Textile Composite Sports Shoe Sole with Molded Protrusions
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Solution Overview
Problem
Conventional sports shoe soles are heavy due to thick, dense materials and require complex manufacturing processes, while textile-based alternatives offer lower friction and traction compared to molded outsoles.
Innovation Solution
A sole structure comprising a first sole element, typically made from midsole materials like EVA, combined with a second sole element made from lightweight textile material, which is molded together to create a compound sole with protrusions for increased friction and traction, eliminating the need for a heavy outsole and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a conventional sole structure with thick outsole and midsole layers is used, then the sole provides sufficient friction and traction, but the weight of the sole increases significantly
Solution Approach 1:
The patent combines a textile material layer with a thermoplastic material layer to create a composite sole structure. The textile material provides lightweight properties while the thermoplastic material, when molded with protrusions, provides the necessary friction and traction. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The patent applies protrusions locally on the sole surface where friction and traction are needed, rather than making the entire sole thick and heavy. The protrusions are formed from thermoplastic material that is molded onto specific areas of the textile layer, providing targeted grip enhancement without increasing overall sole weight.
2Ease of manufacture
If a conventional sole structure with separate outsole and midsole layers is used, then sufficient friction and traction are achieved, but the manufacturing process becomes complex with multiple steps
Solution Approach 1:
The patent merges the outsole and midsole manufacturing into a single molding process. The thermoplastic material is molded directly onto the textile layer in one operation, creating an integrated sole structure that combines both functional layers. This eliminates the need for separate molding and assembly steps while maintaining the necessary friction and traction properties through the protrusion design.
Solution Approach 2:
The patent utilizes temperature parameter changes to facilitate the molding process. The thermoplastic material is heated to become moldable, then cooled to set the protrusion shape. This parameter change approach allows for complex geometric features (protrusions) to be created in a single molding step rather than requiring multiple manufacturing operations.
3Weight of moving object
If textile material is used for the sole, then the sole weight is reduced, but the friction and traction decrease compared to molded outsole
Solution Approach 1:
The patent creates a composite structure where lightweight textile material is combined with thermoplastic material featuring protrusions. The textile layer maintains low weight while the thermoplastic protrusions provide the necessary friction and traction, resolving the contradiction between weight reduction and maintaining grip performance.
Solution Approach 2:
Instead of making the entire sole from heavy friction-providing material, the patent applies protrusions locally on the sole surface. The textile material provides lightweight coverage across the entire sole, while thermoplastic protrusions are concentrated only in areas where friction and traction are needed, optimizing both weight and grip properties.
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 results in a lightweight sole with improved friction and traction, reduced manufacturing complexity, and enhanced stability, while maintaining the stiffness and support comparable to conventional soles.
Implementation Method 1
heating the first sole element to a temperature range of 100-140 °C
Implementation Method 2
pressing the first sole element and the textile material of the second sole element together
Data Source
Figure 1A~1B
Figure 2~3
Figure 4A
AI summary
Described are soles for a shoe(100,70) with a first sole element (11), and a second sole element (12) comprising a textile material (12), wherein the second sole element (12) is coupled to the first sole element (11) and arranged to at least partially cover the first sole element (11). At least one of the first sole element (11) and the second sole element (12) include protrusions, wherein at least a portion of the second sole element (12) is configured to contact an adjacent surface when the sole (10,10) is attached to an upper (101,81). The portion of the second sole element (12) that contacts the adjacent surface generates an amount of at least one of friction and traction between the sole (10,10) and the adjacent surface, and the protrusions are configured to increase the amount of the at least one friction and traction generated between the sole (10,10) and the adjacent surface.