Footwear Soles With Co-Molded Lattice and Solid Regions
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Solution Overview
Problem
Existing methods for manufacturing footwear soles using lattice structures and solid components face challenges in combining these elements effectively, leading to increased manufacturing difficulty, time, and cost, with adhesive bonding being weak, prone to degradation, and adding weight.
Innovation Solution
A co-molding process integrates a lattice structure with a solid material during molding, mechanically binding them without adhesives, allowing for customized performance characteristics by controlling the flow of solid material into the lattice structure through adjustable parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonding is used to combine lattice structure with solid component, then the sole can be assembled from separate parts, but the bonding is weak, prone to degradation, and adds weight
Solution Approach 1:
The patent merges the lattice structure and solid component into a single co-molded piece, eliminating the need for adhesive bonding. The lattice structure is integrated directly into the molded sole, creating a unified component that achieves both manufacturing ease and structural strength without the weaknesses of adhesive joints.
Solution Approach 2:
The patent introduces a co-molding process as an intermediary manufacturing method that combines lattice structure fabrication and solid component formation in one step. This mediator process eliminates the need for secondary bonding operations and their associated weaknesses.
2Ease of manufacture
If adhesive bonding is used to combine lattice structure with solid component, then the sole can be assembled from separate parts, but the process adds weight
Solution Approach 1:
The patent combines the lattice structure and solid component into one integrated molded piece, eliminating the additional weight from adhesives and multiple assembly steps. The co-molding process creates a single-component sole that is lighter than assembled alternatives.
3Ease of manufacture
If traditional molding methods are used to manufacture the sole, then the manufacturing cost is low, but the ability to customize performance characteristics is limited
Solution Approach 1:
The patent applies local quality by varying the lattice structure parameters (cell size, wall thickness, density) in different regions of the sole to achieve customized performance characteristics. This allows different areas of the sole to have tailored mechanical properties while maintaining cost-effective molding processes.
Solution Approach 2:
The patent utilizes parameter changes by modifying lattice structure geometry, material composition, and density distributions within the molded sole. These parameter variations enable customization of performance characteristics such as cushioning, support, and energy return while maintaining manufacturing efficiency.
4Adaptability or versatility
If lattice structure with varying unit cells is used, then the performance characteristics can be optimized, but the manufacturing complexity increases
Solution Approach 1:
The patent implements local quality by creating regions with different unit cell characteristics (density, size, geometry) within the lattice structure. This allows performance optimization in specific areas while maintaining manufacturing feasibility through systematic regional variations rather than entirely complex structures.
Solution Approach 2:
The patent manages complexity through parameter changes by systematically varying lattice parameters (cell size, wall thickness, density) across different regions. This controlled parameter variation achieves performance optimization while maintaining manufacturability through predictable, scalable design approaches.
Data Source
AI summary
A sole for an article of footwear includes a plurality of portions, including at least a first portion and a second portion. The first portion includes a lattice structure having a plurality of unit cells. The plurality of unit cells may include a first subset of unit cells and a second subset of unit cells that is different than the first subset of unit cells. The second portion includes a solid material that at least partially encapsulates one or more of the unit cells of the first subset of unit cells.