Footwear Sole Structure With Staged Compression Energy Return

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Solution Overview

Problem

Existing sole structures in footwear lack targeted and tuned cushioning, failing to provide progressive and efficient energy return under dynamic compressive loads.

Innovation Solution

A sole structure with a cushioning component featuring a protruding shape and a projection that interfaces with a chamber, allowing for staged compression and decompression, tuned by geometry and fluid-filled chambers, to achieve progressive cushioning and energy return.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional sole structure is used, then the footwear is simple to manufacture, but it lacks targeted and tuned cushioning and fails to provide progressive energy return

Engineering Contradiction:

Improvecushioning performanceVSAvoidsole structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sole structure is divided into multiple functional layers: a first sole layer with a first cushioning component, a second sole layer with a second cushioning component, and a sole component with projections. Each layer and component is segmented to provide different cushioning characteristics and energy return properties, enabling targeted and tuned cushioning performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sole structure are assigned different material properties and structural characteristics. The first and second cushioning components have different densities and compressibility characteristics tailored to specific zones, while the projections on the sole component provide localized reinforcement and guidance. This local differentiation enables progressive energy return and targeted cushioning.

Inventive Principle:

Principle #3Local quality

2Reliability

If a sole structure with multiple cushioning components is used, then progressive cushioning and energy return are achieved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveenergy returnVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Multiple cushioning components and sole layers are merged into an integrated assembly where the first sole layer, second sole layer, and sole component work together as a unified system. The projections on the sole component interface with both cushioning components, creating a coordinated mechanism that achieves progressive energy return while streamlining the manufacturing process through integrated design.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If the sole structure uses fluid-filled chambers and tuned geometries, then staged compression and decompression are achieved, but the device complexity increases

Engineering Contradiction:

Improvestaged compressionVSAvoidgeometry tuning

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The sole structure incorporates dynamic elements including fluid-filled chambers that allow staged compression and decompression. The geometries of the cushioning components and projections are designed to engage at different stages of loading, enabling the structure to adapt its stiffness and cushioning characteristics dynamically during the compression and rebound phases of foot strike.

Inventive Principle:

Principle #15Dynamics

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 sole structure provides targeted cushioning and efficient energy return through staged compression, enhancing comfort and performance by absorbing dynamic loads in stages with varying stiffness profiles.

Implementation Method 1

the outer surface of the cushioning component resiliently compresses and inverts, with an inverted portion of the outer surface reverting back to the protruding shape

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

fluid-filled chambers, tuned by geometry and fluid-filled chambers, to achieve progressive cushioning and energy return

Methodology Applied

Scientific EffectCompressibility: Compression

Data Source

PatentUS20260090606A1Sole structure for an article of footwear

Publication Date: 2026.04.02 NIKE INC

AI summary

A sole structure for an article of footwear includes a cushioning component that has an outer surface and at least partially defines a chamber that is at least partially surrounded by the outer surface. At least a portion of the outer surface has a protruding shape in the absence of a compressive load of at least a predetermined magnitude on the cushioning component. The sole structure includes a sole component that includes a projection that either extends through the outer surface of the cushioning component and within the chamber, or interfaces with a recess in the outer surface of the cushioning component, or protrudes from an inner surface of the cushioning component into the chamber.