Safety Footwear Outsole Anti-Perforation Layer Positioning
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Solution Overview
Problem
Existing safety outsoles with anti-perforation layers are rigid due to multiple glue layers, reducing flexibility and breathability, and the layer's distance from the flexing point limits elongation, affecting comfort and assembly efficiency.
Innovation Solution
An outsole design with an anti-perforation layer positioned close to the top surface at the forefoot and between the bottom surface and ventilation passages at the heel, allowing for improved flexibility and breathability, and a manufacturing method using injection molding to eliminate the need for glue layers, facilitating easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple glue layers are used to assemble the outsole layers (tread, anti-perforation layer, midsole), then the outsole becomes more rigid and assembly is more secure, but the flexibility and breathability of the shoe are reduced
Solution Approach 1:
The patent merges the anti-perforation layer with the midsole layer into a single integrated component. This eliminates the need for separate glue layers between these two layers, reducing the number of adhesive applications required while maintaining structural integrity. The integrated design allows the anti-perforation layer to be positioned closer to the flexing point, improving flexibility without compromising assembly strength.
Solution Approach 2:
The patent uses a thin film anti-perforation layer made of flexible material that can be integrated into the midsole structure. This thin film approach maintains puncture resistance while allowing the outsole to flex more naturally compared to thick glued layers, thereby improving both flexibility and breathability.
2Device complexity
If the anti-perforation layer is positioned distant from the top surface (as in prior art), then the shoe structure is simplified, but the outsole cannot correctly follow the walking movement of the foot, reducing flexibility
Solution Approach 1:
The patent changes the dimensional positioning of the anti-perforation layer within the outsole structure. Instead of placing it at the bottom near the ground contact surface, the layer is repositioned closer to the top surface and specifically near the flexing point in the forefoot area. This dimensional repositioning allows the anti-perforation layer to participate in the flexing motion, improving outsole flexibility during walking while maintaining structural integrity.
3Reliability
If traditional textile anti-perforation layers with tight weave are used, then puncture resistance is improved, but the thickness exceeds 4 mm and breathability is blocked
Solution Approach 1:
The patent employs a porous or micro-perforated anti-perforation layer that allows air passage while maintaining puncture resistance. The porous structure enables breathability by allowing air to pass through the layer, contrasting with the tight weave of traditional textile layers that block air flow. This porous material maintains structural integrity and puncture protection while improving shoe ventilation.
Solution Approach 2:
The patent uses composite material construction for the anti-perforation layer, combining materials that provide both puncture resistance and breathability. The integrated midsole-anti-perforation layer uses composite materials that achieve protective function without the thickness and breathability issues of traditional textile layers.
Data Source
AI summary
The present invention relates to an outsole (1) for safety footwear (10) comprising a top surface (2), designed to support the foot of the wearer, a bottom surface (4), designed to be in contact with the ground, and a side surface (6), designed to connect the top surface (2) and the bottom surface (4). The outsole (1) is further provided with an anti-perforation layer (8) and with at least one ventilation passage (12) designed to put into fluidic communication the side surface (6) and the top surface (2) of the outsole (1). According to the invention the outsole (1) is characterized in that the anti-perforation layer (8) is arranged between the bottom surface (4) and the at least one ventilation passage (12) at the heel portion of the outsole (1) and is arranged close to the top surface (2) at a forefoot portion of the outsole (1). The present invention also relates to a method for manufacturing such an outsole (1).