Footwear Sole With Hollow Polymeric Elements
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Solution Overview
Problem
Current footwear soles, particularly in athletic footwear, face challenges in providing consistent cushioning and durability due to the limitations of traditional materials like polyurethane foam, which often suffer from compression set and lack of adaptability to varying foot pressures.
Innovation Solution
A sole structure incorporating hollow polymeric elements with sealed, fluid-filled internal cavities at predetermined pressures, made from thermoplastic polyurethane and gas barrier polymers, which are fixed together using UV light curing or binders to create a resilient and translucent midsole with varying diameters for enhanced cushioning and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional polyurethane foam is used in the sole, then cushioning is provided, but compression set occurs and durability is reduced
Solution Approach 1:
The sole is divided into multiple hollow polymeric elements (spheres, capsules, or irregular shapes) filled with fluid at different pressures, rather than using a single continuous foam material. Each hollow element acts as an independent cushioning unit that resists compression set, collectively providing durable and consistent cushioning performance.
Solution Approach 2:
The hollow polymeric elements are filled with fluid (gas or liquid) at predetermined pressures to provide cushioning. The fluid-filled cavities resist compression forces through pneumatic/hydraulic pressure, preventing the compression set that plagues traditional foam materials while maintaining durability.
2Adaptability or versatility
If uniform sole material is used, then manufacturing is simple, but adaptability to varying foot pressures is limited
Solution Approach 1:
Different regions of the sole contain hollow polymeric elements with varying diameters, shapes, and fluid pressures tailored to specific foot pressure zones. High-pressure areas receive elements optimized for impact absorption, while low-pressure areas use elements for comfort, creating a locally optimized sole structure that adapts to varying foot pressures.
3Adaptability or versatility
If hollow polymeric elements with varying diameters are used, then customizable cushioning is achieved, but manufacturing complexity increases
Solution Approach 1:
The hollow polymeric elements are manufactured with varying parameters (diameter, shape, wall thickness, fluid pressure) to customize cushioning characteristics for different sole regions. By controlling these parameters during manufacturing, the invention achieves customizable cushioning while maintaining production efficiency through standardized manufacturing processes for the hollow elements.
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 solution provides improved cushioning and durability by maintaining resilience and preventing compression set, offering a customizable underfoot feel through varying polymeric element diameters and pressures, while being translucent for aesthetic appeal.
Implementation Method 1
Each of the hollow polymeric elements has a sealed, fluid-filled internal cavity capable of retaining fluid at a predetermined pressure
Implementation Method 2
fixing the hollow polymeric elements relative to one another by curing when the mold assembly is closed
Data Source
AI summary
A sole structure for an article of footwear includes a sole component having a plurality of hollow polymeric elements in contact with one another or with binder between the hollow polymeric elements and fixed relative to one another. Each of the hollow polymeric elements defines a sealed, fluid-filled internal cavity capable of retaining fluid at a predetermined pressure. A method of manufacturing a sole structure for an article of footwear includes placing a plurality of hollow polymeric elements in contact with one another or with binder between the hollow polymeric elements, and fixing the plurality of hollow polymeric elements relative to one another to form a sole component. Each of the hollow polymeric elements has a sealed, fluid-filled internal cavity capable of retaining fluid at a predetermined pressure.