Fluid-Filled Midsole Chamber With Foam Tensile Member Bonding
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Solution Overview
Problem
Conventional polymer foam midsoles in athletic footwear deteriorate with repeated compressions, leading to decreased compressibility and force attenuation, which affects the comfort and performance of the footwear.
Innovation Solution
Incorporating a fluid-filled chamber into the midsole, where a tensile member with varying compressibility is bonded to polymer layers within a mold to form a sealed enclosure, providing additional cushioning and maintaining shape under pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer foam materials are used for the midsole, then the midsole provides initial cushioning and force attenuation, but the cell structure deteriorates following repeated compressions, resulting in decreased compressibility and force attenuation characteristics
Solution Approach 1:
The patent changes the physical state of the midsole from solid polymer foam to fluid-filled chamber, transforming the compressible gas-filled cells into a liquid or gas medium that maintains consistent pressure characteristics over time, thereby resolving the deterioration issue
Solution Approach 2:
The patent employs a fluid-filled chamber (hydraulic or pneumatic system) instead of solid foam, using the incompressibility or controlled compressibility of fluids to maintain reliable force attenuation characteristics throughout the service life of the footwear
2Weight of moving object
If a fluid-filled chamber is incorporated into the midsole, then the mass of the midsole is reduced and deterioration effects are decreased, but the chamber requires additional manufacturing steps including bonding tensile members and sealing
Solution Approach 1:
The patent combines multiple functions into the fluid-filled chamber structure: the chamber serves as both the weight-reducing element and the force attenuation mechanism, while integrated tensile members provide both structural support and shape maintenance, reducing the need for separate components
Solution Approach 2:
The patent uses composite construction combining polymer materials with fluid-filled chambers and integrated tensile members, creating a multi-material structure that achieves weight reduction while maintaining durability and simplifying the overall manufacturing process
3Strength
If uniform compression is applied to the tensile member during manufacturing, then bonding occurs, but areas with greater compressibility (such as cavities) may not bond properly to the polymer layers
Solution Approach 1:
The patent applies local quality by creating non-uniform compression through a protrusion in the mold that corresponds to cavity locations, providing enhanced compression specifically in areas where bonding is most needed while maintaining appropriate compression elsewhere
Solution Approach 2:
The patent performs preliminary action by pre-compressing the tensile member in cavity areas through the mold protrusion before final bonding occurs, ensuring that these difficult-to-bond areas are properly prepared for adhesion to the polymer layers
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 fluid-filled chamber enhances the midsole's ability to attenuate ground reaction forces and maintain cushioning over time, improving the comfort and durability of the footwear.
Implementation Method 1
compressing the tensile member, the first layer of the polymer material, and the second layer of the polymer material within the mold
Implementation Method 2
a resilient midsole at least partially formed from a polymer foam, and a ground-contacting outsole that provides both abrasion-resistance and traction
Implementation Method 3
the cell structure of the polymer foam may deteriorate, thereby resulting in decreased compressibility and decreased force attenuation characteristics
Data Source
AI summary
A fluid-filled chamber may include an outer barrier formed from a polymer material and a foam tensile member located within the outer barrier. In manufacturing the fluid-filled chamber, a mold may be contoured to substantially equalize compressive forces between the outer barrier and various portions of the tensile member, thereby providing substantially uniform bonding between the outer barrier and the tensile member. Surfaces of the tensile member may also be contoured to substantially equalize compressive forces. In some configurations, the outer barrier and tensile member may be formed from thermoplastic polymer materials that form a direct bond between the outer barrier and surfaces of tensile member.