Footwear Midsole Multi-Layer Wave Support Assembly
Solution Overview
Problem
Conventional athletic footwear midsoles, made from polymer foam, face challenges in providing customized support and performance optimization across different areas of the foot, as they are limited by uniform material properties and layer configurations.
Innovation Solution
A multi-layered support assembly in the midsole with varying wave-shaped profiles and frequencies, allowing for adjustable compressibility and stiffness across different sections, tailored through the use of multiple layers with distinct amplitudes and frequencies, and potentially different materials and thicknesses, to enhance stability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional uniform polymer foam midsole is used, then the manufacturing process is simple and cost-effective, but the footwear cannot provide customized support and performance optimization across different areas of the foot
Solution Approach 1:
The midsole is divided into multiple layers (first layer, second layer, third layer) with different wave-shaped profiles, frequencies, and amplitudes. Each layer can be independently configured to provide specific support characteristics to different areas of the foot, enabling customized support while maintaining a systematic manufacturing approach.
Solution Approach 2:
Different portions of the footwear are configured with distinct layer combinations and wave parameters (frequency, amplitude, thickness). This allows specific areas to have tailored compressibility and stiffness properties optimized for their functional requirements, such as higher support in the heel area versus the forefoot area.
2Adaptability or versatility
If multiple layers with varying wave-shaped profiles are used to optimize performance, then customized support is achieved, but the manufacturing complexity increases
Solution Approach 1:
The support assembly is segmented into discrete layers that can be manufactured separately using standardized wave-shaped profile techniques. This segmentation allows each layer to be optimized independently while simplifying the overall manufacturing process through modular assembly of pre-fabricated components.
Solution Approach 2:
The patent varies parameters such as wave frequency, wave amplitude, layer thickness, and material composition across different layers to achieve performance optimization. These parameter changes are implemented through controlled manufacturing processes that can adjust wave characteristics during foam formation or layer construction.
3Reliability
If the midsole material is made more compressible for better cushioning, then comfort is improved, but the stability and pronation resistance may be reduced
Solution Approach 1:
Different layers are assigned different compressibility characteristics through variations in material density, wave amplitude, and layer thickness. The lower layers can provide firmer support for pronation resistance while upper layers offer softer cushioning, creating a gradient of mechanical properties that simultaneously achieves both comfort and stability.
Solution Approach 2:
The multi-layer construction effectively creates a composite midsole system where each layer contributes different mechanical properties. By combining materials and structures with varying stiffness and compressibility, the assembly achieves a balance between cushioning and pronation resistance that cannot be obtained with a single uniform material.
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
This configuration allows for tailored support and performance optimization in different areas of the footwear, improving stability and cushioning by varying the frequency and amplitude of the layers, enabling better resistance to pronation and adaptability to specific activities or user needs.
Implementation Method 1
the midsole is the primary sole structure element that imparts cushioning and controls foot motions. Suitable polymer foam materials for the midsole include ethylvinylacetate or polyurethane, which compress resiliently under an applied load to attenuate ground reaction forces
Implementation Method 2
The compression of the foam is affected by hysteresis loss, and deflection of such systems is affected by the volume of the compressed mass of the midsole
Implementation Method 3
A multi-layered support assembly in the midsole with varying wave-shaped profiles and frequencies, allowing for adjustable compressibility and stiffness across different sections, tailored through the use of multiple layers with distinct amplitudes and frequencies
Data Source
Figure 1
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Figure 6~8
AI summary
An article of footwear (10) including an upper (12) and a sole assembly (14) secured to the upper and including a support assembly (30) having an upper member (32) and a lower member (34) spaced from the upper member. A first layer (36) is positioned beneath and in contact with the upper member and has a wave shaped profile with a plurality of first wave crests (38) and first wave troughs (40). A second layer (42) is positioned above the lower member and has a wave shaped profile with a plurality of second wave crests (44) and second wave troughs (46).