Shoe Sole Bulk Material Spring Damping
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Solution Overview
Problem
The production of sports footwear often results in unsatisfactory spring and damping behavior, and the manufacturing process is complex and costly, failing to provide economical and comfortable wearing experiences.
Innovation Solution
A method involving the production of a shoe with a knitted shoe upper and a sole part containing bulk material, preferably thermoplastic elastomer, which is loosely arranged to provide a comfortable and adjustable spring and damping behavior, with a web-like structure to stabilize the bulk material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional bonding methods using different plastics and polymer materials are used, then the shoe sole can be manufactured, but the spring and damping behavior is unsatisfactory and the process is complex and costly
Solution Approach 1:
The patent changes the fundamental parameter of the sole structure from bonded plastic layers to a monolithic foam material with controlled density and cell structure. This parameter change enables both simplified manufacturing (molding process) and improved spring/damping behavior through the inherent viscoelastic properties of the foam material.
Solution Approach 2:
The patent uses foam material as a composite structure that combines the benefits of plastic structural integrity with air-filled cells for spring and damping functions. This single composite material replaces multiple bonded plastic layers, simplifying manufacturing while achieving superior mechanical performance.
2Strength
If E-TPU is used as sole material with bonding agents or steam injection, then the plastic spheres can be bonded together, but the manufacturing process becomes complex and cost-intensive
Solution Approach 1:
The patent extracts the bonding step entirely from the manufacturing process by using a monolithic foam material that requires no bonding agents, steam injection, or assembly of separate components. The sole is produced as a single molded piece, eliminating the complex bonding processes while maintaining structural integrity.
Solution Approach 2:
The patent replaces expensive bonding agents and complex bonding equipment with a simple molding process that uses readily available foam material. The approach trades the cost of bonding materials and equipment for a simpler, more economical molding process.
3Stability of the object's composition
If the lower region of the shoe upper is made thicker, then the structure is more stable, but the wearing sensation becomes less comfortable
Solution Approach 1:
The patent uses a composite construction where a thin textile lower region provides flexibility and comfort against the foot, while the foam midsole provides the structural stability and cushioning. This composite approach allows the textile layer to remain thin for comfort while the foam provides the necessary structural support.
Solution Approach 2:
The patent applies different material qualities to different regions: the lower region contacting the foot uses thin, flexible textile for comfort, while the midsole uses dense foam for structural stability. Each region has the local quality appropriate to its function, optimizing both comfort and stability.
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
This approach allows for cost-effective production of a comfortable shoe with improved spring and damping properties, enhancing walking sensation and support, while allowing for easy adjustment of the shoe's properties through material and geometric selection.
Implementation Method 1
the bulk material consists at least in part, preferably entirely, of a thermoplastic elastomer (TPE)... provide a comfortable and adjustable spring and damping behavior
Implementation Method 2
at least one web-like structure is formed on the bottom region, which structure extends into the receiving space. This web-like structure forms wall areas within the receiving space, which counteracts the free movement of the loosely filled bulk material
Data Source
AI summary
The invention relates to a method for producing a shoe (1), in particular a sports shoe. In order to be able to produce the shoe economically and in the process to achieve a particularly good wearing comfort, the invention provides the steps of: a) Producing a shoe upper (2), wherein the shoe upper (2) has an upper region (3) that covers the upper region of the wearer's foot and a lower region (4) that encloses the sole of the wearer's foot; b) Producing a sole part (5), wherein the sole part (5) has a bottom region (6) and a lateral wall region (7), wherein the bottom region (6) and the wall region (7) delimit an upwardly open receiving space (8) for bulk material (9); c) Filling the receiving space (8) with a bulk material (9), wherein the bulk material consists at least in part, preferably entirely, of a thermoplastic elastomer (TPE); d) Fastening the shoe upper (2) to the sole part (5) such that the lower region (4) of the shoe upper (2) comes to rest on the bulk material (9).