Nested Footbed Frame for Reliable Shoe Upper Fastening
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Solution Overview
Problem
Existing shoe manufacturing methods limit design flexibility by requiring rigid materials for stapling the upper to the sole, as soft materials like foam rubber are unsuitable for staple fastening, leading to potential dislodgment of staples.
Innovation Solution
A shoe design featuring a footbed with an embedded internal frame, allowing the upper to be secured to a midsole using fasteners that pass through the midsole and into the internal frame, enabling secure attachment without necessitating rigid materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If soft materials like foam rubber are used for the sole, then comfort and flexibility are improved, but staple fastening becomes unreliable causing staples to become dislodged
Solution Approach 1:
The footbed is nested within the midsole structure, with the perimeter of the footbed smaller than the perimeter of the midsole. This allows the footbed to be inserted into the midsole, creating a nested configuration where the upper is stapled between the footbed and midsole, enabling reliable fastening while maintaining soft material composition
Solution Approach 2:
The sole is segmented into multiple independent components: a footbed with internal frame, a midsole, and an outsole. This segmentation allows each component to be optimized independently - the footbed for comfort with soft materials, while the midsole provides the structural framework for reliable staple attachment
2Reliability
If rigid materials or rigid frames are used in the sole, then staple fastening reliability is improved, but design flexibility and shaping options are reduced
Solution Approach 1:
The internal frame is positioned locally within the footbed at specific areas where staple attachment is needed. This localized reinforcement provides reliable fastening only where necessary, while the rest of the footbed maintains its soft, comfortable material composition and design flexibility
Solution Approach 2:
The nested structure allows the footbed with its internal frame to be inserted into the midsole, enabling independent design of each component. The footbed can be shaped and designed independently while the midsole provides the structural framework, increasing overall design versatility
3Adaptability or versatility
If the footbed perimeter is made smaller than the midsole perimeter, then independent design of footbed and outsole is enabled, but manufacturing complexity increases
Solution Approach 1:
The smaller footbed is nested within the larger midsole structure, creating a hierarchical arrangement where components are inserted into one another. This nested configuration enables independent design of each component while maintaining a relatively simple overall assembly process through sequential insertion
Data Source
AI summary
A shoe includes an upper attached to a sole, where the sole may include a footbed having an embedded internal frame and a midsole/outsole combination. The perimeter of the footbed is smaller than the perimeter of the midsole so that the portion of the footbed encompassing the internal frame may be inserted into the midsole. The upper of the shoe is inserted into a perimeter space formed between the footbed and the midsole whereupon the upper and midsole are secured together with fasteners, such as staples extending through the midsole and the upper, and into the internal frame.