Footwear Frame With Replaceable Midsole Members for Custom Support
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Solution Overview
Problem
Conventional shoes suffer from outsoles wearing out faster than the rest of the sole structure and upper, leading to unnecessary replacement of entire shoes despite the upper and other components being usable, and lack customization for varying support requirements during different physical activities.
Innovation Solution
An article of footwear with a frame surrounding midsole members, featuring apertures for a lace to tighten or loosen the frame, allowing customizable midsole members and enabling replacement of worn-out components, manufactured through additive manufacturing processes using materials like thermoplastic polyurethane (TPU) and foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional shoes are used with traditional sole structures, then the outsole provides initial traction and support, but the outsole wears out faster than the rest of the sole structure and upper, leading to unnecessary replacement of entire shoes
Solution Approach 1:
The sole structure is divided into separate components: a frame, multiple replaceable midsole members, and an outsole. This segmentation allows the outsole and midsole members to be independently replaced when worn, extending the overall shoe lifespan without requiring replacement of the entire shoe.
Solution Approach 2:
The patent enables selective replacement of worn-out midsole members and outsoles while retaining the frame and upper. Users can discard only the worn components and recover/reuse the durable frame and upper portions, reducing waste and extending product life.
2Ease of manufacture
If conventional shoes have fixed sole structures, then manufacturing is simplified, but customization for varying support requirements during different physical activities is not possible
Solution Approach 1:
The sole structure transitions from a fixed design to a dynamic, customizable system where midsole members can be selectively replaced based on different physical activities and support requirements, enabling adaptability while maintaining manufacturing efficiency through modular components.
Solution Approach 2:
The frame and upper are designed as universal components that can accommodate multiple different midsole members tailored for various activities (running, walking, sports). This multi-functionality allows a single shoe platform to serve multiple purposes through component interchangeability.
3Reliability
If shoes are replaced when the outsole wears out, then continuous support and safety are maintained, but the upper and other components are discarded despite being usable, increasing waste
Solution Approach 1:
The patent enables selective replacement of only the worn-out outsole and midsole members while retaining and reusing the durable frame and upper components. This reduces material waste by discarding only the necessary worn parts rather than the entire shoe.
Solution Approach 2:
The design allows different parts of the shoe to have different replacement cycles based on their wear characteristics. The outsole and midsole members are designed for periodic replacement, while the frame and upper are designed for long-term reuse, optimizing both reliability and resource efficiency.
Data Source
AI summary
An article of footwear has a forefoot region, a heel region, a midfoot region, a lateral side, and a medial side and includes an upper and a sole structure coupled to the upper. The sole structure includes a frame coupled to the upper and defines a plurality of apertures along the lateral side and the medial side. The frame has a frame exterior surface and a frame interior surface, opposite the frame exterior surface, that defines a frame internal cavity, a lace received within the plurality of apertures and extends along the frame exterior surface to the frame interior surface in each of the forefoot region, the midfoot region, and the heel region, and a plurality of midsole members disposed within the frame internal cavity. When the lace is in a tightened configuration, the frame is pulled toward the upper to secure the frame to the sole structure.