Mesh-Backed Sockliner With Through-Hole Upper Layer for Pressure Distribution
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Solution Overview
Problem
Existing sockliners do not effectively combine shock absorption and comfort, often leading to discomfort and reduced durability due to uneven surfaces and inadequate pressure dispersion.
Innovation Solution
A sockliner with a two-layer structure, comprising a base layer of a three-dimensional mesh structure and an upper layer with through-holes, made using vat polymerization three-dimensional additive manufacturing, providing enhanced shock absorption and comfort through material and structural design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional single-layer sockliner structure is used, then manufacturing is simple, but shock absorption and comfort are insufficient
Solution Approach 1:
The sockliner is divided into two distinct layers: a base layer with three-dimensional mesh structure for shock absorption and an upper layer with through-holes for comfort and breathability. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between manufacturing simplicity and shock absorption performance.
Solution Approach 2:
The invention uses a composite two-layer structure where the base layer and upper layer are integrated through additive manufacturing. This composite approach combines the shock absorption capability of the mesh structure with the comfort benefits of the through-hole layer, achieving both reliability and manufacturability.
2Reliability
If a three-dimensional additive manufacturing method is used, then shock absorption and comfort are improved, but manufacturing complexity increases
Solution Approach 1:
The invention merges the base layer and upper layer into a single integrated component manufactured in one additive manufacturing process. This eliminates the need for separate manufacturing and assembly steps, reducing manufacturing complexity while maintaining the shock absorption and comfort benefits of the two-layer structure.
Solution Approach 2:
The additive manufacturing process allows for precise control of structural parameters such as mesh density, through-hole distribution, and layer thickness. By optimizing these parameters, the invention achieves high shock absorption performance and comfort while managing manufacturing complexity through digital design flexibility.
3Ease of operation
If the upper layer has an uneven surface, then comfort is reduced, but manufacturing is simpler
Solution Approach 1:
The upper layer is designed with locally optimized features including through-holes in high-pressure areas and a controlled surface profile. This local quality approach ensures comfort in critical contact zones while maintaining manufacturability through the additive manufacturing process that can selectively create different surface characteristics in different regions.
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 sockliner achieves improved shock absorption, comfort, and durability by distributing foot pressure evenly and reducing wear-induced discomfort, while allowing for efficient mass production.
Implementation Method 1
made using vat polymerization three-dimensional additive manufacturing
Data Source
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AI summary
A sockliner (1A) includes: a base layer portion (10) formed of a three-dimensional mesh structure body; and an upper layer portion (20) formed of a sheet-like structure body that covers an upper surface of the base layer portion (10). The upper layer portion (20) includes a through-hole group including a plurality of holes (24), and each of the holes (24) is located inward from a peripheral edge of the upper layer portion (20) without reaching the peripheral edge. In a case where a surrounding region is defined as a region between the peripheral edge and a position offset by 4.0 mm inward from the peripheral edge, the through-hole group includes an outermost hole group including a plurality of holes located closest to the peripheral edge so as to overlap with the surrounding region and to align along the peripheral edge.