Midsole With 3D Wear-Resistant Shell And Foam Core

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current midsole manufacturing methods struggle to achieve high-resolution ornamental details on the outer surface due to insufficient lateral compressive forces, which are necessary for enhanced stability and cushioning in athletic shoes.

Innovation Solution

A method involving the formation of a three-dimensional TPU or EVA shell with a receiving space, filled with foam material to enhance strength, and bonded to a foam main body using an adhesive layer, allowing for precise ornamental details and reduced weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If compression molding is used to manufacture midsole, then material life is extended, but lateral compressive forces are insufficient resulting in poor ornamental detail resolution

Engineering Contradiction:

Improvematerial lifeVSAvoidornamental detail resolution

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The midsole is divided into two functional components: an inner foam midsole for shock absorption and an outer shell for providing lateral compressive forces and ornamental details. This segmentation allows each component to be optimized for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining foam material (for cushioning) with a shell material (for structural support and ornamental details). This composite approach enables the midsole to simultaneously achieve energy absorption, lateral stability, and high-resolution ornamentation.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If compressive forces are applied parallel to the inner surface of the mold sidewall, then molding process is simplified, but outer surface receives insufficient lateral compressive forces

Engineering Contradiction:

Improvemolding process simplicityVSAvoidlateral compressive force application

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Instead of applying lateral compressive forces directly during molding, the invention inverts the approach by forming the shell with ornamental details first, then filling it with foam material. This allows the shell to inherently provide the lateral compressive forces needed for high-resolution details.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The shell component is designed as a thin-walled structure that can be formed with complex ornamental details. This thin shell provides sufficient lateral rigidity to maintain high-resolution patterns while being lightweight and flexible enough for athletic shoe applications.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If traditional foam midsole material is used, then cushioning is provided, but external surface tension is insufficient for required stabilizing forces

Engineering Contradiction:

Improvecushioning capabilityVSAvoidexternal surface tension

Core Design Contradiction:

StrengthVSForce

Solution Approach 1:

The midsole is segmented into an inner foam layer for cushioning and an outer shell for providing lateral stability and surface tension. This division allows the foam to specialize in shock absorption while the shell specializes in providing the external forces needed for stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The combination of foam material and shell material creates a composite midsole structure where the foam provides compressive cushioning and the shell provides tensile strength and lateral stability, achieving both cushioning and sufficient external surface tension.

Inventive Principle:

Principle #40Composite materials

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 enables the creation of a midsole with high-resolution patterns and improved strength, providing enhanced stability and cushioning while maintaining a lightweight design.

Implementation Method 1

filling a foam material into the receiving space thereby to enhance the strength of the shell

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

bonding the shell together with the filled foam material to the main body of the midsole

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS8276295B2Midsole with three-dimensional wear-resistant component and the method for manufacturing it

Publication Date: 2012.10.02 DAH LIH PUH

AI summary

The present invention provides a midsole with a main body and a peripheral component having foam material filled inside, precise ornamental details and wear-resistant outer shell. According to the present invention, a preferred method of manufacturing a midsole with less weight than traditional and high resolution pattern is provided with the steps of: forming a TPU thin sheet into a shell with three-dimensional ornamental details and a receiving space, filling a foam material into the receiving space thereby to enhance the strength of the shell, trimming the shell together with the filled foam material from the thin sheet to be a peripheral component of the present invention, forming a main body of the midsole by foam material, and bonding the peripheral component to the main body of the midsole.