Braided Shoe Upper Using Segmented Braid Density
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Solution Overview
Problem
Conventional footwear manufacturing methods require multiple material elements for the upper, leading to increased waste, complexity, and reduced recyclability, along with discomfort due to stress concentration at stitch junctions.
Innovation Solution
A braiding machine overbraids a forming last with threads to create a seamless braided structure that reduces the number of material elements and stress concentrations, enhancing comfort and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material elements are used for the upper, then different properties (stretch resistance, wear resistance, flexibility, air permeability, compressibility, comfort) can be imparted to different areas, but the number of material elements increases leading to increased waste, complexity, and reduced recyclability
Solution Approach 1:
The upper is divided into multiple zones along the longitudinal axis, each zone having distinct braid characteristics (density, strand composition, orientation) to provide different functional properties. This segmentation is achieved within a single continuous braided structure rather than assembling multiple separate material elements, thereby maintaining functional versatility while reducing waste and improving recyclability.
Solution Approach 2:
Different regions of the braided upper are engineered with locally optimized properties: higher braid density in areas requiring support and protection, lower density in areas requiring flexibility and ventilation, and specific strand material compositions tailored to local functional requirements. This local quality approach eliminates the need for multiple different material elements while achieving the same functional differentiation.
2Adaptability or versatility
If multiple material elements are joined together with stitching or adhesive bonding, then multiple properties can be imparted to the same areas, but the time and expense associated with transporting, stocking, cutting, and joining increases
Solution Approach 1:
Multiple material elements that would traditionally be separately cut, transported, stored, and joined are merged into a single continuous braided structure. The braiding process integrates what would otherwise be separate manufacturing steps into one continuous operation, eliminating the time and expense associated with handling multiple discrete material elements while maintaining the ability to provide different functional properties in different areas.
Solution Approach 2:
The different functional properties are built into the upper during the braiding process itself, rather than requiring subsequent assembly operations. The braid characteristics (density, strand composition, orientation) are predetermined and implemented as the upper is being formed, performing the differentiation function in advance and eliminating later joining operations.
3Adaptability or versatility
If multiple material elements are joined together, then multiple properties can be imparted to the upper, but waste material from cutting and stitching processes accumulates to a greater degree
Solution Approach 1:
The invention consolidates multiple material elements into a single continuous braided structure. By merging what would otherwise be separate materials and components into one integrated structure, the complexity of managing multiple material elements is eliminated while the functional versatility is preserved through spatial variation of braid characteristics within the unified structure.
4Adaptability or versatility
If multiple pieces are stitched together, then the upper can be formed with multiple properties, but stitch junctions transfer stress at an uneven rate which may cause failure or discomfort
Solution Approach 1:
The invention eliminates stitch junctions by merging multiple material elements into a single continuous braided structure. The continuous nature of the braid ensures uniform stress distribution throughout the upper, as there are no discrete joining points where stress would concentrate. The interlaced structure of the braid naturally distributes loads evenly across all strands, improving reliability and comfort.
5Strength
If additional material and stitch joints are used, then the upper can provide extra support in certain areas, but it leads to discomfort when worn
Solution Approach 1:
The invention provides localized support by varying braid density and strand composition in specific regions of the upper, rather than adding separate reinforcement pieces. Areas requiring extra support feature tighter braid density or stronger strand materials, while areas requiring comfort maintain appropriate flexibility. This local quality approach achieves differential support without the discomfort of additional material layers and stitch joints.
Data Source
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AI summary
A method of forming a braided upper using a braiding machine (100) comprising: connecting a first shoe last (124) and a second shoe last (125) to each other by a non-rigid connection mechanism (129); locating the first shoe last (124) adjacent a first opening (116) of a passageway (170), wherein the passageway (170) extends through an enclosure of the braiding machine (100) and wherein a track (122) of the braiding machine (100) extends around the enclosure (170); passing the first shoe last (124) through the passageway (170) from the first opening (116) to a second opening (131); passing the first shoe last (124) from a first side of a braiding point to a second side of the braiding point of the braiding machine (100); wherein the braiding machine (100) further includes a plurality of spools (102) located along the track (122), the plurality of spools (102) including a first spool (102) and a second spool (102), the first spool (102) being adjacent to the second spool (102), wherein as the first spool (102) moves the second spool (102) remains stationary; and advancing the first shoe last (124) through the braiding machine (100), wherein the connection mechanism (129) is tensioned such that the second shoe last (125) is pulled though the braiding machine (100) and the braiding point, and as each of the plurality of spools (102) is passed around the track, thread is deposited around the first shoe last (124).