Published Technical Disclosure Archive

Advanced Composite Midsole Foam: Performance Footwear Innovation

Publication ID: 24-11857024_0006_PTD
Published: October 27, 2025
Category:Direct Improvements & Enhancements

Legal Citation

pr1or.art Inc., “Advanced Composite Midsole Foam: Performance Footwear Innovation,” Published Technical Disclosure No. 24-11857024_0006_PTD, Published October 27, 2025, available at https://archive.pr1or.art/24-11857024_0006_PTD
This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,024.

Background and Problem Solved

The original patent disclosed a high-performance composite foam for midsoles, comprising a pelletized expanded thermoplastic elastomer and a polyurethane matrix. However, this design has limitations in terms of durability, cushioning, thermal insulation, and customization. The present invention addresses these limitations by introducing surface treatments, controlled temperature profiles, varied pellet size distributions, thermally insulating coatings, and tunable properties, thereby providing a more efficient and effective midsole composite foam.

Novelty and Inventive Step

The present invention introduces novel and non-obvious improvements to the original patent, including surface treatments, controlled temperature profiles, varied pellet size distributions, thermally insulating coatings, and tunable properties, which provide enhanced durability, cushioning, thermal insulation, and customization capabilities.

Alternative Embodiments and Variations

Alternative embodiments of the invention may include varying the type of thermoplastic elastomer, the shape and size of the pellets, the composition of the polyurethane matrix, and the specific surface treatments and coatings used. Additionally, the invention may be adapted for use in other applications, such as orthotics or prosthetics.

Potential Commercial Applications and Market

The enhanced composite foam for midsoles has significant commercial potential in the athletic footwear industry, particularly in high-performance and specialty shoes. The invention's improved durability, cushioning, thermal insulation, and customization capabilities make it an attractive solution for manufacturers and consumers alike.

CPC Classifications

SectionClassGroup
A A43 A43B13/026
A A43 A43B13/04
C C08 C08J9/0061
C C08 C08L75/04
C C08 C08J2367/02
C C08 C08J2375/04
C C08 C08J2377/00
C C08 C08J2467/02
C C08 C08J2475/04
C C08 C08J2477/00

Field of Art

Footwear materials engineering, specifically composite foam technologies for athletic shoe midsoles, involving polymer chemistry, materials science, and manufacturing processes for performance footwear components

Person of Ordinary Skill (PHOSITA) Profile

A materials engineer or polymer scientist with expertise in thermoplastic elastomers, polyurethane matrix compositions, and shoe manufacturing techniques, holding at least a bachelor's degree with 3-5 years of industry experience in material design and performance footwear development

Obviousness Rationale

A person having ordinary skill would recognize that the PTD's variations represent standard engineering optimization techniques for composite foam materials. The disclosed surface treatments, temperature profile modifications, and pellet size distributions are predictable extensions of the source patent's core composite foam technology. These modifications represent routine material engineering approaches to incrementally improve mechanical and thermal properties of midsole foams.

Obvious Combinations & Variations

Source Patent Element
Pelletized expanded thermoplastic elastomer mixed within a polyurethane matrix
PTD Variation
Surface treatment of pellets to enhance bonding to polyurethane matrix
Obviousness Reasoning
Adhesion enhancement through surface modification is a known technique in polymer composites, representing a predictable design optimization for improving interfacial bonding
Source Patent Element
Spheroid pellets ranging between 1-12 mm
PTD Variation
Varied pellet size distribution to optimize energy absorption
Obviousness Reasoning
Controlling particle size and distribution is a standard method for tuning mechanical properties in composite materials, representing a routine engineering design choice
Source Patent Element
Expanded thermoplastic elastomer in polyurethane matrix
PTD Variation
Thermally insulating coating applied to pellets and matrix
Obviousness Reasoning
Adding thermal barrier properties through surface coatings is a well-established approach in materials engineering for modifying thermal performance
Source Patent Element
Composite foam for midsole applications
PTD Variation
Customizable foam properties through adjustable pellet characteristics
Obviousness Reasoning
Developing tunable material systems is a predictable progression in advanced materials design, representing an expected innovation for performance optimization
35 U.S.C. § 103 Summary: Based on the teachings of US Patent 11857024, a person having ordinary skill in the art would find the variations disclosed in the present technical publication to represent obvious modifications to the prior art. The incremental improvements in surface treatment, thermal properties, and material customization would be considered routine engineering optimizations within the ordinary capabilities of a skilled practitioner in footwear materials design.

Original Patent Information

Patent NumberUS 11,857,024
TitleComposite foam for midsole
Assignee(s)Columbia Sportswear North America, Inc.