Modular Cleated Footwear Sole Structure for Recyclable Disassembly
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Solution Overview
Problem
Existing cleated footwear designs often lack recyclability and sustainability, with components typically made from multiple materials that are difficult to disassemble and reuse.
Innovation Solution
A footwear structure comprising three main parts - an outer cage component, an inner upper component, and a foot support component - each made from a single material and assembled in a releasable manner, featuring cleat shells with undercuts and inserts for secure engagement, enhancing recyclability and sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If footwear components are made from multiple materials, then structural integrity and performance are improved, but recyclability and sustainability deteriorate
Solution Approach 1:
The footwear is divided into separate modular components (upper, midsole, outsole, lacing system) that can be independently removed and replaced. Each component is designed as a discrete unit with standardized connection interfaces, enabling easy disassembly for recycling while maintaining structural integrity during use.
Solution Approach 2:
Each footwear component is constructed from a single material type throughout (e.g., the outsole is entirely thermoplastic polyurethane, the upper is entirely thermoplastic elastomer), eliminating material complexity within each component and facilitating straightforward recycling processes.
2Ease of repair
If footwear components are made from a single material, then recyclability and sustainability are improved, but structural integrity and performance may deteriorate
Solution Approach 1:
The footwear system is segmented into multiple single-material components, each optimized for its specific function. The upper uses thermoplastic elastomer for flexibility, the midsole uses thermoplastic polyurethane for cushioning, and the outsole uses thermoplastic polyurethane for durability, allowing each component to achieve optimal structural integrity while maintaining recyclability.
Solution Approach 2:
The footwear achieves composite material benefits through assembly of different single-material components rather than using multi-material construction within each component. This composite approach at the system level provides diverse performance characteristics while each individual component remains homogeneous for easy recycling.
3Strength
If footwear components are assembled permanently, then structural integrity is improved, but ease of disassembly for recycling deteriorates
Solution Approach 1:
The connection interfaces between components are designed to be dynamically reversible - firmly engaged during normal use to maintain structural integrity, but easily disengaged when recycling is needed. The lace-up system and molded connections provide this dynamic characteristic, allowing transition between secure and separable states.
Solution Approach 2:
The lacing system is extracted as a separate removable component that can be independently removed without damaging the footwear structure. This extraction approach maintains structural integrity during use while enabling complete disassembly for recycling by removing non-essential components first.
4Ease of manufacture
If footwear is designed as a simple three-component structure, then ease of manufacture and recyclability are improved, but adaptability and versatility may deteriorate
Solution Approach 1:
The standardized connection interfaces and modular component design enable universal interchangeability. Different upper, midsole, or outsole components can be mixed and matched to create various footwear configurations for different activities or preferences, providing adaptability while maintaining the simple three-component manufacturing structure.
Data Source
AI summary
Articles of footwear in accordance with some aspects of this technology include a simple construction that includes three main parts, with each made from a single material and fit together in a releasable manner. The invention enhances the recyclability and sustainable nature of the article of footwear and shoe. At least some more specific aspects of this technology relate to footwear structure that may include three main parts: (a) an outer cage, which may include a single piece having features of: (i) a footwear upper and (ii) a sole structure having one or more cleat outer shells; (b) an inner upper component; and (c) a chassis and heel counter component with a bottom surface thereof that includes one or more cleat inserts and supports that fit inside the one or more cleat outer shells.