overview
Problem
Current athletic footwear sole structures lack effective progressive cushioning that adapts to dynamic compressive loads, leading to inadequate energy absorption and return, and often compromise on weight and flexibility.
Innovation Solution
A sole structure with multiple cushioning layers of varying stiffness, where the first layer provides initial linear cushioning, followed by a second layer with non-linear and then exponential compression, and a third layer for energy return, utilizing gas-filled sealed chambers and polymeric sheets for optimized load distribution and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cushioning layers of varying stiffness are used to provide staged progressive cushioning, then energy absorption and return is improved, but device complexity increases
Solution Approach 1:
The midsole is divided into multiple discrete cushioning layers (first, second, and third layers) with different stiffness characteristics. Each layer is responsible for a specific stage of compression, creating a staged progressive cushioning effect that improves energy absorption and return while managing the complexity through functional segmentation.
Solution Approach 2:
Each cushioning layer is assigned a specific stiffness value tailored to its function: the first layer has lower stiffness for initial compression, the second layer has intermediate stiffness for mid-stage compression, and the third layer has higher stiffness for final compression. This local differentiation of material properties enables optimized performance at each compression stage.
2Reliability
If multiple cushioning layers are stacked to provide progressive cushioning, then cushioning performance is improved, but weight increases
Solution Approach 1:
The patent varies the stiffness parameter across different cushioning layers rather than using uniform material throughout. By selecting materials with progressively increasing stiffness values across the three layers, the design achieves superior cushioning performance without proportionally increasing weight, as each layer is optimized for its specific compression stage.
3Adaptability or versatility
If multiple cushioning layers of different stiffness are implemented, then adaptability to dynamic compressive loads is improved, but manufacturing complexity increases
Solution Approach 1:
The midsole is constructed as separate, stackable layers that can be manufactured independently and then assembled. This segmentation allows each layer to be optimized for its specific stiffness requirement while simplifying the overall manufacturing process, as each layer can be produced using standard foam manufacturing techniques and then bonded together.
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 solution provides staged cushioning that effectively absorbs and returns energy, maintaining lightweight and flexible properties, enhancing the overall performance of the footwear by adapting to different stages of compressive loads.
Implementation Method 1
absorb a dynamic compressive load in stages of progressive cushioning
Implementation Method 2
first cushioning layer has a first stiffness, the second cushioning layer has a second stiffness greater than the first stiffness, and the third cushioning layer has a third stiffness greater than the second stiffness
Data Source
AI summary
A sole structure for an article of footwear comprises a midsole including a first cushioning layer, a second cushioning layer, and a third cushioning layer. The first cushioning layer has a central portion, and a peripheral portion surrounding the central portion. The first cushioning layer, the second cushioning layer, and the third cushioning layer are stacked with the second cushioning layer directly overlying the peripheral portion of the first cushioning layer, and the third cushioning layer overlying the second cushioning layer and directly overlying the central portion of the first cushioning layer. The first cushioning layer has a domed lower surface extending away from the second cushioning layer and the third cushioning layer and substantially centered under the central portion.