Foamed Polymer Outsole Reducing Shoe Weight and Gravel Entrapment

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Solution Overview

Problem

Conventional shoes with ground engaging surfaces featuring high projections and deep recesses result in a heavy sole that can be uncomfortable and prone to gravel entrapment, compromising both weight and wearability.

Innovation Solution

An outsole composed of an elastomer sheet with dispersed foamed polymer particles, which provides a lightweight and simplified ground engaging surface by varying mechanical performance characteristics through the presence and absence of polymer particles, reducing thickness and weight while maintaining grip performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high projections and deep recesses are formed on the ground engaging surface, then grip performance is improved, but the shoe sole becomes thick and heavy

Engineering Contradiction:

Improvegrip performanceVSAvoidshoe weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent changes the material composition parameter by incorporating foamed polymer particles into the elastomer sheet, altering the density and mechanical properties of the outsole material itself, allowing for lighter weight while maintaining structural integrity and grip performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite material structure combining elastomer with dispersed foamed polymer particles, creating a heterogeneous material that provides both the necessary mechanical strength for grip and reduced weight through the air-filled voids in the foam particles

Inventive Principle:

Principle #40Composite materials

2Reliability

If high projections and deep recesses are formed on the ground engaging surface, then grip performance is improved, but the shoe becomes uncomfortable and prone to gravel entrapment

Engineering Contradiction:

Improvegrip performanceVSAvoidwearing comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent modifies the material parameters of the outsole by using foamed polymer particles, which change the compliance and cushioning characteristics of the material, providing comfort even with simplified surface geometry

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of creating complex projections and recesses to achieve grip performance, the patent inverts the approach by using a material with inherent compliant characteristics that can deform to provide grip without requiring complex geometric features, thereby eliminating gravel entrapment issues

Inventive Principle:

Principle #13The other way round (Inversion)

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 outsole achieves a lightweight and comfortable shoe design with improved grip and reduced risk of gravel entrapment, maintaining excellent mechanical performance and adhesiveness without an overly complex shape.

Implementation Method 1

a plurality of polymer particles dispersed in the sheet body, and the plurality of polymer particles being foamed particles each having a plurality of voids therein

Methodology Applied

Scientific EffectFoaming: Foam

Data Source

PatentUS11589638B2Outsole and shoe

Publication Date: 2023.02.28 ASICS CORP

AI summary

Provided in the present invention is a shoe that has a ground engaging surface with a simplified structure and that is excellent in lightweight properties since an outsole is composed of an elastomer sheet including a sheet body and foamed polymer particles dispersed in the sheet body.