Stacked Sole Cushioning With Isolated Chambers for Balanced Comfort
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Solution Overview
Problem
Conventional sole structures with single-slab polymer foams struggle to balance cushioning characteristics, as foams that are too soft compromise compressibility and those that are too hard sacrifice comfort, and achieving a gradient load response is difficult.
Innovation Solution
A sole structure design featuring a midsole with segmented cushions and plates, including fluid-filled chambers and tensile members, to provide customizable cushioning and force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single-slab polymer foam is made softer to improve cushioning comfort, then comfort is improved, but compressibility and ability to attenuate ground-reaction forces deteriorates
Solution Approach 1:
The midsole is divided into multiple discrete cushioning elements (first cushioning element, second cushioning element, third cushioning element) with different material properties and compression characteristics. This segmentation allows each element to be optimized independently - softer elements provide comfort while harder elements maintain compressibility and force attenuation capability.
Solution Approach 2:
Different regions of the midsole are assigned different material properties. The cushioning elements have varying durometer values, densities, and compression sets tailored to specific locations and functions. This local quality optimization enables simultaneous achievement of comfort in contact areas and structural integrity in load-bearing areas.
2Speed
If a single-slab polymer foam is made harder to improve responsiveness, then responsiveness is improved, but softness and comfort are sacrificed
Solution Approach 1:
The midsole incorporates multiple cushioning elements with different responsiveness characteristics. Some elements use harder, more responsive materials for immediate feedback, while others use softer, more compliant materials for comfort. This segmentation allows the system to deliver both responsiveness and comfort simultaneously.
Solution Approach 2:
The midsole uses composite construction combining different polymer foam materials with varying properties (durometer, density, cell structure). This composite approach enables the integration of hard, responsive materials with soft, comfortable materials in a single functional unit, achieving both responsiveness and comfort.
3Object-affected harmful factors
If different regions of a polymer foam slab vary in density and hardness to balance softness and responsiveness, then cushioning balance is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of creating a single complex gradient foam, the design segments the midsole into discrete cushioning elements that can be manufactured separately using standard foam molding processes. Each element maintains relatively uniform properties, simplifying manufacturing while achieving the desired cushioning balance through the assembly of multiple elements.
Solution Approach 2:
Multiple separately manufactured cushioning elements are combined into a single midsole assembly. This merging approach allows each element to be optimized and manufactured independently using simple processes, while the combined assembly achieves the complex cushioning balance that would be difficult to attain in a single homogeneous or gradient foam.
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
Enhances comfort and cushioning performance by allowing for tailored responsiveness and reduced impact forces, improving user experience.
Implementation Method 1
the chambers are configured to compress and expand in response to applied loads
Implementation Method 2
configured to compress and expand in response to applied loads
Implementation Method 3
Each of the chambers includes a tensile member disposed therein
Data Source
AI summary
A sole structure for an article of footwear is provided. The sole structure includes an outsole having a ground-engaging surface and an upper surface formed on an opposite side of the outsole than the ground-engaging surface. A first cushion is disposed proximate to a medial side of the sole structure and includes a first fluid-filled chamber attached to the upper surface of the outsole and a second fluid-filled chamber attached to the first fluid-filled chamber and disposed between the first fluid-filled chamber and the upper. A second cushion is disposed proximate to a lateral side of the sole structure and includes a third fluid-filled chamber attached to the upper surface of the outsole and a fourth fluid-filled chamber attached to the third fluid-filled chamber and disposed between the third fluid-filled chamber and the upper. The second cushion is fluidly isolated from the first cushion.