Dual-Layer Braided Footwear Upper with Independent Spool Control
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Solution Overview
Problem
Existing braiding machines for footwear lack the ability to efficiently create articles with varying braid patterns and tensile strand configurations that provide both durability and flexibility, particularly in regions like the toes and heel, while maintaining flexibility in other areas like the instep.
Innovation Solution
A braiding machine system that uses independent spool control to create a compound braided structure with an outer braided structure and an inner braided structure, where the two structures are intertwined with tensile strands to form a hybrid pattern, allowing for varying braid patterns and tensile strand configurations that enhance durability and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single braided structure is used throughout the footwear upper, then the manufacturing process is simple, but the footwear lacks regional variations in durability and flexibility
Solution Approach 1:
The upper is divided into multiple regions (toe box, vamp, quarter, heel) with distinct braid patterns and tensile strand configurations. The braiding machine is segmented into multiple spool assemblies, each independently controllable to create different braid patterns in different regions. This allows each section of the upper to have optimized properties for its specific functional requirements.
Solution Approach 2:
Different regions of the upper are given different local qualities through varying braid patterns, tensile strand densities, and material compositions. The toe box receives a tighter, more durable braid pattern, while the instep uses a more flexible configuration. This principle enables the footwear to have heterogeneous properties tailored to regional performance needs.
2Adaptability or versatility
If multiple spool assemblies with independent control are used, then varying braid patterns can be created, but the device complexity increases
Solution Approach 1:
Each spool assembly is designed to be multi-functional, capable of creating different braid patterns through independent control of multiple spools within each assembly. The same basic spool assembly structure can produce various braid configurations by adjusting spool speeds, tensions, and engagement patterns, reducing the need for completely different mechanisms for each pattern type.
Solution Approach 2:
The spool control system incorporates dynamic adjustment capabilities, allowing real-time modification of spool speeds, tensions, and engagement during the braiding process. This enables the system to adaptively create different braid patterns without requiring complex mechanical reconfiguration, as the dynamics of spool operation can be varied programmatically.
3Strength
If tensile strands are intertwined between outer and inner braided structures, then durability and strength are enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process merges the creation of outer and inner braided structures into a single integrated braiding operation. Multiple spool assemblies work simultaneously to interweave tensile strands between concentric braided layers as they are being formed, rather than creating separate structures and assembling them later. This combining of operations enhances structural integrity while streamlining the manufacturing process.
Solution Approach 2:
The tensile strands are preliminarily positioned and tensioned during the braiding process itself, before the final structure is completed. The spool assemblies are configured to interweave these strands as the braided structures are being formed, ensuring proper integration and tension distribution from the outset, rather than requiring subsequent assembly or adjustment steps.
Data Source
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AI summary
An article includes a two layered braided upper assembly with an outer braided structure (120) and an inner braided structure (140). The braided structures may have different braid patterns. The dual layered upper assembly can be manufactured using a braid machine with multiple rings of spools.