Multi-Part Footwear Sole Assembly with U-Shaped Midsole
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Solution Overview
Problem
Conventional athletic footwear sole structures lack optimal stability, cushioning, and support, primarily due to the limitations of single-layer midsoles made from polymer foam materials that fail to adapt effectively to varying demands of different activities.
Innovation Solution
A multi-part sole assembly featuring a U-shaped outer midsole member and a more resilient inner member, both secured to the upper and outsole, with distinct materials and design features such as retaining walls for enhanced support and stability, allowing for customized performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-layer polymer foam midsole is used, then the manufacturing process is simple and cost-effective, but the footwear lacks optimal stability, cushioning, and support for varying activity demands
Solution Approach 1:
The midsole is divided into multiple layers: a first midsole layer and a second midsole layer with different material properties. The first layer provides foundational support while the second layer enhances cushioning and stability, allowing the footwear to adapt to varying activity demands through layered material characteristics
Solution Approach 2:
The patent employs composite materials by combining different polymer foam materials with distinct hardness and density properties in the midsole layers. This composite structure enables the footwear to provide both stability and cushioning simultaneously, addressing the need for adaptability across different activities
2Stability of the object's composition
If the midsole hardness is increased for stability, then structural support improves, but ground reaction force attenuation and cushioning decrease
Solution Approach 1:
The patent applies local quality by creating regions of different hardness within the midsole structure. The first midsole layer has a first hardness providing structural support, while the second midsole layer has a second hardness optimized for cushioning. This spatial variation in material properties allows simultaneous achievement of stability and force attenuation
3Reliability
If a multi-layer midsole structure is implemented, then stability and cushioning are improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The manufacturing process is segmented into sequential steps: forming the first midsole layer, then forming the second midsole layer on top of it. This segmented approach allows each layer to be optimized independently while maintaining overall manufacturing feasibility through a systematic multi-step process
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 multi-part sole assembly provides improved stability, cushioning, and support, enhancing the overall performance and feel of the footwear by customizing the material properties and design features to meet specific activity demands.
Implementation Method 1
An inner member is positioned between the arms of the outer member and is formed of a second material that is more resilient than the first material
Data Source
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AI summary
An article of footwear includes an upper, a midsole beneath the upper, and an outsole beneath the midsole. The midsole includes a substantially U-shaped outer member defining a pair of forwardly extending arms spaced from one another and formed of a first material. An inner member is positioned between the arms of the outer member and is formed of a second material that is more resilient than the first material.