3D-Printed Shoe Soles With Interconnected Cells for Torsional Stiffness
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Solution Overview
Problem
Existing footwear designs lack sufficient torsional stiffness, which affects the structural integrity and performance during various activities.
Innovation Solution
Incorporating a 3-D printed sole with interconnected cells and a welt or a heel clip, which significantly enhances the torsional stiffness of the shoe by at least 100% compared to designs without these features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional footwear construction methods are used, then manufacturing simplicity is maintained, but torsional stiffness is insufficient
Solution Approach 1:
The footwear is divided into separate functional components: a 3-D printed sole unit, an upper assembly, a welt, and a heel clip. Each component is manufactured independently with optimized properties and then assembled, allowing the sole unit to provide torsional stiffness while other components address different functional requirements.
Solution Approach 2:
The sole unit is constructed as a composite structure combining a 3-D printed base material with an integrated tread pattern and structural reinforcements. This composite approach enables the sole to achieve high torsional stiffness while maintaining flexibility in specific regions for comfort and performance.
2Strength
If 3-D printed sole with interconnected cells is used, then torsional stiffness is enhanced, but manufacturing complexity increases
Solution Approach 1:
The 3-D printing process allows for precise control of material parameters including cell size, wall thickness, density, and material composition. By optimizing these parameters, the sole unit achieves maximum torsional stiffness for a given weight and volume, while the additive manufacturing process itself simplifies production compared to traditional multi-step molding operations.
Solution Approach 2:
The interconnected cell structure introduces a three-dimensional internal architecture that provides torsional stiffness without increasing external dimensions. The vertical and diagonal struts within the cell structure create geometric resistance to twisting forces, achieving high stiffness-to-volume ratio.
3Stability of the object's composition
If welt and heel clip are added, then structural integrity is improved, but number of components increases
Solution Approach 1:
The welt and heel clip are designed to integrate with the upper assembly and sole unit through standardized connection interfaces. This merging approach allows multiple components to work together as a unified structure, where the welt provides lateral support and the heel clip reinforces the heel counter, collectively enhancing structural integrity without requiring excessive separate parts.
Data Source
AI summary
A shoe comprising a sole, an upper secured to the sole, and a welt. The welt comprises at least one piece separate from the sole and upper. The welt is adjacent both the sole and the upper and is secured to at least one of the sole and the upper. The sole is a 3-D printed sole comprising a plurality of interconnected cells. Each cell of the plurality of interconnected cells is connected to at least one adjacent cell of the plurality of interconnected cells. The shoe has a torsional stiffness at least 100% greater than the torsional stiffness of a first comparison shoe. The first comparison shoe is identical to the shoe except the first comparison shoe is devoid of a welt. The torsional stiffness is a torque sufficient to rotate the heel-widest portion ten degrees (10°) from an un-torqued condition as the ball-widest portion is held stationary.