Embroidered Foaming Cords for Customized Midsole Cushioning
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Solution Overview
Problem
Current methods for forming midsoles in footwear lack the ability to efficiently combine dissimilar materials with varying properties to achieve customized cushioning and support, leading to suboptimal performance in terms of comfort and durability.
Innovation Solution
The use of embroidered foaming cords made of different materials, stitched together with thread, allows for the creation of midsoles with customized cushioning and support properties by embedding these cords into a substrate material and molding them into specific shapes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-material midsole construction is used, then manufacturing process is simple, but cushioning and support performance is suboptimal
Solution Approach 1:
The midsole is divided into multiple cords made from different materials (e.g., EVA, PU, rubber) that are embroidered separately and then assembled together. Each cord can be optimized for specific properties (cushioning, support, durability) and the segmentation allows independent manufacturing and customization of each material component.
Solution Approach 2:
The invention uses composite material construction by combining multiple different materials in a single midsole assembly. Different cords made from various foam materials, rubbers, and polymers are integrated through embroidery to create a midsole that leverages the unique properties of each material for enhanced overall performance.
2Adaptability or versatility
If dissimilar materials are combined for customized properties, then cushioning and support are enhanced, but manufacturing complexity increases
Solution Approach 1:
The embroidery technique serves multiple functions: it acts as both the attachment method and the structural framework for assembling the dissimilar material cords. This universal application of embroidery simplifies the manufacturing process by using a single technique for both joining and shaping the midsole components.
Solution Approach 2:
Different regions of the midsole can incorporate different material cords tailored to specific functional requirements. For example, higher cushioning materials can be placed in high-impact areas while more durable materials are used in high-wear regions, allowing localized optimization without complicating the overall manufacturing process.
3Reliability
If multiple materials with varying properties are integrated, then durability and comfort are improved, but the manufacturing process becomes less efficient
Solution Approach 1:
The different material cords are prepared and pre-embroidered separately before final assembly. This preliminary action allows for optimized manufacturing of each material type independently, maintaining high productivity while enabling the integration of multiple specialized materials in the final midsole construction.
Data Source
AI summary
In one embodiment, a midsole for an article of footwear is described that includes a first foaming cord made of a first material and a second foaming cord made of a second material. The first material is different than the second material. The first foaming cord and the second foaming cord are embroidered into a shape of the midsole. The first foaming cord and the second foaming cord may be embroidered to a substrate material by thread. A midsole can include multiple layers of foaming cords. Customized midsoles may be formed by selective placement of one or more foaming cords in different locations or layers to provide different properties or characteristics to the midsole.