Shoe Midsole Casting via Elastic Receiving Pocket
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Solution Overview
Problem
Existing shoe manufacturing methods face challenges in creating a midsole that provides adequate support while maintaining an attractive appearance and economical production, as high midsoles can make shoes feel heavy and require labor-intensive connection processes.
Innovation Solution
A method involving a receiving pocket on the shoe upper made of thin, elastic material, which expands like a balloon to form the midsole when filled with flowable plastic, eliminating the need for separate connection processes and allowing the midsole to extend beyond the outsole for improved support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the midsole is made high to provide adequate foot support, then the support function is improved, but the shoe feels heavy and the appearance is unfavorable
Solution Approach 1:
The patent extends the midsole vertically along the shoe upper in the lateral dimension, allowing the midsole to wrap around and support the ankle and heel areas. This dimensional extension provides comprehensive foot support without requiring excessive height in the traditional vertical direction, maintaining a sleek appearance while achieving reliable support through spatial redistribution of the midsole structure.
2Strength
If special connection methods are used to attach the midsole to the upper, then the connection strength is improved, but the production process becomes labor-intensive and expensive
Solution Approach 1:
The patent integrates the midsole and upper into a unified construction where the midsole extends continuously along the shoe upper without requiring separate attachment processes. This merging eliminates the need for gluing, stitching, or other connection methods, thereby maintaining strong structural integrity while dramatically simplifying the manufacturing process and reducing labor requirements.
Solution Approach 2:
The patent employs a homogeneous material composition for both the midsole and upper, using the same or compatible materials throughout the construction. This material uniformity enables direct formation of the midsole along the upper without requiring specialized bonding agents or complex joining techniques, thus achieving strong connection with simplified production.
3Reliability
If anatomically shaped lasts are used to create high midsoles, then the heel support is improved, but the lever ratio increases and the shoe feels heavier
Solution Approach 1:
Instead of increasing midsole height vertically to support the heel, the patent extends the midsole laterally along the shoe upper, wrapping around the ankle and heel areas. This dimensional shift provides anatomical heel support through lateral extension rather than vertical height, maintaining favorable lever ratios while achieving reliable heel support.
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 method results in a shoe with enhanced foot support, a seamless visual transition between the upper and midsole, reduced production costs, and increased comfort by eliminating the need for gluing and adhesives, while maintaining a slim and lightweight appearance.
Implementation Method 1
a receiving pocket is arranged on the underside of the shoe upper, which forms an at least largely closed receiving space for the material of the midsole, wherein the receiving pocket consists of a thin, elastic material; b) placing the shoe upper together with the receiving pocket in a casting tool; c) Pouring or injecting flowable plastic material into the receiving space of the receiving pocket in order to form the midsole, with the receiving pocket increasing in volume like a balloon
Data Source
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AI summary
The invention relates to a method for producing a shoe (1), in particular an athletic shoe, comprising a shoe upper part (2) and a midsole (3) that is arranged on the shoe upper part (2). The aim of the invention is to allow an improved ergonomics of the shoe without disrupting the appearance of said shoe. This is achieved by the following method steps: a) producing the upper part (2) of the shoe (1), wherein a receiving pocket (4) is arranged on the lower face of the shoe upper part (2), said pocket forming a receiving space (5), which is at least substantially closed, for the material of the midsole (3); b) placing the shoe upper part (2) together with the receiving pocket (4) in a casting tool (6, 7, 8); c) casting or injecting flowable plastic material into the receiving space (5) of the receiving pocket (4) in order to form the midsole (3); d) allowing the cast or injected plastic material to cure; and e) removing the shoe upper part together with the receiving pocket (4) and the cast or injected midsole (3) from the casting tool (6, 7, 8). The invention further relates to a shoe.