Footwear Toe Cap with Elastomeric Transition Layer
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Solution Overview
Problem
Existing footwear technologies do not adequately provide both comfort and protection for the toe area, especially in environments where objects or obstacles may contact the foot, and they often fail to maintain ankle flexibility and support effectively.
Innovation Solution
The design incorporates a toe cap made from a stiff, non-metal material with an elastomeric transition layer that enhances comfort and protection, along with a seam channel configuration between the ankle collar and heel portion to provide excellent ankle support and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a stiff toe cap is used to protect the toe area, then protection is improved, but comfort deteriorates
Solution Approach 1:
The patent uses a composite construction with a stiff outer toe cap layer for protection and a softer inner layer for comfort. The transition layer combines different material properties to bridge the hard toe cap and the flexible upper, creating a multi-material system that simultaneously achieves protection and comfort.
Solution Approach 2:
The transition layer acts as an intermediary element between the stiff toe cap and the flexible upper. This intermediate layer has intermediate stiffness properties that gradually transition from the hard outer cap to the soft inner upper, preventing direct contact between the foot and the hard protective layer while maintaining structural integrity.
2Strength
If a stiff transition region is used to support the forefoot, then support is improved, but flexibility deteriorates
Solution Approach 1:
The transition region has locally varied stiffness properties, with the stiffest portion positioned to support the forefoot while allowing other areas to remain more flexible. The elastomeric transition layer is strategically placed and dimensioned to provide support exactly where needed in the forefoot area while maintaining flexibility elsewhere.
3Strength
If the ankle collar is connected to the heel portion for support, then ankle support is improved, but flexibility deteriorates
Solution Approach 1:
The ankle collar is segmented into multiple portions with different connection configurations. At least a first portion is connected to the heel portion for support, while a second portion remains spaced apart to allow flexibility. This segmentation allows different regions of the ankle collar to perform different functions simultaneously.
Solution Approach 2:
The ankle collar configuration allows dynamic adaptation through selective connection. The spaced-apart portions enable the ankle collar to flex and move with the ankle joint, while the connected portions provide structural support. This creates a dynamic system that adapts to different movement states.
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 solution effectively protects the toe area while maintaining comfort and flexibility of movement, suitable for various applications including athletic and industrial footwear, by using a stiff toe cap and elastomeric transition layer, and a specific ankle collar and heel portion configuration.
Implementation Method 1
a transition region including an elastomeric transition layer disposed between the upper and the toe cap
Data Source
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AI summary
An article of footwear includes an upper having a toe box and a forefoot portion adjacent the toe box. The forefoot portion has a first region having a first stiffness. The article of footwear also includes a transition region including an elastomeric transition layer disposed on and partially covering the first region. The transition region has a second stiffness that is greater than the first stiffness. The article of footwear further includes a toe cap disposed on and partially covering the elastomeric transition layer at the toe box.