Braided Footwear Upper Merging Strands to Reduce Waste
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Solution Overview
Problem
Conventional footwear manufacturing processes are inefficient and wasteful due to the use of multiple material elements in the upper, leading to increased waste, complexity, and reduced recyclability, as well as discomfort and stress concentration at stitch junctions.
Innovation Solution
A method of forming a braided upper using a lace braiding machine that reduces the number of material elements by creating a seamless, three-dimensional braided structure around a forming mandrel, which decreases waste and enhances manufacturing efficiency and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material elements are used in the upper, then different properties (stretch resistance, wear resistance, flexibility, air permeability) can be imparted to different areas, but waste material accumulates to a greater degree and manufacturing time and expense increase
Solution Approach 1:
The patent merges multiple material elements into a single continuous braided structure formed by intertwining multiple strands during the braiding process. This single integrated upper replaces the conventional approach of joining multiple separate material pieces, thereby eliminating cutting waste while maintaining diverse functional properties through the selection and arrangement of different strand materials.
Solution Approach 2:
The patent employs composite materials by combining different strand materials (e.g., polyester, nylon, elastane) in a braided configuration. Each strand can have different properties, and their integration into a single braided structure creates a composite upper that exhibits multiple functional characteristics simultaneously without requiring separate material pieces to be joined together.
2Adaptability or versatility
If multiple material elements are used in the upper, then different properties can be imparted to different areas, but the time and expense associated with transporting, stocking, cutting, and joining the material elements increase
Solution Approach 1:
The patent combines multiple material strands into a single continuous braided upper through one integrated braiding process, eliminating the need for separate transporting, stocking, cutting, and joining operations for multiple material elements. This merging of materials and processes significantly reduces manufacturing time and operational complexity.
Solution Approach 2:
The patent performs preliminary action by forming the complete multi-functional upper structure in a single braiding operation before any cutting or joining is needed. The braiding machine interweaves multiple strands into the final upper configuration in advance, eliminating subsequent assembly steps and reducing overall manufacturing time.
3Adaptability or versatility
If multiple material elements are stitched together, then the upper can be formed with different properties in different areas, but stitch junctions transfer stress at an uneven rate which may cause failure or discomfort
Solution Approach 1:
The patent merges multiple material strands into a single continuous braided structure where the strands are interwoven throughout the entire upper. This eliminates discrete stitch junctions and creates uniform stress distribution across the entire upper surface, as the braided structure naturally distributes forces evenly through its interconnected strand network.
Solution Approach 2:
The patent achieves homogeneity in stress distribution by creating a uniformly braided structure where all strands are interwoven in a consistent pattern throughout the upper. This homogeneous braided configuration ensures that stress is transferred evenly across all areas of the upper, eliminating the stress concentration problems associated with uneven stitch junctions in multi-piece constructions.
4Adaptability or versatility
If multiple material elements are used in the upper, then the upper can provide extra support in certain areas, but the upper becomes more difficult to recycle
Solution Approach 1:
The patent merges multiple material strands into a single continuous braided upper, which simplifies recycling compared to multi-piece constructions. While the upper contains multiple materials with different support properties, they are integrated into one unified structure that can be processed as a single item, eliminating the complexity of separating and recycling multiple joined components.
Data Source
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AI summary
A braiding machine and method of forming an upper that includes braiding over a forming mandrel located adjacent to a ring. The braiding machine being capable of forming intricate braided structures.