Footwear Sole Assembly Monolithic Chamber Design

Solution Overview

Problem

Conventional footwear with fluid-filled bladders are costly and complex to manufacture, heavy, and difficult to recycle due to their multi-part design, which increases part count and weight, hindering movement and posing environmental challenges.

Innovation Solution

A sole assembly with a monolithic construction featuring two portions made of different materials, forming a sealed chamber that can contain fluid to provide cushioning and support, reducing part count and manufacturing complexity by integrating the bladder-like function into the sole assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fluid-filled bladder is embedded within the midsole to provide cushioning and support, then comfort and shock attenuation are improved, but manufacturing complexity and cost increase due to separate bladder assembly

Engineering Contradiction:

Improvecushioning performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the bladder and midsole into a single integrated unit. The midsole includes a sealed chamber formed by its own structure rather than requiring a separate bladder component. This integration eliminates the need for separate bladder assembly while maintaining the cushioning function, directly resolving the contradiction between improved comfort and increased manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a fluid-filled bladder is embedded within the midsole to provide cushioning and support, then comfort and shock attenuation are improved, but manufacturing cost increases due to separate bladder production and assembly

Engineering Contradiction:

Improvecushioning performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the bladder and midsole into a single integrated unit. The midsole includes a sealed chamber formed by its own structure rather than requiring a separate bladder component. This integration eliminates the need for separate bladder assembly while maintaining the cushioning function, directly resolving the contradiction between improved comfort and increased manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a fluid-filled bladder is embedded within the midsole to provide cushioning and support, then comfort and shock attenuation are improved, but weight of the sole assembly increases

Engineering Contradiction:

Improvecushioning performanceVSAvoidsole assembly weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent employs a thin sealed chamber within the midsole structure rather than a bulky separate bladder. The chamber is formed as an integral part of the midsole, using minimal material to enclose the fluid while maintaining structural integrity. This approach reduces the overall weight compared to traditional bladder systems while preserving the cushioning performance.

Inventive Principle:

Principle #30Flexible shells and thin films

4Reliability

If a fluid-filled bladder is embedded within the midsole to provide cushioning and support, then comfort and shock attenuation are improved, but recyclability decreases due to multiple parts

Engineering Contradiction:

Improvecushioning performanceVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the bladder and midsole into a single integrated unit. The midsole includes a sealed chamber formed by its own structure rather than requiring a separate bladder component. This integration eliminates the need for separate bladder assembly while maintaining the cushioning function, directly resolving the contradiction between improved comfort and increased manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 solution reduces manufacturing costs and complexity, decreases weight, and enhances comfort and support while being more recyclable, offering improved performance and environmental sustainability.

Implementation Method 1

weight of the wearer and other loading on the bladder can cause the fluid to displace within the bladder

Methodology Applied

Scientific EffectFluid displacement:

Implementation Method 2

the bladder can resiliently deform and conform to the wearer's foot

Methodology Applied

Scientific EffectResilient deformation: Elasticity

Implementation Method 3

the bladder can dampen or attenuate shock loads or other loads during jumping, running, and other activities to provide better cushioning

Methodology Applied

Scientific EffectShock damping: Damping

Data Source

PatentUS9743711B2Sole assembly with plural portions that cooperatively define chamber

Publication Date: 2017.08.29 NIKE INC

AI summary

A method of forming a sole assembly of an article of footwear including an interior space and an exterior surface includes providing a first portion of the sole assembly. The first portion includes a first surface that at least partially defines the interior space and a first chamber surface that opposes the first surface. The first portion is made from a first material. The method also includes providing a second portion of the sole assembly that includes a second surface that at least partially defines the exterior surface of the article of footwear and a second chamber surface that opposes the second surface. The second portion is made from a second material that is different from the first material. The method additionally includes operably securing the first and second portions such that the first chamber surface and the second chamber surface cooperate to at least partially define a chamber.