Shoe Sole Cushioning Member Integrated Foamed Non-foamed Interface

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Solution Overview

Problem

Conventional shoe soles with foamed and non-foamed areas experience reduced durability due to shear stress at the interface when external forces are applied, leading to issues like peeling.

Innovation Solution

A cushioning member for shoes is produced by filling a mold with unfoamed foamable and non-foamable materials, where the foamable material forms the foamed area by foaming after molding, and the non-foamable material forms the non-foamed area without an intervening layer, ensuring no clear interface between the two areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a sole is made by blending foamed material with non-foamable material, then the weight of the sole is reduced, but the durability is reduced due to shear stress at the interface between foamed area and non-foamed area

Engineering Contradiction:

Improveweight of the soleVSAvoiddurability of the sole

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent merges the foamed area and non-foamed area into a single integrated cushioning member formed from the same material. By using a one-shot molding process where the material is molded in the mold and then foamed in-situ, the interface between foamed and non-foamed regions is eliminated, preventing peeling and improving durability while maintaining weight reduction benefits

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the physical state and density parameters of the material during the molding and foaming process. The material is molded in an unfoamed state to create the basic structure, then foamed to create regions of different density (foamed area vs. non-foamed area) without creating a harmful interface, thus resolving the contradiction between weight reduction and durability

Inventive Principle:

Principle #35Parameter changes

2Reliability

If an intervening layer is added at the interface between foamed area and non-foamed area to prevent peeling, then the durability is improved, but the structural complexity increases

Engineering Contradiction:

Improvedurability of the cushioning memberVSAvoidstructural complexity of the cushioning member

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the problematic intervening layer from the structure. By using a one-shot molding process where the same material forms both foamed and non-foamed areas without requiring a separate bonding layer or interface material, the structure is simplified while durability is maintained through the inherent integration of the single-material construction

Inventive Principle:

Principle #2Taking out (Extraction)

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 reduces shear stress at the interface, enhancing the durability of the cushioning member by preventing peeling and maintaining the lightweight benefits of the foamed area while improving the structural integrity.

Implementation Method 1

the foamable material forms the foamed area by foaming after the mold is filled

Methodology Applied

Scientific EffectFoaming: Foam

Data Source

PatentUS20240074532A1Cushioning member and sole for shoe

Publication Date: 2024.03.07 ASICS CORP

AI summary

A method of producing a cushioning member for a shoe includes a foamed area and a non-foamed area. The cushioning member is formed by filling a mold with an unfoamed foamable material and a non-foamable material in a mold and molding, and the foamable material forms the foamed area by foaming after the mold is filled, and the non-foamable material forms the non-foamed area.