Fluid-Filled Lasting Element for Footwear Shape Retention
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Solution Overview
Problem
The existing methods for manufacturing footwear, particularly athletic footwear, face challenges in achieving a comfortable and secure fit due to the limitations of traditional lasting processes, which often result in pressure points and inadequate shape retention during the manufacturing of the sole and upper structures.
Innovation Solution
The method involves using a pressurized barrier formed from polymer material with a tensile member secured within, creating a fluid-filled chamber that is bonded to the upper, providing a flange extension around the perimeter to secure the sole structure, enhancing shape retention and comfort by distributing pressure evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional lasting processes are used to tighten the upper around the last, then the upper can be formed around the foot shape, but pressure points are created and fit comfort is reduced
Solution Approach 1:
The patent employs a fluid-filled chamber (pneumatic system) that can be pressurized to apply uniform distributed pressure across the foot, replacing traditional mechanical lasting methods that create concentrated pressure points. The fluid pressure evenly distributes force across the entire foot surface, eliminating hot spots and improving comfort while maintaining proper foot shape.
Solution Approach 2:
The patent changes the pressure application parameter from concentrated mechanical force to distributed fluid pressure. By controlling the fluid pressure within the chamber, the system can adjust the magnitude and distribution of force applied to the foot, optimizing both fit and comfort without creating pressure points.
2Stability of the object's composition
If traditional lasting methods are used to tighten the upper, then the upper can be secured around the last, but shape retention during manufacturing is inadequate
Solution Approach 1:
The fluid-filled chamber provides stable, controllable pressure to maintain the upper's shape during the manufacturing process. The incompressible nature of fluid ensures consistent pressure application, preventing deformation and maintaining manufacturing precision throughout the assembly process.
Solution Approach 2:
The lasting element with fluid chamber is positioned and pressurized before the final assembly steps are completed. This preliminary application of distributed pressure ensures the upper maintains its proper shape and position during subsequent manufacturing operations, improving overall shape retention.
3Ease of operation
If a pressurized barrier with tensile member is used as a lasting element, then shape retention and pressure distribution are improved, but device complexity increases
Solution Approach 1:
The patent uses a flexible barrier (thin film) that can be pressurized with fluid to create the lasting element. This flexible membrane approach simplifies the structure compared to rigid mechanical systems, allowing the barrier to conform to the foot shape while providing uniform pressure distribution through fluid containment.
Solution Approach 2:
By using a fluid-filled chamber as the core mechanism, the patent replaces complex mechanical pressure distribution systems with a simple pneumatic system. The fluid pressure automatically distributes force evenly across the barrier surface, eliminating the need for complex mechanical linkages or adjustable components.
4Strength
If the flange is formed from polymer material of the pressurized barrier, then the lasting element can be securely joined to the upper, but the barrier requires additional sealing to contain pressurized fluid
Solution Approach 1:
The patent merges the bonding function and sealing function into a single integrated peripheral bond structure. The same bond that attaches the flange to the upper also serves as the seal containing the pressurized fluid, eliminating the need for separate sealing components and reducing overall structural complexity.
Solution Approach 2:
The peripheral bond structure performs multiple functions simultaneously: it provides structural attachment of the flange to the upper and creates the fluid seal. This multi-functional design reduces the number of components needed while maintaining both bonding strength and fluid containment.
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
This approach improves the fit and comfort of footwear by maintaining the intended shape and reducing pressure points, allowing for a more secure and comfortable wear experience through the use of a pressurized fluid-filled chamber with a tensile member, which secures the sole structure effectively.
Implementation Method 1
The pressurized fluid within the barrier may cause the barrier to expand
Implementation Method 2
a pressurized barrier formed from a polymer material and a tensile member located within the barrier
Implementation Method 3
the tensile member being secured to opposite sides of the barrier... the tensile member restrains outward movement of the barrier when pressurized
Implementation Method 4
the first barrier portion and the second barrier portion are joined together with a peripheral bond
Data Source
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AI summary
A method of manufacturing an article of footwear (10) may include assembling at least a portion of an upper (30) of the article of footwear, the upper having a lower perimeter edge (34). A lasting element (40) is secured to the upper adjacent to the lower perimeter edge. The lasting element includes a barrier (41) and a tensile member (46) located within the barrier, the tensile member being secured to opposite sides of the barrier. In addition, a sole structure (20) of the article of footwear is joined to at least one of the upper and the lasting element.