Foam-Enclosed Lattice Footwear Outsole for Durability

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Solution Overview

Problem

Customized footwear components created through additive manufacturing, such as 3D printing, face challenges with durability and abrasion resistance due to being non-removable and prone to debris collection in open lattice structures, requiring additional gluing to the footwear upper.

Innovation Solution

Enclosing customized components in foam and using injected foam as a bonding agent between the footwear upper and outsole, allowing for automated manufacturing and improved durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If customized components are created through additive manufacturing with open lattice structure, then customization and fit are improved, but debris collection and durability are worsened

Engineering Contradiction:

ImprovecustomizationVSAvoiddebris collection

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

A foam material is injected to enclose the lattice structure, creating a protective shell that prevents debris collection while maintaining the customized fit benefits of the additive-manufactured component. The foam acts as a flexible enclosure that fills the voids of the lattice structure.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention combines the additive-manufactured lattice structure with injected foam material to create a composite component. This composite structure maintains the customization advantages of 3D printing while adding the protective and durability benefits of the foam enclosure.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If customized components are created through additive manufacturing, then customization is improved, but durability and abrasion resistance are worsened

Engineering Contradiction:

ImprovecustomizationVSAvoiddurability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The additive-manufactured lattice structure is combined with injected foam material to form a composite component. This composite construction provides both the customization capability of 3D printing and the enhanced durability and abrasion resistance of the foam enclosure.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The injected foam creates a protective shell around the lattice structure, providing durability and abrasion resistance while preserving the customized geometry and fit of the original additive-manufactured component.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If traditional gluing methods are used to attach components to footwear upper, then manufacturing simplicity is maintained, but automation capability is worsened

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidautomation capability

Core Design Contradiction:

Ease of manufactureVSExtent of automation

Solution Approach 1:

The foam material is injected in a liquid state and then expands and cures within the mold to automatically attach the customized component to the footwear upper. This self-service mechanism eliminates the need for separate manual gluing operations and enables automated manufacturing.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The foam material undergoes phase transition from liquid injection state to expanded solid state, automatically bonding the component to the footwear upper. This phase change process provides both attachment and structural formation in a single automated step.

Inventive Principle:

Principle #36Phase transitions

4Reliability

If foam is injected to enclose lattice structure and bond components, then durability and automation are improved, but manufacturing complexity is worsened

Engineering Contradiction:

ImprovedurabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges multiple functions into a single foam injection process: enclosing the lattice structure, protecting against debris, providing durability, and bonding the component to the footwear upper. This consolidation reduces the number of separate manufacturing steps despite the added functionality.

Inventive Principle:

Principle #5Merging (Combining)

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

Enhances durability and abrasion resistance while automating parts of the manufacturing process, addressing the issues of debris collection and limited durability in existing custom components.

Implementation Method 1

injecting foam into the closed mold such that the foam operates to couple the lasted upper and the lattice structure together

Methodology Applied

Scientific EffectFoam injection and curing: Phase Change

Data Source

PatentUS11363855B2Footwear articles and methods for preparing a footwear article

Publication Date: 2022.06.21 VANS INC

AI summary

Methods for preparing a footwear article are disclosed herein. An example method may comprise disposing resin adjacent a mold, disposing a lattice structure in at least a portion of the resin disposed adjacent the mold, closing the mold using a lasted upper, injecting foam into the closed mold such that the foam operates to couple the lasted upper and the lattice structure together.