Braided Footwear Upper With Integrated Midsole Structure
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Solution Overview
Problem
Existing footwear technologies face challenges in creating a comfortable and secure upper structure that effectively integrates a midsole for cushioning and shock absorption while maintaining a braided design that provides 360-degree coverage and secure attachment of an outer sole.
Innovation Solution
A method involving a braiding process where a midsole structure is associated with a last, inserted through a braiding device to form a braided upper structure, with the midsole disposed within the upper's interior cavity, and an outer sole attached to the lower portion, ensuring the midsole is closer to the inner surface than the outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a midsole structure is integrated within the upper structure during braiding, then cushioning and shock absorption are enhanced, but the manufacturing process complexity increases
Solution Approach 1:
The patent combines the midsole structure integration with the upper formation process by inserting the midsole structure onto the last before the braiding process begins. The braided material is then formed around both the last and the midsole structure simultaneously, creating a unified integrated structure in one manufacturing operation rather than assembling separate components later.
Solution Approach 2:
The midsole structure is inserted and positioned on the last before the braiding process starts. This preliminary placement allows the midsole to be properly positioned and secured within the upper structure during the subsequent braiding operation, ensuring correct integration without requiring complex post-processing steps.
2Ease of operation
If the midsole structure is disposed within the interior cavity closer to the inner surface, then comfort is improved, but the structural complexity increases
Solution Approach 1:
The patent positions the midsole structure at a specific location within the upper structure - specifically closer to the inner surface of the lower portion rather than centrally or externally. This localized placement optimizes the comfort function by placing cushioning material where it directly contacts the foot, while the braided construction method maintains overall structural simplicity.
3Strength
If a braided structure with 360-degree coverage is formed, then secure attachment of outer sole is achieved, but manufacturing complexity increases
Solution Approach 1:
The braided structure serves multiple functions simultaneously: it forms the upper structure, provides 360-degree coverage around the midsole and last, and creates attachment surfaces for the outer sole. This multi-functional design achieves secure attachment without requiring separate reinforcement components or complex assembly steps.
Data Source
AI summary
A method of making an article of footwear includes temporarily attaching a midsole structure to a last and inserting the midsole structure and footwear last through a braiding machine. A braided structure in the form of an upper is formed. The upper includes a midsole structure disposed within an interior cavity of the upper.