Segmented Footwear Sole Plates for Stability and Lower Energy Loss

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Solution Overview

Problem

Conventional footwear lacks targeted support structures to enhance stability and reduce energy dissipation during physical activities, such as running or walking, thereby reducing user efficiency.

Innovation Solution

The footwear incorporates a sole structure with a plate positioned between upper and lower midsole cushioning members, featuring angled segments and splits, constructed from materials like carbon fiber and thermoplastic polyurethane, to provide enhanced support and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional shoes include basic sole structures with foam materials, then cushioning and basic stability are provided, but targeted support and energy efficiency are insufficient

Engineering Contradiction:

ImprovestabilityVSAvoidenergy dissipation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The plate is divided into multiple segments including a forefoot segment, midfoot segment, and heel segment, with splits allowing independent movement of foot regions. This segmentation provides targeted support to specific areas while allowing natural foot motion, improving stability without restricting energy-efficient movement patterns.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plate incorporates varying material properties and structural characteristics at different locations - carbon fiber for stiffness in load-bearing areas, thermoplastic polyurethane for flexibility in movement areas. This local differentiation provides targeted support where needed while maintaining energy efficiency in dynamic regions.

Inventive Principle:

Principle #3Local quality

2Reliability

If the sole structure includes rigid plates for stability, then support is improved, but flexibility and comfort may be reduced

Engineering Contradiction:

ImprovestabilityVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The plate transitions from static rigid structures to dynamic segmented structures that adapt to foot motion. The splits and curved portions allow the plate to flex and move with the foot during different phases of gait, maintaining stability support while accommodating flexibility requirements.

Inventive Principle:

Principle #15Dynamics

3Reliability

If the plate includes curved portions and splits for targeted support, then stability is enhanced, but manufacturing complexity increases

Engineering Contradiction:

ImprovestabilityVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The plate is positioned within recessed portions of the midsole cushioning members, creating a nested structure where the plate fits into prepared cavities. This nesting approach simplifies assembly while maintaining the complex curved geometry and splits of the plate structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The plate utilizes composite materials including carbon fiber and thermoplastic polyurethane that can be molded into complex curved shapes with integrated splits. These materials provide both the structural complexity needed for targeted support and the manufacturability through modern composite forming techniques.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250280921A1Articles of footwear with support structures

Publication Date: 2025.09.11 PUMA SE

AI summary

An article of footwear includes an upper coupled with a sole structure that defines a forefoot region, a midfoot region, and a heel region. The sole structure includes an upper midsole cushioning member, a lower midsole cushioning member, an outsole coupled to a bottom surface of the lower midsole cushioning member, and a plate positioned between the upper midsole cushioning member and the lower midsole cushioning member. The plate includes a toe segment that extends through the forefoot region, the toe segment defining a first concave curved portion that extends downward from a distal end to a first inflection point disposed within the midfoot region. The plate further includes a middle segment defining a second concave curved portion that extends upward from the first inflection point and toward the heel region before transitioning to a convex curved portion at a second inflection point in the midfoot or heel region.