TPU Footwear Base with Integrated Shock-Absorbing Insert
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Solution Overview
Problem
Safety footwear often compromises comfort and natural foot movement due to rigid reinforcing materials, leading to foot and posture problems, and existing solutions for energy absorption in soles are ineffective or incompatible with production processes.
Innovation Solution
A base or tread component made of thermoplastic polyurethane (TPU) with a casing or wrapping element that integrates a shock-absorbing insert, allowing for the use of various materials and ensuring the insert's position and functionality during the molding process, creating a comfortable and durable sole with enhanced energy dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid reinforcing materials are used in safety footwear, then protection from injuries is improved, but natural foot movement and comfort deteriorate
Solution Approach 1:
The sole is divided into multiple layers with different properties: a rigid protective layer for injury prevention and a flexible energy-absorbing layer for natural foot movement. This segmentation allows each layer to perform its specific function without compromising the other.
Solution Approach 2:
The invention uses composite construction combining rigid materials (for protection) with flexible materials containing energy-absorbing elements (for comfort and natural movement). This creates a multi-functional sole that simultaneously provides protection and allows natural foot articulation.
2Ease of operation
If energy-absorbing inserts are added to soles, then comfort is improved, but device complexity and risk of breakage increase
Solution Approach 1:
The energy-absorbing elements are integrated directly into the flexible layer of the sole during manufacturing, merging the energy-absorption function with the structural layer. This eliminates separate inserts that could break or malfunction, while maintaining comfort benefits.
Solution Approach 2:
The flexible layer with embedded energy-absorbing elements is designed as a consumable component that can be easily replaced if deteriorated, rather than attempting to make the energy-absorption system permanent and break-resistant. This reduces overall device complexity and maintenance requirements.
3Adaptability or versatility
If removable insoles are used for customization, then adaptability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The flexible layer is designed with specific local properties (energy-absorbing characteristics) that can be customized for different user needs while maintaining overall sole integrity. This allows customization without requiring separate removable insoles and their associated certification processes.
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 provides increased comfort and reduced risk of breakage or malfunction, allowing for a wide range of materials to be used, ensuring the footwear's suitability for hostile environments and maintaining the insert's effectiveness over time.
Implementation Method 1
a shock-absorbing insert (4) housed in the positioning zone (PZ) closed, if desired sealed, between the upper (10) and the base or tread component (1)
Implementation Method 2
The latter, properly treated, protects HRO certified footwear, which resist heat (by contact) up to 300° C
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention concerns a base or tread component for a footwear comprising a main plate element (2) made of thermoplastic polyurethane (TPU) and a casing or wrapping element (3) made by molding of thermoplastic polyurethane (TPU) on an upper rear portion (2a) of the main plate element (2).