Integrated Footwear Structure With Movable Support Components
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Solution Overview
Problem
Existing footwear designs often require complex, multi-component structures that increase manufacturing time and complexity, failing to adequately address the need for cushioning and support while being durable and comfortable.
Innovation Solution
The development of footwear comprising integrated components formed as a single structure with movable parts that can be transformed from a first to a second position, allowing for the integration of features like lace supports, cages, and heel counters through a single manufacturing process, reducing complexity and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If footwear is designed with complex multi-component structures to provide proper cushioning and support, then footwear performance is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent combines multiple footwear components (upper, sole, lace support, cage, heel counter) into a single integrated article formed from one continuous piece of material. This merging eliminates the need for separate manufacturing and assembly steps for each component, thereby reducing manufacturing time while maintaining the functional performance of each individual component.
Solution Approach 2:
The single continuous material structure performs multiple functions simultaneously: it provides the upper portion for foot coverage, the sole portion for ground contact, lace supports for securing, cages for structural integrity, and heel counters for support. This multi-functionality within a single component resolves the contradiction by eliminating the need for multiple specialized components.
2Ease of manufacture
If footwear components are formed as a single integrated structure, then manufacturing complexity is reduced, but the ability to provide movable components (e.g., lace supports, cages) is limited
Solution Approach 1:
The patent incorporates movable elements within the single continuous structure by creating regions with different degrees of flexibility. The lace support and cage portions are designed to be movable relative to the main body through controlled flexibility zones, allowing these components to adapt and move as needed while remaining part of the integrated structure. This resolves the contradiction by enabling dynamic functionality without requiring separate movable components.
3Manufacturing precision
If multiple formation steps and assembly steps are used to create footwear components, then component precision is improved, but manufacturing time increases
Solution Approach 1:
The patent performs all formation operations on the footwear article while it is in a green (uncured) state, before the material sets and hardens. This preliminary action allows for precise shaping and positioning of all components (upper, sole, lace support, cage, heel counter) in a single continuous process, eliminating the need for subsequent assembly steps and reducing total manufacturing time while maintaining precision.
Data Source
AI summary
Articles of footwear comprising movable components integrally formed with other parts of the footwear. The article of footwear can comprise a component integrally formed with an upper portion, a sole portion, or both, and connected to the upper portion or the sole portion at a hinged end. The component can comprise a second end opposite the hinged end that is attached to the upper portion or the sole portion at one or more connection points.