Reinforced Footwear Sole Structure With Injected Composite Conduits

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

There is a need for articles of footwear with improved stability, energy return, comfort, and weight savings, as well as efficient methods of manufacturing such footwear with reinforcements.

Innovation Solution

The use of additive manufacturing systems to create a sole structure with conduits that are filled with a composite reinforcement material, which is then cured to form reinforcements within the sole structure, allowing for customized lattice geometries and materials like continuous fiber bundles to enhance stability and strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If reinforcements are added to the sole structure to improve stability and energy return, then the stability and strength are improved, but the weight of the footwear increases

Engineering Contradiction:

Improvesole structure strengthVSAvoidfootwear weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies local quality by placing reinforcement members selectively at specific locations within the sole structure where stability and energy return are most needed, rather than uniformly reinforcing the entire sole. This allows targeted strengthening while minimizing unnecessary weight in other areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining a base sole material with reinforcement members made of different materials (such as fibers, foams, or polymers) to create a multi-material structure. This allows the sole to have both the base material's properties and the reinforcement material's enhanced properties, optimizing strength-to-weight ratio.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If traditional manufacturing methods are used to create reinforcements, then the manufacturing process is simpler, but construction defects and waste increase

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidconstruction defect rate

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the reinforcement creation process with the main sole manufacturing process by using additive manufacturing to deposit reinforcement materials directly during sole formation. This integration eliminates separate reinforcement steps and reduces the risk of defects from multi-step assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical reinforcement methods (such as hand-laying fibers or separate molding steps) with additive manufacturing technology, which uses computer-controlled material deposition. This substitution reduces human error, improves consistency, and minimizes waste through precise material placement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If reinforcement materials are injected into conduits to enhance stability, then the stability and comfort are improved, but the device complexity increases

Engineering Contradiction:

Improvesole structure stabilityVSAvoidmanufacturing system complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming conduits or channels within the sole structure before injecting reinforcement materials. These conduits are created using additive manufacturing or molding techniques, establishing the reinforcement pathways in advance to simplify the subsequent injection process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses conduits as intermediary structures that facilitate the injection of reinforcement materials. These conduits act as mediators between the injection system and the final reinforcement structure, allowing controlled material delivery while simplifying the overall manufacturing process despite the added component.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method enables the sole structure to be reinforced with high-performance materials, reducing construction defects and waste while optimizing reinforcement placement and material properties for enhanced stability and comfort.

Implementation Method 1

forming a sole structure using an additive manufacturing system

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

connecting the end of the conduit to an injector, injecting a reinforcement material into the channel of the conduit

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 3

injecting a reinforcement material into the channel of the conduit to form a reinforcement member

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS20250366563A1Article of footwear having reinforcements

Publication Date: 2025.12.04 PUMA SE

AI summary

A method of manufacturing an article of footwear includes forming a sole structure that uses an additive manufacturing system. The sole structure includes a conduit that extends within a region of the sole structure. The conduit includes an end that protrudes outwardly from a surface of the sole structure and a channel defined through the conduit. The method also includes connecting the end of the conduit to an injector and injecting a reinforcement material into the channel of the conduit to form a reinforcement member. The method further includes removing a portion of the end of the conduit.