Segmented Outsole Bonding for Midsole Cushioning
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Solution Overview
Problem
The existing method for manufacturing shoes, where the midsole's cushioning function is impaired due to the outsole covering its peripheral surface, leading to reduced flexibility and increased manufacturing costs.
Innovation Solution
A shoe design featuring a midsole with notches for an additional sole material, which includes a body portion, a bonding portion, and an embedded portion, allowing the midsole and upper to be bonded together without covering the midsole's peripheral surface, thus maintaining its cushioning function while reducing manufacturing costs through mechanized bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outsole covers the entire peripheral surface of the midsole to bond the upper and sole together, then the bonding strength and durability are improved, but the midsole's cushioning function is impaired due to reduced flexibility
Solution Approach 1:
The outsole is segmented into a body portion and a bonding portion that are spaced apart in the thickness direction of the midsole, with the bonding portion extending through notches to contact the upper. This segmentation allows the outsole to provide bonding strength at specific locations while leaving other areas of the midsole exposed to maintain cushioning flexibility.
Solution Approach 2:
The outsole is designed with different functional regions: the body portion provides durability and coverage, while the bonding portion provides adhesion to the upper. By concentrating the bonding function in specific localized areas rather than covering the entire peripheral surface, the midsole's cushioning function is preserved in non-bonding regions.
2Manufacturing precision
If manual bonding of upper and sole is performed to maintain quality, then the bonding quality is improved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The outsole structure is designed to bond the upper and midsole automatically through its own configuration. The bonding portion extends through notches in the midsole to contact the upper, creating self-aligning bonding features that eliminate the need for manual positioning and skilled labor while ensuring consistent bonding quality.
Solution Approach 2:
The bonding function is merged into the outsole structure itself rather than being a separate manual process. The outsole incorporates bonding portions that simultaneously provide structural support and adhesion, combining multiple functions into a single component that can be manufactured and attached as one unit.
3Duration of action of stationary object
If the outsole covers the entire midsole peripheral surface, then the durability is improved, but the manufacturing time and personnel requirements increase
Solution Approach 1:
The outsole is divided into functional segments (body portion and bonding portion) that can be manufactured and positioned independently. This segmentation allows for more efficient manufacturing processes such as injection molding where the outsole can be formed in one operation with integrated bonding features, reducing production time and labor requirements while maintaining durability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for the production of shoes at a lower cost without compromising the midsole's cushioning function, enabling stable quality and design flexibility while reducing manufacturing time and personnel requirements.
Implementation Method 1
an additional sole material covering a portion of the non-facing region. The additional sole material has a body portion stuck to the non-facing region, a bonding portion stuck to both the upper and the midsole to bond the upper and the midsole together
Data Source
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AI summary
A shoe (1A) comprises an upper (10) and a sole (20A). The sole (20A) includes: a midsole (21) covering a lower surface of the upper (10), the midsole (21) having an external surface having a facing region facing the upper (10) and a non-facing region excluding the facing region; and an additional sole material (22) covering a portion of the non-facing region. The midsole (21) is provided with a notch in the form of a throughhole or a groove reaching both the facing region and the non-facing region. The additional sole material (22) has a body portion (22a) stuck to the non-facing region, a bonding portion (22b) stuck to both the upper (10) and the midsole (21) to bond them together, and an embedded portion (22c) embedded in the notch of the midsole (21). The body portion (22a) and the bonding portion (22b) are connected together via the embedded portion (22c) and thus integrated together such that the body portion (22a) and the bonding portion (22b) are spaced from each other in a thickness-wise direction of the midsole (21).