Double Layer Single Tube Braided Footwear Upper

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Solution Overview

Problem

Traditional footwear upper manufacturing methods involve cutting and stitching or knitting, which do not efficiently utilize braided structures, limiting the flexibility and adaptability of shoe design.

Innovation Solution

A double-layer tubular braid structure is created using a circular braiding machine, where a draw yarn is braided to connect and then decouple the layers, allowing the structure to expand from a double-layer to a single-layer configuration, enabling a larger diameter and customizable design features such as varying braid density and open edges.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional cutting and stitching methods are used to manufacture footwear uppers, then manufacturing precision and structural integrity are maintained, but design flexibility and adaptability are limited

Engineering Contradiction:
Improvedesign flexibilityVSAvoidmanufacturing complexity
Core Design Contradiction:
Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The footwear upper is divided into multiple braided layers that can be independently configured and then assembled, allowing design flexibility while maintaining manufacturing efficiency through modular construction

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent transitions from traditional 2D cutting and stitching to a 3D braided tubular structure, enabling design flexibility in the third dimension while maintaining manufacturing precision through controlled braiding parameters

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If a double-layer tubular braid structure is used, then structural integrity and adaptability are enhanced, but device complexity increases

Engineering Contradiction:
ImprovecustomizabilityVSAvoidstructure complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The double-layer tubular braid structure nests one braided layer within another, creating a complex adaptable structure from simpler repeated units that can be manufactured using standard braiding processes

Inventive Principle:
Principle #7Nested doll (Nesting)

3Shape

If the double-layer structure is expanded to single-layer configuration, then diameter and design freedom increase, but structural integrity may be compromised

Engineering Contradiction:
ImprovediameterVSAvoidstructural integrity
Core Design Contradiction:
ShapeVSStrength

Solution Approach 1:

The draw yarn provides a dynamic mechanism that allows the structure to transition between compressed double-layer and expanded single-layer states, maintaining structural integrity through controlled mechanical action rather than fixed geometry

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS11457685B2Double layer, single tube braid for footwear upper
Publication Date: 2022.10.04 NIKE INC
  • US11457685B2 patent drawing
  • US11457685B2 patent drawing
  • US11457685B2 patent drawing

AI summary

A method of manufacturing a braided footwear upper is provided. The method includes braiding a two-layer, single-tube structure with a first end that couples a first braided layer to a second braided layer, and second end that couples the first braided layer to the second braided layer of the tubular braided structure. The first end is proximate the second end. At least one yarn from the first end, and at least one yarn from the second end are braided with at least one draw yarn. The draw yarn is braided to be easily removable, such that the first end is selectively de-coupled from the second end. When the draw yarn is removed, the double-layer tubular braided structure is expandable to form a larger diameter tubular braided structure.