Segmented Footwear Midsole with Protective Cage Components
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Solution Overview
Problem
Conventional athletic footwear midsoles lack optimal balance between light weight, energy absorption, and durability, particularly in areas that require varying levels of stiffness and traction, which can lead to inadequate performance in different athletic activities.
Innovation Solution
The design incorporates a soft and lightweight foam midsole component partially covered by more rigid and dense cage components, with strategically placed spaces to expose the midsole surface, allowing for natural flexion lines and enhanced traction, while maintaining durability through the use of materials like ethylvinylacetate foam and rubber for the cage components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a soft and lightweight foam midsole component is used, then weight is reduced and flexibility is improved, but durability and traction are compromised
Solution Approach 1:
The midsole is segmented into two distinct components: a lightweight foam midsole component and separate cage components. This segmentation allows each component to perform its specialized function - the foam provides weight reduction and flexibility, while the cage components provide durability and traction where needed.
Solution Approach 2:
Different regions of the footwear have different material properties. The cage components are strategically positioned at areas requiring durability and traction (such as the heel and toe areas), while the lightweight foam is exposed in areas where flexibility and weight savings are priorities. This local differentiation resolves the contradiction between overall weight reduction and localized durability requirements.
2Reliability
If rigid protective components are added to the midsole, then durability and traction are improved, but weight increases and flexibility is reduced
Solution Approach 1:
The protective elements are segmented into separate cage components rather than being integrated into the entire midsole structure. This allows rigid protective material to be placed only where durability and traction are needed, rather than throughout the entire midsole, thereby minimizing weight increase while maintaining necessary protection.
Solution Approach 2:
Rigid cage components are applied locally at specific areas requiring enhanced durability and traction, while the majority of the midsole retains the lightweight foam material. This localized application of rigid material minimizes the overall weight penalty while providing protection where it is most needed.
3Reliability
If the midsole is fully covered by protective components, then durability is maximized, but flexibility and natural flexion are compromised
Solution Approach 1:
The protective coverage is segmented rather than continuous. The cage components are positioned to protect critical areas while leaving gaps that allow the midsole to flex naturally. This segmented approach maintains durability at protected points while preserving overall flexibility through the unprotected regions.
Solution Approach 2:
Instead of fully covering the midsole with protective components, the design applies protective elements only partially - specifically at areas where durability is most critical. This partial coverage approach provides sufficient protection while maintaining flexibility in the uncovered areas, avoiding the excessive rigidity that would result from complete coverage.
Data Source
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Figure 1B
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AI summary
Sole structures for articles of footwear, including athletic footwear, include: (a) a lightweight foam midsole component for supporting the foot; and (b) a plurality of heavier and/or denser cage components covering selected areas of the midsole component. Spaces are provided between the cage components. These spaces may be sized, shaped, and oriented to define and/or correspond to flexion lines of the foot and/or to produce a more natural flex motion to the sole. The soles additionally may include one or more outsole components, e.g., on bottom surface(s) of the cage component(s) and/or the foam midsole. These sole structures may be engaged with an upper to form a shoe. The uppers may include one or more lace receiving openings supported by elongated wire or textile components. Methods of making footwear including such uppers and/or sole structures also are described.