Braided Shoe Upper Production with Empty-Center 3D Braiding
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Solution Overview
Problem
Existing methods for producing braided shoe uppers are slow, mechanically complex, costly, and difficult to modularize, limiting customization and applicability beyond footwear.
Innovation Solution
A method involving braiding with an empty braiding center using a 3D braiding machine to create a biaxial braided tube, allowing for modular production and customization, with adjustable properties through varying yarn types and braiding angles, and optionally combining layers for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If braiding is performed over a shoe last or forming mandrel, then the component can be shaped to the desired form, but the production process becomes slow, mechanically complex, and costly
Solution Approach 1:
The process is divided into two independent stages: first braiding the tubular component with an empty braiding center, then separately arranging it on the form. This segmentation eliminates the mechanical complexity of guiding forms through braiding machines while maintaining both shaping capability and production efficiency.
Solution Approach 2:
Instead of braiding over a form (traditional approach), the invention inverts the sequence by first braiding the component in isolation and then arranging it on the form. This reversal simplifies the braiding process while achieving the same shaping result.
2Shape
If braiding is performed over a shoe last or forming mandrel, then the component can be shaped to the desired form, but the device complexity and cost increase
Solution Approach 1:
By separating the braiding operation from the forming operation, the invention eliminates the need for complex guiding mechanisms in the braiding machine. The braiding machine only needs to create a tubular structure, while the form is used separately in the arranging stage, significantly reducing device complexity.
Solution Approach 2:
The invention inverts the traditional sequence by first creating the component structure in isolation and then applying the form. This eliminates the need for complex coordination between the braiding machine and the form, reducing mechanical complexity and cost.
3Shape
If traditional braiding methods are used with shoe lasts, then components can be produced for specific footwear, but customization and applicability beyond footwear are limited
Solution Approach 1:
The braided tubular component produced with an empty braiding center is a universal intermediate product that can be arranged on different forms for various applications including footwear, apparel, and sporting goods. This universal approach enables customization across multiple product categories from a single braiding process.
Solution Approach 2:
By separating the component production from the application-specific forming stage, the invention enables flexible customization. The same braided tube can be arranged on different forms to create various products, greatly enhancing adaptability and versatility across footwear, apparel, and other applications.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
The present invention concerns a method of producing a component (19) for an article of footwear or apparel or a sporting goods accessory, comprising: (a) forming at least a first layer (L1) by braiding a first braided tube (16), wherein braiding is performed with an empty braiding center; and (b) arranging the first layer (L1) on a form (18).