Polyolefin Sole Plates for Bonding, Flex, and Abrasion Resistance

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Solution Overview

Problem

There is a need for lower-cost, recyclable materials in footwear and sporting equipment that offer improved mechanical properties, resistance to stress whitening and cracking under cold conditions, and effective bonding, while maintaining abrasion resistance and surface energy compatibility.

Innovation Solution

The use of polyolefin resin compositions in sole structures, optionally with a textile layer, to enhance bonding and mechanical properties, and the inclusion of clarifying agents for optical clarity, along with elastomeric materials for anti-clog properties and hydrogel materials for soil prevention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polyolefin resin compositions are used in sole structures, then cost is reduced and recyclability is improved, but bonding effectiveness and mechanical properties may deteriorate

Engineering Contradiction:

ImprovecostVSAvoidbonding effectiveness

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent modifies the polyolefin resin composition by adjusting parameters such as incorporating specific additives, modifying molecular weight distribution, and controlling crystallinity to enhance bonding effectiveness while maintaining cost-effectiveness and recyclability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates composite material systems by combining polyolefin resin with other materials or additives that improve bonding properties, mechanical strength, and surface energy compatibility without significantly increasing cost or compromising recyclability

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If polyolefin resin compositions are used in sole structures, then cost is reduced and recyclability is improved, but resistance to stress whitening and cracking under cold conditions may deteriorate

Engineering Contradiction:

ImprovecostVSAvoidresistance to stress whitening and cracking

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent adjusts parameters of the polyolefin resin composition including adding antioxidants, UV stabilizers, and plasticizers to improve resistance to stress whitening and cracking under cold conditions while maintaining cost-effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent develops composite formulations that combine polyolefin resin with reinforcing agents and protective additives to enhance durability and resistance to environmental degradation without significantly increasing cost

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If polyolefin resin compositions are used in sole structures, then weight is reduced, but abrasion resistance may deteriorate

Engineering Contradiction:

ImproveweightVSAvoidabrasion resistance

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent optimizes the polyolefin resin composition by adjusting molecular weight, branching structure, and crosslinking density to improve abrasion resistance while maintaining low weight characteristics

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates lightweight composite materials by incorporating reinforcing fillers, fibers, or nanomaterials into the polyolefin resin matrix to enhance abrasion resistance without significantly increasing weight

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If polyolefin resin compositions are used in sole structures, then surface energy compatibility is improved, but mechanical properties may deteriorate

Engineering Contradiction:

Improvesurface energy compatibilityVSAvoidmechanical properties

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent modifies the polyolefin resin composition by adjusting surface energy parameters through additives or surface treatments while maintaining bulk mechanical properties through careful formulation and processing control

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250261721A1Sole structures including polyolefin plates and articles of footwear formed therefrom

Publication Date: 2025.08.21 NIKE INC

AI summary

A variety of plates for footwear are provided including a polyolefin resin. Sole structures and articles of footwear formed therefrom are also provided. Methods of making the polyolefin resin compositions, plates, sole structures, and articles of footwear are also provided. In some aspects, the polyolefin resin composition includes an effective amount of a polymeric resin modifier. The effective amount can be an amount effective to allow the resin composition to pass a flex test, and in particular to pass a flex test without significant change in abrasion loss. In some aspects, the resin composition also includes a clarifying agent to improve optical clarity of the plate. In some aspects, the plates include a textile disposed on one or both of a first side and the second side of the plate. The textile can provide for improved bonding of the plate to other components such as a chassis or an upper.