Intermediate Outsole with Graded Midsole for Footwear Size Reduction
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Solution Overview
Problem
Current footwear manufacturing methods require multiple outsole sizes for each whole and half size, increasing production costs and complexity due to the need for separate dies and components for each size variation.
Innovation Solution
The method involves producing intermediate-sized outsoles that serve as a midpoint between standard sizes, allowing a single outsole size to accommodate both whole and half sizes by using a graded or contoured outer peripheral edge on the midsole to align with different upper and outsole sizes, reducing the number of required components and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple outsole sizes are used for each whole and half size, then the fit and performance for each size is optimized, but the production cost and manufacturing complexity increase
Solution Approach 1:
The midsole is divided into two distinct portions: an upper portion that interfaces with the upper and a lower portion that interfaces with the outsole. This segmentation allows each portion to be optimized for its specific size requirement while being part of the same component, enabling the midsole to bridge the size mismatch between uppers and outsoles.
Solution Approach 2:
The midsole exhibits different sizes at different locations - the upper portion has one size (matching the upper) while the lower portion has another size (matching the outsole). This local variation in dimensions allows the single midsole component to accommodate both whole and half sizes effectively.
2Reliability
If multiple outsole sizes are used for each whole and half size, then the fit and performance for each size is optimized, but the production cost increases
Solution Approach 1:
The intermediate-sized outsole serves multiple functions: it can be paired with both whole-size uppers and half-size uppers through the graded midsole. This multi-functionality reduces the number of outsole sizes needed by nearly 50%, allowing a single outsole design to serve multiple size requirements.
Solution Approach 2:
The graded midsole acts as an intermediary component that mediates between the upper and outsole of different sizes. It provides the transition needed to match a smaller upper with a larger outsole or a larger upper with a smaller outsole, eliminating the need for multiple outsole sizes.
3Device complexity
If a single outsole size is used for both whole and half sizes, then the production cost and complexity are reduced, but the fit and performance for specific sizes may be compromised
Solution Approach 1:
The midsole is designed with dynamic adaptability through its graded structure, allowing it to effectively connect components of different sizes. The gradual transition in dimensions enables the system to accommodate size variations without compromising the fit and performance for specific sizes.
4Productivity
If intermediate-sized outsoles with graded midsoles are used, then the number of outsole sizes needed is reduced by nearly 50%, but the midsole manufacturing complexity increases
Solution Approach 1:
The solution introduces a dimensional gradient within the midsole itself, transitioning from one size at the upper portion to another size at the lower portion. This dimensional variation within a single component allows it to bridge size mismatches without requiring multiple discrete outsole sizes, thereby improving productivity.
Data Source
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AI summary
An article of footwear and a method of assembling the article of footwear are disclosed. The article of footwear comprises an upper with a first size and an outsole with a second size that is different from the first size. A midsole of the article of footwear may be configured with an upper portion that fits the first size of the upper and a lower portion that fits the second size of the outsole.