Footwear Flat Pattern Upper With Integrated Collar Liner
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Solution Overview
Problem
The traditional footwear manufacturing process is laborious and inefficient, involving batch-like operations that lead to inefficiencies due to the need for multiple operators to perform different series of tasks on a shoe, resulting in a start and stop process.
Innovation Solution
A continuous in-line manufacturing method for footwear that integrates the upper and footbed portions, using a flat pattern upper with forming apertures and overlays to form a dimensional shoe, allowing for automated and varied production of shoe styles, sizes, and materials, with machine and human involvement to achieve consistency and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional batch-like manufacturing operations are used with multiple operators performing different tasks, then flexibility in performing various operations is maintained, but manufacturing efficiency and productivity deteriorate due to start and stop processes
Solution Approach 1:
The patent implements a continuous in-line manufacturing system where the flat pattern upper moves continuously through multiple processing stations. Each station performs a specific operation (cutting, overlay application, forming) as the material progresses along the production line, eliminating the start-stop nature of traditional batch processing and significantly improving manufacturing efficiency
Solution Approach 2:
The manufacturing process is divided into discrete segments or stations along the production line, with each station dedicated to a specific operation. The flat pattern upper is segmented into functional zones (cut regions, overlay regions, forming regions) that are processed sequentially as they pass through each station, allowing specialized equipment to work on specific portions simultaneously
2Productivity
If automated continuous in-line manufacturing is implemented, then productivity and consistency are improved, but the requirement for integrated flat pattern design with precise aperture and overlay alignment increases complexity
Solution Approach 1:
The flat pattern upper is pre-designed with precisely positioned forming apertures, origin apertures, and overlay alignment features before entering the manufacturing line. Overlays are pre-cut and pre-positioned with alignment apertures that correspond to the flat pattern features, allowing for rapid and accurate assembly during the continuous manufacturing process without requiring complex real-time alignment mechanisms
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a registration-based approach using aligned apertures. The overlay alignment aperture and flat pattern origin aperture provide a simple mechanical registration system where pins or guides pass through both apertures to automatically position the overlay correctly, eliminating the need for sophisticated sensors or adjustable mechanical alignment devices
3Adaptability or versatility
If traditional piece-by-piece cutting and sewing is used, then adaptability to different shoe styles and materials is maintained, but labor requirements and manufacturing time increase
Solution Approach 1:
The flat pattern upper serves as a universal substrate that can be configured for different shoe styles by varying the cutting patterns, overlay designs, and forming parameters. The same continuous manufacturing line can produce different footwear styles by changing the flat pattern templates and overlay specifications, eliminating the need for separate production lines for different styles while maintaining high productivity
Solution Approach 2:
The manufacturing system is designed to be dynamic and reconfigurable, allowing the flat pattern upper to be adjusted for different styles, sizes, and materials. The continuous production line can quickly transition between different product configurations by changing the cutting paths, overlay application parameters, and forming tooling, enabling versatile production without sacrificing speed
Data Source
AI summary
An article of footwear flat pattern with an integrated collar liner is provided. The flat pattern has a flat upper with a top surface forming an exterior of a dimensionally formed article of footwear and a bottom surface facing an internal cavity of the dimensionally formed article of footwear. The flat pattern also includes a collar liner that is coupled with the flat upper at an ankle opening. The collar liner has an interior surface and an opposite exterior surface. The exterior surface forms an exposed surface of the internal cavity of the dimensionally formed article and the interior surface faces the flat upper bottom surface within the internal cavity of the dimensionally formed article. However, the collar liner external surface faces the flat upper top surface at an ankle opening coupling location.