Injection Molded Shoe Shell With Flexible Membrane Relief Zones
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Solution Overview
Problem
Existing sports shoes with rigid plastic shells and compressible cushioning elements are complex to manufacture, costly, and prone to damage, while also failing to provide adequate comfort and moisture sealing, especially for varying foot shapes and sizes.
Innovation Solution
A sports shoe design featuring a membrane element with a flexible membrane skin and support body, which allows for adjustable volume and width to accommodate different foot shapes without pressure points, while maintaining a reliable seal and reducing production complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If compressible cushioning elements are used in the shell, then user comfort is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention merges the cushioning function directly into the shell structure by creating integrated relief zones during the injection moulding process. The shell itself forms recesses and relief zones that provide cushioning effects, eliminating the need for separate cushioning components and their associated manufacturing steps.
Solution Approach 2:
The shell structure serves multiple functions simultaneously: it provides structural support, protection, and comfort through integrated relief zones. The same shell that protects the foot also contains built-in cushioning features that reduce pressure points, eliminating the need for separate cushioning elements.
2Adaptability or versatility
If multiple plastic materials of differing rigidity are used, then flexibility and comfort are improved, but production technology becomes more difficult
Solution Approach 1:
The invention applies local quality by creating specific zones within the shell with different rigidity characteristics. Relief zones and recesses are formed in areas requiring flexibility (such as over metatarsal bones), while the rest of the shell maintains its protective rigidity. This is achieved through strategic placement of relief zones rather than using multiple materials throughout.
Solution Approach 2:
The invention changes physical parameters of the shell structure by varying wall thickness and creating geometric relief zones rather than changing material composition. Thinner walls and recessive areas provide flexibility where needed, while thicker sections maintain structural integrity, all within a single-material construction.
3Ease of operation
If cut-outs or windows are provided in the shell, then comfort is improved, but sealing and moisture protection become problematic
Solution Approach 1:
The invention segments the shell into different functional zones: protective rigid areas and flexible relief areas with recesses. These relief zones provide comfort without creating through-cutouts that would compromise sealing. The segmentation allows the shell to respond to foot pressure locally while maintaining overall integrity and moisture protection.
4Ease of operation
If cushioning elements overlap cut-outs by a multiple, then comfort is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention combines the shell structure and cushioning relief zones into a single integrated component manufactured in one injection moulding process. The relief zones are formed directly as part of the shell geometry, eliminating the need for separate cushioning elements and their assembly, thereby improving manufacturing efficiency.
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 membrane element provides enhanced comfort and durability by allowing for flexible adjustment to fit various foot shapes, reduces pressure points, and ensures a long-lasting, impermeable seal, while simplifying the manufacturing process and maintaining a lightweight design.
Implementation Method 1
a membrane element (11) is provided in the front foot shell (4) which enables the volume and width which the front foot shell (4) can accommodate to be changeable as a function of compression stress
Implementation Method 2
the membrane element is laterally deflectable relative to the shell (2)
Data Source
AI summary
The invention relates to a sports shoe with an outer shell of injection molded plastic, comprising a front foot shell for accommodating the front foot and an adjoining shoe cuff for stabilizing the lower leg portion of a user, and with a relatively flexible inner shoe at least partially accommodated in the shell. Disposed in the outer shell is at least one elastically flexible portion which is provided as a means of reducing pressure points from the inner shoe on a user's foot when subjected to compression stress. The elastically flexible portion is provided in the form of at least one membrane element which is designed to vary the volume or width which the shell can accommodate as a function of compression stress due to its slackness or ability to deflect relative to the surrounding part-portions of the shell.