Thermocompressed Textile Sole Element with Integrated Cushioning
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Solution Overview
Problem
Conventional footwear manufacturing methods are complex, energy-intensive, and generate significant material waste, with a need for simplified methods that reduce steps, energy consumption, and environmental impact while allowing for customization and improved sole performance.
Innovation Solution
The use of textile sole elements comprising at least partly hot-melted yarns, which are thermoformed or thermocompressed to create a sole assembly that can be easily integrated with footwear uppers, providing adjustable weight, aesthetic options, and enhanced mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional footwear manufacturing methods are used with multiple sole elements and stitching, then the sole structure provides adequate mechanical performance, but the manufacturing process becomes complex and generates significant material waste
Solution Approach 1:
The patent merges multiple separate sole elements (insole, midsole, outsole) into a single integrated sole assembly element made from one continuous piece of thermoplastic material. This eliminates the need for stitching and assembly of multiple components, reducing manufacturing complexity while maintaining structural integrity and mechanical performance through the unified design
2Reliability
If conventional footwear manufacturing methods are used with multiple cutting and assembly steps, then the sole structure achieves required functions, but energy consumption and material waste increase significantly
Solution Approach 1:
The patent applies segmentation by incorporating distinct functional zones within a single continuous piece of material. The sole assembly element includes a footbed region, a sole region with external surface, and integrated cushioning elements distributed throughout the structure. This allows each zone to be optimized for its specific function while being manufactured as one piece, eliminating the energy-intensive processes of separate manufacturing and assembly
3Reliability
If conventional footwear manufacturing methods are used, then the sole structure provides adequate performance, but the manufacturing process produces numerous scraps from material cuttings
Solution Approach 1:
The patent segments the sole into functional zones (footbed, sole region, cushioning elements) that are all formed from one continuous piece of thermoplastic material through molding. This segmentation approach allows for optimized material distribution in each functional area while eliminating the need for cutting and joining separate pieces, thereby preventing material waste from scraps and cuttings
4Strength
If traditional multi-step manufacturing methods are used, then the sole structure achieves required mechanical properties, but the manufacturing time and production complexity increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single molding process that produces the complete sole assembly element in one step. The thermoplastic material is molded directly into the final three-dimensional shape with all functional zones and cushioning elements integrated, eliminating sequential steps such as cutting, stitching, and assembly that reduce productivity and increase production time
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 simplifies footwear manufacturing, reduces material waste, and allows for customizable sole designs with improved cushioning, wear resistance, and comfort, while minimizing environmental impact by enabling localized production and the use of recycled materials.
Implementation Method 1
a heating step is implemented under a mold at a temperature Tc higher than or equal to the melting temperature of the thermoplastic material
Implementation Method 2
at a temperature Tc higher than or equal to the melting temperature of the thermoplastic material, and a pressure p is applied to the textile sole element
Implementation Method 3
a pressure p is applied to the textile sole element so as to force it according to the cavity of the mold structure
Data Source
AI summary
The object of the present disclosure is a sole assembly element comprising at least one textile, in particular thermocompressed, sole element comprising one or several at least partly hot-melted yarn(s) as well as at least one housing and particles disposed in said at least one housing. The present disclosure also relates to a footwear article comprising such a sole assembly element, the methods for manufacturing such a sole assembly element and such a footwear article.