Foam Pod Sole and Chassis Structure for Stable Flexible Footwear
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Solution Overview
Problem
Conventional shoes lack targeted support and optimization for a user's foot to enhance stability, reduce energy dissipation, and provide additional cushioning and protection during physical activities.
Innovation Solution
The shoe design incorporates a sole structure with a plurality of pods made from foam materials of varying densities and a chassis with an elongated fork structure, including a chassis stem, legs, and a continuous groove, which provides enhanced flexibility and support across different regions of the foot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional uniform foam material is used in the sole, then manufacturing is simple, but targeted support and energy dissipation are insufficient
Solution Approach 1:
The sole structure is segmented into multiple discrete foam pods distributed across the sole, each pod providing localized support. This segmentation allows different regions of the foot to receive targeted support while maintaining a relatively simple overall structure that is easier to manufacture than continuous variable-density foam.
Solution Approach 2:
Different foam pods are assigned different material properties (density, hardness, elasticity) based on the specific support needs of each foot region. This local quality approach provides targeted support and energy dissipation where needed without requiring complex global structure modifications.
2Reliability
If multiple foam pods with varying densities are used, then targeted support and energy dissipation are improved, but manufacturing complexity increases
Solution Approach 1:
The sole is divided into multiple independent foam pods that can be manufactured separately using standardized processes, then assembled into the final sole structure. This segmentation enables flexible material selection for each pod while maintaining manufacturing efficiency through modular assembly.
Solution Approach 2:
The foam pod design serves multiple functions simultaneously: providing localized support, dissipating energy, cushioning impact, and potentially providing thermal insulation. This multi-functionality reduces the need for additional separate components, simplifying the overall manufacturing process.
3Stability of the object's composition
If a rigid chassis structure is used, then stability is improved, but flexibility and comfort are reduced
Solution Approach 1:
The chassis is segmented into multiple discrete struts or support elements distributed throughout the sole structure. This segmentation provides stability through the collective rigidity of multiple elements while allowing flexibility between the segments, enabling the structure to adapt to foot movement while maintaining overall stability.
Solution Approach 2:
The chassis structure provides localized rigid support at critical stability points (heel, arch, forefoot) while leaving other regions more flexible. This local quality approach ensures stability where needed without compromising overall flexibility and comfort.
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 design improves flexibility and support, reduces energy loss, and enhances stability and cushioning, particularly in athletic activities, while allowing for customization to accommodate different foot sizes and shapes.
Implementation Method 1
Each pod may have a pod body and may also optionally have a coating that is disposed on an outer surface of the pod body. The pod body of each pod in the plurality of pods may be formed from a foam material.
Implementation Method 2
The sole structure may also include a chassis that is attached to a bottom surface of each pod in the plurality of pods. The chassis may include a plurality of ground contacting regions. The chassis may have an elongated fork structure.
Data Source
AI summary
An article of footwear includes an upper and a sole structure coupled with the upper. The sole structure defines a forefoot region, a midfoot region that corresponds with a portion of the article of footwear that is configured to encase an arch of a foot, and a heel region that is proximate and adjoining the midfoot region. The footwear also includes a first foam material and a second foam material within the sole structure. The first foam material has a density that is different than a density of the second foam material. At least one of the first and second materials is directly attached to the upper. The footwear further includes a plurality of ground contacting regions and a heel support plate that extends along a portion of the upper in the heel region.