Shoe Sole Cleat Concavity and Midsole Convexity Interlock
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Solution Overview
Problem
Existing shoe soles face challenges in balancing light-weight, durability, gripping, shock-absorbing, and bendability while accommodating environmental considerations, with previous designs often compromising on these properties due to tradeoffs such as increased weight from higher cleats or reduced durability from uniform rubber thickness.
Innovation Solution
A shoe sole design featuring a rubber outsole with a tread surface and a midsole made of a foam body with a thermoplastic resin component, where the outsole includes protruding cleats with concave surfaces and a midsole with convex surfaces that fit into these concavities, allowing for increased flexibility and shock absorption while maintaining durability and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the height of the cleats is increased to increase gripping force, then the gripping force is improved, but the weight of the shoe increases and upthrust is likely to be felt
Solution Approach 1:
The patent applies local quality by making the cleat height variable rather than uniform. The cleats have different heights in different regions, with higher cleats in areas needing more grip and lower cleats where less grip is needed. This localized differentiation allows the shoe to achieve sufficient gripping force without uniformly increasing cleat height throughout, thereby avoiding excessive weight increase and upthrust.
2Force
If the cleat height is increased to improve gripping, then the grip is enhanced, but the thickness of the cleats increases leading to more weight
Solution Approach 1:
The patent implements local quality by designing cleats with varying heights tailored to specific functional requirements of different shoe sole regions. This selective approach ensures grip enhancement is concentrated where most needed, rather than uniformly distributed, thus minimizing the overall weight penalty associated with high cleats.
3Ease of manufacture
If a uniform thickness rubber outsole is used, then the manufacturing is simplified, but durability problems occur due to the outsole wearing out
Solution Approach 1:
The patent applies local quality by varying the rubber outsole thickness across different regions. The outsole has greater thickness in high-wear areas such as the heel and forefoot regions, while maintaining thinner sections in areas subjected to less wear. This differentiated thickness distribution enhances durability in critical areas without significantly complicating the manufacturing process or adding excessive weight.
4Device complexity
If the outsole is made with uniform thickness, then the manufacturing process is simplified, but the durability is reduced due to wear
Solution Approach 1:
The patent implements local quality through a non-uniform outsole thickness design that strategically places thicker rubber sections in high-wear zones. This approach extends the service life of the outsole by providing enhanced wear resistance where it is most needed, while keeping the overall structural complexity manageable and avoiding excessive material usage.
5Ease of operation
If high-hardness base with thin lower portion is used, then the flexibility and grip are higher when stud is intact, but the durability is reduced
Solution Approach 1:
The patent applies local quality by creating a hardness gradient in the base structure. The base has higher hardness in regions requiring durability and lower hardness in regions needing flexibility and grip. This localized hardness differentiation allows the shoe to simultaneously achieve good flexibility for comfort and grip, while maintaining durability in high-stress areas through the harder base material.
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 design enhances gripping and shock-absorbing properties, improves durability by reducing wear, and allows for greater design flexibility while maintaining a lightweight and environmentally friendly approach.
Implementation Method 1
a main (primary) component of the mid sole 2 is a foam body (foamed material) having a thermoplastic resin component
Implementation Method 2
the concave surface 1F and the convex surface 2F are in contact with, and attached to, each other
Data Source
Figure 1
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AI summary
An outsole includes: a plate-like base; a plurality of first cleats protruding in the downward direction from the base to form the tread surface, wherein the plurality of first cleats are arranged in the longitudinal direction and in the transverse direction; and a concave surface recessed in the downward direction on the upper surface of each of the first cleats, wherein: the lower surface of the midsole includes a convex surface formed by a surface of a convex portion protruding in the downward direction from a base of the midsole; the concave surface and the convex surface are in contact with, and attached to, each other; and a distance from the tread surface in each of the first cleats to a top of the convex surface is greater than a thickness of the base.