Variable Rigidity Composite Footwear Sole
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Solution Overview
Problem
Footwear requires varying levels of support and flexibility depending on the user's activity and intended use, with a need for maximum performance, comfort, and durability, while also being lightweight and able to efficiently transfer energy.
Innovation Solution
A composite sole element with regions of varying rigidity, incorporating fiber-reinforced layers and a method of manufacturing that involves molding and bonding to create a midsole, outsole, and innersole, allowing for tailored flexure characteristics based on the user's needs and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a uniform rigid sole is used, then support and durability are improved, but flexibility and comfort deteriorate
Solution Approach 1:
The sole is divided into multiple regions (heel region, midfoot region, forefoot region) with different rigidity characteristics. Each region is configured with specific fiber orientation and layer structure to provide localized support or flexibility appropriate to its functional requirements, resolving the contradiction between overall support and localized flexibility.
Solution Approach 2:
The sole structure is segmented into distinct functional zones with varying composite material configurations. The heel region uses higher rigidity for support, the midfoot region provides transitional properties, and the forefoot region allows greater flexibility for toe movement, thus achieving both support and flexibility simultaneously.
2Weight of moving object
If a lightweight sole is used, then performance and flexibility are improved, but durability and support deteriorate
Solution Approach 1:
The sole utilizes composite materials consisting of fiber reinforcement (such as carbon fiber, glass fiber, or aramid fiber) embedded in a polymer matrix. This composite structure provides high strength-to-weight ratio, achieving both lightweight requirements and durability needs simultaneously through the synergistic combination of materials.
Solution Approach 2:
The rigidity and durability parameters are adjusted by changing the fiber orientation angles, layer thicknesses, and material composition in different sole regions. By optimizing these parameters, the sole achieves maximum strength with minimum weight in each specific area.
3Ease of manufacture
If a single rigidity sole is used, then manufacturing simplicity is improved, but adaptability to different activities deteriorates
Solution Approach 1:
The sole is manufactured as a single integrated component with pre-configured regional variations in rigidity. The different fiber orientations and layer structures are built into the sole during one manufacturing process, eliminating the need for post-manufacturing assembly while providing activity-specific support characteristics.
Solution Approach 2:
The multi-region sole design provides universal adaptability for different activities (running, walking, cycling, cross-training) within a single footwear unit. Each region's optimized properties enable the sole to perform multiple functions across various athletic disciplines without requiring separate footwear for each activity.
Data Source
AI summary
Embodiments of the present invention generally relate to a composite element adapted for use with an article of footwear. The composite element generally comprises a first portion with a first rigidity and a second portion with a second, different rigidity. The first portion and the second portion each comprise at least one fiber-reinforced layer and are configured to provide the desired rigidity characteristics according to a wearer's characteristics and/or an intended use of the footwear.