Multi-Plate Footwear Sole Structure for Region-Specific Cushioning

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Solution Overview

Problem

Conventional shoes have a unitary midsole and outsole structure that limits the ability to customize properties between the heel and forefoot regions, and a single plate construction that restricts the variety of performance characteristics.

Innovation Solution

A sole structure with multiple plates, including a first plate extending from the toe to the heel region, a second plate in the forefoot region coupled to the outsole, and a forefoot cushion supporting the anterior end of the first plate, with a heel cushion supporting the posterior end, forming a bridge in the midfoot region, and a gap between the cushions, allowing for customized material properties and improved performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a unitary midsole and outsole structure is used, then manufacturing is simpler, but the ability to customize properties between heel and forefoot regions is limited

Engineering Contradiction:

Improvecustomizability of sole propertiesVSAvoidsole structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The sole structure is divided into multiple discrete components including a forefoot cushion, heel cushion, and multiple plates (first plate, second plate, third plate) that can be independently configured. This segmentation allows each component to have customized material properties and geometric characteristics tailored to specific functional requirements of different foot regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sole are assigned different materials and structural characteristics. The forefoot region receives a forefoot cushion with specific cushioning properties, while the heel region receives a heel cushion with different properties. Plates are strategically positioned to provide localized stiffness or flexibility where needed.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If a single plate construction is used, then the sole structure is simpler, but the variety of performance characteristics is restricted

Engineering Contradiction:

Improveperformance characteristics varietyVSAvoidplate configuration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Instead of a single plate, the invention uses multiple plates (first plate extending from toe to heel, second plate in forefoot region, third plate in midfoot region) that can have different materials, thicknesses, and geometric configurations to provide diverse performance characteristics across different foot regions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sole structure combines multiple plate materials with different properties. Plates may be made from rigid materials for stability in certain regions or more flexible materials in other regions, allowing optimization of performance characteristics for running, walking, or other activities.

Inventive Principle:

Principle #40Composite materials

3Weight of stationary object

If continuous midsole and outsole materials are used, then structural integrity is maintained, but material usage and weight increase

Engineering Contradiction:

Improvesole weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of stationary objectVSStability of the object's composition

Solution Approach 1:

The continuous material structure is replaced with discrete segmented components (cushions and plates) that are strategically positioned to provide structural support only where needed. This eliminates unnecessary material in regions where full continuity is not required for structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Material is removed from the continuous midsole and outsole structure, replacing it with a framework of plates and cushions. This extraction of material reduces weight while the strategically positioned plates maintain structural integrity by providing support at critical locations.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of manufacture

If the same midsole material is used throughout, then manufacturing is easier, but the ability to provide different cushioning properties in different regions is lost

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidregion-specific cushioning

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The midsole is segmented into a forefoot cushion and heel cushion that can be manufactured as separate components with different materials and properties. This allows each cushion to be optimized for its specific functional requirements while potentially using standardized manufacturing processes for each component type.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12569031B2Sole structure for an article of footwear

Publication Date: 2026.03.10 PUMA SE

AI summary

A sole structure for an article of footwear includes a first plate, a second plate and a third plate. The first plate has a first anterior end disposed adjacent a toe end of the sole structure and a first posterior end disposed within a heel region of the sole structure. The second plate has a second anterior end disposed adjacent the toe end and a second posterior end disposed in a midfoot region of the sole structure. The third plate has a third anterior end disposed adjacent the toe end and a third posterior end disposed in the midfoot region. A first cushion is arranged between the first plate and the second plate, and wherein the second plate and the third plate are coplanar in the forefoot region.