Thermoformed Polyamide Sole Plate Assembly
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Solution Overview
Problem
Current sole systems for footwear lack an efficient method to create ultra-lightweight, rigid, and flexible sole plate assemblies that provide optimal traction and durability while being adaptable to various footwear types and regions of the foot.
Innovation Solution
A method involving thermoforming and injection molding to create a sole plate assembly with a thermoformed outer shell and injection-molded structural components, including cleat members, which can be tailored for different regions of the foot, using materials like polyamide and thermoplastic polyurethane foils, to achieve a lightweight yet supportive and grippy sole structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional sole systems are used, then durability and support are maintained, but weight is excessive and flexibility is reduced
Solution Approach 1:
The sole plate is divided into multiple regions (forefoot, midfoot, heel) with each region having customized properties. Different materials and configurations are used in different zones to optimize both weight and structural support locally, rather than using a uniform design throughout.
Solution Approach 2:
The invention uses composite material construction combining thermoplastic polyurethane (TPU) for the outer shell with polyamide foam for internal structures. This composite approach allows the outer shell to provide durability and structural integrity while the foam reduces weight and adds flexibility.
2Stability of the object's composition
If rigid materials are used for sole plate, then structural support is improved, but flexibility and adaptability to foot regions are reduced
Solution Approach 1:
Different regions of the sole plate are assigned different material properties and configurations. The forefoot region may use different density foam or cleat configurations compared to the heel region, allowing each area to be optimized for its specific functional requirements while maintaining overall structural integrity.
3Productivity
If traditional manufacturing methods are used, then ease of manufacture is maintained, but productivity and manufacturing precision are reduced
Solution Approach 1:
The invention uses pre-formed foam components that are manufactured separately with precise dimensions and configurations before being integrated into the final sole plate assembly. This preliminary manufacturing of critical components allows for higher precision in complex regions while maintaining overall manufacturing efficiency through modular assembly.
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 method results in an ultra-lightweight sole plate assembly that offers enhanced traction, durability, and flexibility, suitable for various footwear types, by combining the structural support of a rigid outer shell with the adaptability and grip of injection-molded components.
Implementation Method 1
an outer shell (140) made from a thermoformed foil material
Implementation Method 2
injection molded to the outer shell (140)
Data Source
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AI summary
An ultra-lightweight sole plate assembly can include a ground engaging outer shell, a structural component, and one or more cleat members. A method of making the outer shell includes thermoforming a foil material such as polyamide. Thermoforming the foil includes applying vacuum to the foil material. Excess foil material can be trimmed from the outer shell. The structural component can be made by injecting a molding material onto the outer shell. The cleat members can be co-molded with the shell during forming of the structural component. The resulting sole plate assembly has a reduced weight with the desired traction, strength and durability.