Waterproof Shoe Sole with Perforated Membrane and Overmolded Mesh
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing waterproof and breathable shoe soles do not maximize membrane breathability due to limited surface area exposure and may compromise strength and manufacturing efficiency.
Innovation Solution
A sole design featuring a lower layer with large through holes, a mesh layer overlapping these holes, and a water-impermeable, vapor-permeable membrane joined hermetically to the sole, with a perforated upper layer, where the lower layer is overmolded onto the mesh to enhance adhesion and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the membrane area is enlarged to maximize breathability, then the breathability performance is improved, but the mechanical strength of the sole is compromised
Solution Approach 1:
The sole is divided into multiple functional layers: a supporting layer (12) made of rigid material, a mesh layer (15) for structural integrity, and a membrane layer (18) for breathability. This segmentation allows each layer to specialize in one function, enabling the membrane to cover larger areas without compromising overall sole strength.
Solution Approach 2:
The sole combines multiple materials with different properties: rigid supporting layer material for strength, mesh material for structural support and breathability, and membrane material for water vapor permeability. This composite structure allows the sole to simultaneously achieve high breathability and mechanical strength.
2Reliability
If extensively perforated material is used below the membrane to support large hole structures, then breathability is improved, but the mechanical strength of the supporting layer is compromised
Solution Approach 1:
The supporting structure is segmented into two distinct layers: a rigid supporting layer (12) that provides mechanical strength, and a mesh layer (15) that provides breathability. This segmentation allows the rigid layer to maintain structural integrity while the mesh layer maximizes vapor exchange.
Solution Approach 2:
Different regions of the sole have different structural qualities. The supporting layer (12) is made of rigid material for strength, while the mesh layer (15) has extensive perforations for breathability. Each layer is optimized for its specific function rather than trying to make a single layer perform both functions.
3Adaptability or versatility
If multiple separate components are composed by adhesive bonding to manufacture the sole, then design flexibility is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Multiple layers (supporting layer 12, mesh layer 15, membrane layer 18) are combined into a single integrated structure through overmolding. The membrane layer is overmolded directly onto the mesh layer, which is itself attached to the supporting layer, creating a unified component that reduces assembly steps and manufacturing complexity.
Solution Approach 2:
The mesh layer (15) and membrane layer (18) are pre-assembled into a integrated unit through overmolding before being attached to the supporting layer. This preliminary integration simplifies the overall manufacturing process by reducing the number of separate assembly operations required.
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 design significantly increases membrane breathability, maintains sole strength, and allows for more automated and cost-effective manufacturing, ensuring effective moisture management in shoes.
Implementation Method 1
a membrane (18) made of a material that is impermeable to water and permeable to water vapor
Implementation Method 2
a membrane (18) made of a material that is impermeable to water and permeable to water vapor
Implementation Method 3
said lower layer being overmolded on said mesh and partially incorporating it
Data Source
AI summary
A waterproof and breathable sole for shoes, including a lower layer, including at least one large through hole. Above the lower layer, a mesh is provided, arranged to overlap at least the large through hole. A membrane made of a material that is impermeable to water and permeable to water vapor is associated in an upward region with respect to the mesh at least at the large hole. The membrane is joined hermetically at least perimetrically to at least one component of the sole so as to avoid liquid rise through the perimeter of the large hole. A perforated upper layer is arranged above the membrane. The lower layer is overmolded on the mesh and partially incorporates the mesh.