Footwear Upper Mesh With Interlocking High Strength Strands
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Solution Overview
Problem
The challenge in designing athletic footwear is to combine various materials for the upper while minimizing weight, which is often compromised by the increased number of material elements, leading to higher mass, reduced mobility, and increased waste during manufacturing.
Innovation Solution
Incorporating a mesh material with a combination of high tensile strength strands and non-high tensile strength strands that intersect to provide strength, stretch resistance, and a stylish design, eliminating the need for a base layer and cover layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material elements are combined to form the upper, then design freedom and desired appearance are achieved, but the overall mass of the footwear increases
Solution Approach 1:
The patent merges multiple material elements into a single integrated knit upper that combines different fiber types (natural and synthetic) with varying properties during the knitting process itself. This allows the upper to incorporate breathability, moisture management, durability, and comfort properties in one unified structure rather than assembling separate material layers, thereby achieving design freedom without proportionally increasing mass.
Solution Approach 2:
The knit upper utilizes composite materials by integrating natural fibers (cotton, wool, silk) with synthetic fibers (nylon, polyester, spandex) in the same knitted structure. This composite approach allows different regions of the upper to exhibit different properties based on fiber composition and knit density, achieving diverse functional requirements while maintaining overall weight efficiency through the single-knit-structure architecture.
2Adaptability or versatility
If multiple material elements are combined to form the upper, then desired appearance and functionality are achieved, but the number of manufacturing steps and expense increase
Solution Approach 1:
The patent merges multiple material elements into a single integrated knit upper that combines different fiber types (natural and synthetic) with varying properties during the knitting process itself. This allows the upper to incorporate breathability, moisture management, durability, and comfort properties in one unified structure rather than assembling separate material layers, thereby achieving design freedom without proportionally increasing mass.
Solution Approach 2:
The knitting machine and knit upper structure serve multiple functions simultaneously: they create the structural framework of the upper, integrate different fiber types for various functional properties, define the aesthetic appearance through knit patterns, and even incorporate branding elements. This multi-functionality reduces the need for separate manufacturing steps for each of these tasks.
3Adaptability or versatility
If multiple material elements are combined to form the upper, then design flexibility is achieved, but waste material from cutting and stitching increases
Solution Approach 1:
The patent merges multiple material elements into a single integrated knit upper that combines different fiber types (natural and synthetic) with varying properties during the knitting process itself. This allows the upper to incorporate breathability, moisture management, durability, and comfort properties in one unified structure rather than assembling separate material layers, thereby achieving design freedom without proportionally increasing mass.
4Adaptability or versatility
If multiple material elements are combined to form the upper, then functional properties are achieved, but the difficulty of recycling increases
Solution Approach 1:
The patent achieves functional diversity not through heterogeneous material assemblies but through a homogeneous knit structure where different fiber types are uniformly integrated during the knitting process. This uniform integration of natural and synthetic fibers in a single knit fabric simplifies end-of-life processing compared to multi-layer constructions with different adhesives and bonding methods, as the entire upper can be processed as one material system.
Data Source
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AI summary
An article of footwear, which includes an upper, and a mesh material incorporated into the upper. The mesh material include high tensile strength strands and non-high tensile strength strands. The high tensile strength strands enhance the stretch resistance of the mesh material. The high tensile strength strands and the non-high tensile strength strands interlock so that the high tensile strength strands are substantially held in place and the interlocking mesh structure limits movement of the high tensile strength strands. The mesh material is the only layer provided for the upper in portions of the upper.