Polygonal Lug Outsole Pattern for Footwear Traction and Flexibility
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Solution Overview
Problem
Conventional athletic footwear sole structures lack optimal traction and flexibility, particularly in areas that require enhanced support and cushioning, due to the limitations of materials used in the outsole design.
Innovation Solution
The implementation of a polygonal lug pattern in the outsole, featuring hexagonal, pentagonal, or octagonal lugs with varying sizes and wall thicknesses, which are configured to provide additional support and traction by being uniformly or differently sized and constructed across the outsole surface, allowing for flexibility and improved ground contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional outsole materials and designs are used, then durability is maintained, but traction and flexibility are insufficient
Solution Approach 1:
The outsole is segmented into multiple polygonal lugs (hexagonal, pentagonal, octagonal) distributed across the sole surface. Each lug acts as an independent traction element that can deform and adapt to terrain variations, providing both durability through material strength and flexibility through individual lug deformation capability.
Solution Approach 2:
Different regions of the outsole feature lugs with varying sizes, shapes, and wall thicknesses tailored to specific functional requirements. High-traction areas have larger, thicker-walled lugs for durability, while areas requiring flexibility have smaller, thinner-walled lugs that can deform more easily during foot movement.
2Reliability
If polygonal lugs with varying sizes are implemented, then traction is improved, but manufacturing complexity increases
Solution Approach 1:
The invention varies geometric parameters (number of sides, size, wall thickness) of the polygonal lugs to optimize traction for different terrain conditions. By systematically adjusting these parameters across different outsole regions, the design achieves superior adaptability while maintaining manufacturability through standardized production processes for each lug type.
3Reliability
If multiple material layers are used in the upper, then comfort and wear-resistance are enhanced, but weight increases
Solution Approach 1:
The upper incorporates multiple material layers including leather or synthetic leather for wear-resistant areas (toe, heel) and breathable textiles for other areas. This composite construction provides targeted protection where needed while maintaining overall lightness and comfort through material selection optimized for each specific region's functional requirements.
Data Source
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AI summary
Articles of footwear, including athletic footwear, include one or more of: (a) an upper (120); (b) a sole structure (130) including a midsole (131) and an outsole (132), the outsole having a plurality of polygonal lugs (210) arranged about a base surface of the outsole. The outsole may include one or more regions wherein the characteristics of a portion of the lugs within a region differ from the characteristics of a portion of the lugs in another region. The lugs may differ, for example based on size, construction and/or spacing between the lugs. Methods of manufacturing such articles of footwear also are disclosed.