Multi-density Footwear Sole Elements via Press-Forming
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Solution Overview
Problem
Current footwear technologies face challenges in providing effective, targeted support and cushioning without increasing complexity and cost, particularly in sports that induce high stress on joints, leading to potential injuries.
Innovation Solution
A method for manufacturing customized sole elements with varying densities and hardness regions using polymeric materials, such as ethylene vinyl acetate, through a process involving preform molding and press-forming to create unitary constructions with distinct density and hardness profiles, allowing for tailored support and cushioning in specific areas of the shoe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support elements are incorporated into footwear to prevent over-pronation/supination, then the risk of injury is reduced, but the complexity and cost of the footwear increases
Solution Approach 1:
The sole element incorporates regions of varying density (first, second, third, and fourth maximum densities) at specific locations to provide targeted support. The first perimeter region, second perimeter region, third perimeter region, and central region each have different density characteristics that address specific biomechanical needs, eliminating the need for complex mechanical support structures while maintaining injury prevention functionality.
Solution Approach 2:
The invention changes the physical parameter of material density across different regions of the sole element. By varying the density from the first maximum density at the first perimeter region to the fourth maximum density at the central region, the sole element provides differentiated support characteristics that control foot movement and prevent injury without requiring complex mechanical mechanisms.
2Stability of the object's composition
If multiple support elements are added to control foot movement, then joint stability is improved, but the weight of the footwear increases
Solution Approach 1:
The invention merges the support function into the sole element itself by creating a unitary construction with varied density regions. Instead of adding separate support elements, the sole element's internal density structure (with first, second, third, and fourth maximum densities) provides the necessary joint stability, thereby avoiding additional weight from extra components.
3Adaptability or versatility
If customized support regions are created in the sole element, then targeted cushioning is improved, but the manufacturing complexity increases
Solution Approach 1:
The customized density distribution is built into the sole element during the initial molding process. The mold cavity is designed with features that create the first, second, third, and fourth maximum density regions in their final positions, allowing the complex density pattern to be produced in a single manufacturing step rather than requiring post-production customization or assembly.
Solution Approach 2:
The manufacturing process controls the density parameter during molding by using a mold cavity design that creates varying material compression or expansion during formation. This allows different regions (perimeter regions and central region) to achieve their target densities directly during production, maintaining manufacturing simplicity while achieving customized cushioning characteristics.
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 provides enhanced support and cushioning tailored to specific athletic needs, reducing the risk of injury by distributing stress more effectively across the foot, while maintaining a simpler and cost-effective manufacturing process.
Implementation Method 1
press-forming the sole element preform within the press mold cavity to form a unitary finished sole element
Data Source
AI summary
The invention relates to sole elements for articles of footwear, and systems and methods for manufacturing same. One embodiment of the invention includes a method of manufacturing a sole element for an article of footwear including the steps of forming a sole element preform, inserting the sole element preform into a press mold cavity, and press-forming the sole element preform within the press mold cavity to form a unitary finished sole element comprising a first region having a first density and hardness and a second region having a second density and hardness different from the first density and hardness.