Nested Foam Sole Structure for Cushioning and Wear Resistance
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Solution Overview
Problem
Footwear sole structures often face challenges in balancing durability, stability, and cushioning, as components with high energy return and elastic resiliency may wear out quickly, while those with greater abrasion resistance compromise cushioning properties.
Innovation Solution
A sole structure design featuring a foam core nested within a sole component, where the foam core is partially secured and partially unconstrained, allowing it to deform resiliently while being protected by a stiffer outer component, enhancing cushioning and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a foam core with high energy return and elastic resiliency is used, then cushioning ability is improved, but wear resistance deteriorates
Solution Approach 1:
The foam core is nested within the sole component, creating a protective enclosure where the softer foam core is shielded by the harder outer shell. This nesting structure allows the foam core to provide cushioning without direct exposure to wear-inducing external forces.
Solution Approach 2:
The sole structure combines two materials with different properties: a foam core material optimized for energy return and cushioning, and a sole component material optimized for durability and abrasion resistance. This composite structure allows each material to perform its specialized function without compromising the other.
2Stability of the object's composition
If the foam core is fully constrained by the sole component, then stability is improved, but cushioning performance deteriorates
Solution Approach 1:
The attachment configuration creates different local conditions within the foam core structure. The first portion is attached to provide stability, while the second portion remains detached to allow free deformation for cushioning. This local differentiation of constraints optimizes both stability and cushioning performance in their respective zones.
Solution Approach 2:
The foam core's side surface is divided into two distinct portions with different attachment states. This segmentation allows independent optimization of each portion's function: one for structural stability through attachment, and one for cushioning through detachment and free deformation capability.
3Reliability
If the foam core is left unconstrained, then cushioning performance is improved, but stability deteriorates
Solution Approach 1:
Instead of fully constraining or fully leaving unconstrained, the invention applies partial attachment to the foam core. The first portion is attached to provide sufficient stability, while the second portion is intentionally left detached to provide sufficient cushioning performance. This partial action approach optimizes the trade-off between the two competing requirements.
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 design ensures that the foam core maintains its cushioning properties by minimizing wear and maximizing deformation, while providing stability and energy return through a combination of materials with different stiffnesses.
Implementation Method 1
the foam core may have high energy return and elastic resiliency under compressive loading
Implementation Method 2
allowing it to deform resiliently while being protected
Implementation Method 3
the foam core may have a first stiffness and the sole component may have a second stiffness greater than the first stiffness. Accordingly, the relatively compliant foam core may be protected by the stiffer sole component
Data Source
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AI summary
A sole structure for an article of footwear may include a sole component having a bottom wall and a peripheral wall extending upward from the bottom wall and partially surrounding a space above the bottom wall. The sole structure may have a midsole that includes a foam core nested in the space. The peripheral wall of the sole component may be disposed outward of a side surface of the foam core. The sole component may be attached to a first portion of the side surface and detached from a second portion of the side surface. The second portion of the side surface may be disposed between the first portion and the bottom wall. The bottom wall of the sole component has a through hole and the foam core extends over the through hole.