Composite Footwear Upper With Embedded Polymer Threads
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Solution Overview
Problem
Conventional footwear upper materials often have superfluous layers that do not contribute to desired properties, such as stretch-resistance, leading to increased mass without enhanced performance.
Innovation Solution
A method of manufacturing a composite element by embedding polymer threads within a textile layer, where the threads are embroidered to provide structural elements that offer specific properties like stretch-resistance, wear-resistance, and air-permeability, minimizing unnecessary material and optimizing the upper's configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple material layers are used in the upper to provide different properties (stretch-resistance, wear-resistance, flexibility, air-permeability), then the desired functional properties are improved, but the mass and complexity of the upper increase
Solution Approach 1:
The upper is divided into functional zones with different thread densities and orientations. High-density thread regions provide stretch-resistance where needed, while low-density regions maintain flexibility and air-permeability. This segmentation allows each area to contribute only the necessary mass for its specific function, eliminating superfluous material throughout the upper structure.
Solution Approach 2:
Different regions of the upper are assigned different thread properties, densities, and orientations based on local functional requirements. For example, the toe area receives higher thread density for wear-resistance, while the heel area uses specific orientations for stretch-resistance. This local optimization ensures that mass is distributed only where it provides functional benefit, rather than uniformly throughout the entire upper.
2Reliability
If multiple material layers are used in the upper to provide different properties, then the desired functional properties are improved, but the device complexity increases
Solution Approach 1:
Multiple functional properties are merged into a single integrated upper structure through strategically placed threads. Instead of separate layers for stretch-resistance, wear-resistance, and flexibility, the invention combines these functions into one cohesive upper where thread density, orientation, and material properties vary by region. This merging reduces the number of discrete components and simplifies the overall configuration while maintaining all necessary functional properties.
Solution Approach 2:
The thread structure serves multiple functions simultaneously: providing stretch-resistance through specific orientations, wear-resistance through high-density regions, and flexibility through lower-density areas. This multi-functionality eliminates the need for separate specialized layers, reducing device complexity while achieving the same functional outcomes that would otherwise require multiple distinct material layers.
3Reliability
If threads are embroidered to provide structural elements with specific properties, then performance is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The thread pattern and density distribution are predetermined through computer-aided design before manufacturing. The embroidery machine is programmed with precise instructions for thread placement, density, and orientation based on pre-calculated functional requirements for each region. This preliminary planning allows the complex embroidery process to be executed automatically with high precision, reducing the perceived manufacturing complexity while achieving optimized performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a footwear upper with tailored properties, reducing unnecessary mass and enhancing performance by strategically placing threads to resist stretching and reinforce specific areas, thereby improving comfort and durability.
Implementation Method 1
The polymer material is heated to bond the section of the thread and the cover layer to the textile layer
Data Source
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AI summary
A composite element (80) includes a base layer (81), a thermoplastic polymer material (83), a thread(82), and a cover layer(84). The base layer has a first surface and an opposite second surface. The polymer material (83) is separate from the base layer(81), extends into the base layer(81), and is at least partially located at the first surface. The thread (82) has a section lying adjacent to the first surface layer and substantially parallel to the first surface throughout a distance of at least five centimeters, and the thread (82) is bonded to the base layer with the polymer material (83). The cover layer (84) is located adjacent to the first surface and bonded to the base layer (81) with the polymer material (83), and the section of the thread(82) is located between the cover layer (84) and the base layer (81).