E-TPO Shoe Sole Segmentation for Weight and Springback
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Solution Overview
Problem
Existing sports shoes with thermoplastic polyurethane soles face challenges in optimizing weight, spring, and damping properties while maintaining manufacturability simplicity.
Innovation Solution
The sole is composed of sections of expanded thermoplastic polyolefin (E-TPO) and other materials like EVA, TPU, TPE, polyamide, and rubber, with E-TPO sections consisting of spherical or ellipsoidal plastic bodies connected through welding or gluing, offering a lighter and more durable option with improved springback properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If expanded thermoplastic polyurethane (E-TPU) is used as sole material, then good spring and damping properties are achieved, but the weight is higher than desired
Solution Approach 1:
The sole is divided into multiple sections with different materials: E-TPO sections (lighter weight) and other material sections (EVA, TPU, rubber, etc. for enhanced spring and damping). This segmentation allows optimization of weight in certain areas while maintaining performance in critical zones.
Solution Approach 2:
The patent uses composite construction by combining E-TPO (expanded thermoplastic polyolefin) with other materials such as EVA, TPU, TPE, polyamide, foamed polyurethane, and rubber in different sole sections. This composite approach achieves lighter overall weight while preserving spring and damping properties through strategic material placement.
2Weight of moving object
If the sole is made lighter by using expanded materials, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The sole is segmented into E-TPO sections and other material sections, which can be manufactured separately and then assembled. This modular approach simplifies manufacturing by allowing each section to be optimized independently and joined through standard processes.
Solution Approach 2:
The patent specifies controlled parameters for E-TPO sections including density (100-250 g/l), plastic body dimensions (0.5-5.0 mm), and weight (5-10 mg per body). These parameter specifications standardize the material properties, making manufacturing and quality control more manageable despite the complexity of expanded materials.
3Reliability
If spherical or ellipsoidal plastic bodies are used in E-TPO sections, then spring properties are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent defines specific parameter ranges for plastic bodies: dimensions between 0.5-5.0 mm in three spatial directions and weight between 5-10 mg. These standardized parameters balance spring property optimization with manufacturability, allowing mass production while maintaining functional performance.
Solution Approach 2:
The combination of E-TPO sections with other materials in the sole structure provides complementary properties that compensate for tolerances in the plastic bodies, allowing broader manufacturing tolerances while maintaining overall spring and damping performance.
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 results in a sole that is up to 30% lighter than traditional E-TPU, with comparable springback properties, reduced yellowing, higher resistance to hydrolysis, and simplified manufacturing, enhancing both performance and production efficiency.
Implementation Method 1
The welding process can be carried out in particular by introducing steam into a tool mold at a pressure of between 0.1 and 0.4 MPa (1.0 and 4.0 bar), preferably between 0.1 and 0.2 MPa (1.0 and 2.0 bar) bar.
Implementation Method 2
the section of the sole consisting of expanded thermoplastic polyolefin (E-TPO) consisting of a large number of (initially, i.e. in Initial state) consists of spherical or ellipsoidal plastic bodies
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a shoe (1), in particular a sports shoe, having a sole (2) and a shoe upper part (3) connected to the sole (2). According to the invention, in order to improve the use properties of the shoe, the sole (2) is made, at least in sections, from an expanded thermoplastic polyolefin (E-TPO).