Insertable Lightweight Interior Midsole for Footwear
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Solution Overview
Problem
Conventional athletic footwear midsoles, primarily made of polymer foam materials like EVA, lose cushioning over time due to air compression and do not provide adequate comfort and support, especially in the forefoot area for children's shoes.
Innovation Solution
An insertable lightweight interior midsole component made from a foam material comprising a reaction product of hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer, optionally with a cloth or sockliner-type material, which can be inserted into the footwear to provide enhanced comfort and support, particularly in the heel and forefoot regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer foam midsoles (EVA) are used, then the footwear provides initial cushioning and support, but the cushioning is lost over time due to air compression and the material does not provide adequate comfort in the forefoot area
Solution Approach 1:
The patent changes the material parameters by using a foam material comprising a reaction product of about 10 to about 100 phr hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer, 0 to about 40 phr modified hydrogenated acrylonitrile butadiene copolymer, and 0 to about 90 phr alpha olefin copolymer. This chemical composition change provides superior resistance to compression set and maintains cushioning properties over time compared to conventional EVA materials.
Solution Approach 2:
The patent divides the midsole into two separate components: an exterior midsole component and an insertable interior midsole component. The interior component can be removed and replaced, allowing the cushioning element to be maintained separately from the footwear upper, thereby extending the functional life of the cushioning system.
2Strength
If traditional midsole materials are used, then the structure provides basic support, but it does not provide adequate lightweight comfort and support in the forefoot area for children's shoes
Solution Approach 1:
The patent uses a composite foam material system consisting of hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer, modified hydrogenated acrylonitrile butadiene copolymer, and alpha olefin copolymer. This composite material provides both the necessary mechanical support properties and reduced weight, meeting both strength and weight requirements simultaneously.
Solution Approach 2:
The patent applies different material properties to different regions by providing an insertable interior midsole component that can be specifically designed with varying thickness and density in the forefoot area. This allows localized optimization of support and comfort where needed most, particularly in the forefoot region for children's shoes.
3Ease of manufacture
If the midsole is made as a single integrated component, then the manufacturing is simpler, but it cannot be replaced or adjusted for different foot sizes and conditions
Solution Approach 1:
The patent separates the midsole into an exterior midsole component that remains with the footwear and an insertable interior midsole component that can be removed and replaced. This segmentation maintains manufacturing simplicity for the integrated exterior component while enabling easy replacement and adjustment of the interior component for different foot sizes, growth stages, and comfort requirements.
Solution Approach 2:
The patent creates a dynamic midsole system where the insertable interior component can be exchanged based on changing needs. This allows the footwear to adapt to different foot sizes, growth conditions, and comfort requirements over time, transforming a static product into a dynamically adjustable solution.
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 offers improved comfort and support by maintaining cushioning and reducing energy loss, providing a soft and lightweight feel, suitable for various foot sizes including children's shoes, with adjustable thickness in different regions for optimal fit and performance.
Implementation Method 1
Conventional articles of athletic footwear include two primary elements, an upper and a sole structure... In addition to attenuating ground reaction forces and absorbing energy...
Implementation Method 2
The insertable lightweight interior midsole component is prepared from a foam material formed from a reaction product of about 10 to about 100 phr hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer... providing enhanced comfort and support... reducing energy loss
Data Source
AI summary
An article of footwear includes an upper that at least in part defines an interior chamber for receiving a foot; an insertable interior midsole component received within the interior chamber; and an exterior sole structure engaged with the upper, wherein the exterior sole structure includes: (a) an exterior midsole component and (b) optionally an outsole component that extends under the forefoot region, wherein the insertable interior midsole component is formed from a foam material comprising a reaction product of about 10 to about 100 phr hydrogenated or non-hydrogenated acrylonitrile butadiene copolymer, 0 to about 40 phr modified hydrogenated acrylonitrile butadiene copolymer, and 0 to about 90 phr alpha olefin copolymer, and at least one additive in an amount suitable to form the foam material; wherein the density of the foam material is less than 0.25 g/cm3.