Footwear Upper Mesh Material Strength and Weight Trade-off
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Solution Overview
Problem
Conventional footwear uppers are heavy due to multiple material elements, which diminish mobility, performance, and comfort, and are difficult to recycle, while also being resource-intensive and wasteful in production.
Innovation Solution
Incorporating a mesh material with high tensile strength strands and non-high tensile strength strands that interlock to provide strength, stretch resistance, and a stylish design, reducing the need for additional layers and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple material elements are combined to form the upper, then durability and comfort are improved, but weight increases and mobility diminishes
Solution Approach 1:
The patent combines multiple material elements (textiles, polymer sheets, foam layers, leather, synthetic leather) into a single integrated upper structure that is stitched or adhesively bonded together, merging the functions of durability, comfort, and support into one unified component rather than separate layers
Solution Approach 2:
The upper is constructed from composite materials including textiles for breathability, foam layers for compression and comfort, and leather or synthetic leather for durability and wear-resistance, creating a multi-functional material system that addresses both durability and weight concerns
2Adaptability or versatility
If multiple material elements are used in the upper, then design freedom and appearance are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The upper is divided into distinct material zones with specific functions (textile areas for breathability, foam areas for comfort, leather areas for durability) that can be independently selected and combined based on design requirements, allowing design freedom while managing manufacturing complexity through modular material selection
Solution Approach 2:
Each material element in the upper serves multiple functions simultaneously - for example, textile elements provide both breathability and structural support, while leather elements provide both durability and aesthetic appearance, reducing the need for additional specialized components
3Reliability
If multiple material elements are incorporated into the upper, then functional properties are improved, but waste material and environmental impact increase
Solution Approach 1:
The patent addresses waste material from cutting and stitching processes by implying optimization of material utilization patterns that reduce offcuts and waste, though specific recovery methods are not detailed in the excerpt
Solution Approach 2:
The patent optimizes the number and arrangement of material elements to achieve the minimum necessary for functional performance, reducing excess material usage and waste generation while maintaining required functional properties
Data Source
AI summary
An article of footwear includes include an upper and a mesh material. The mesh material may be incorporated into the upper. The mesh material may include high tensile strength strands and non-high tensile strength strands. The high tensile strength strands and non-high tensile strength strands may interlock so that the high tensile strength strands are substantially held in place. The mesh material may be provided as a woven material or a knitted material. The mesh material can have a stylish design, which can be a plaid pattern, herringbone pattern, seersucker pattern, or other pattern.