Footwear Upper Composite Material Flexibility Durability
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Solution Overview
Problem
Existing footwear composite materials are stiff and lack flexibility, leading to decreased durability in uncovered regions and limited suitability for various types of footwear that require flexibility, such as soccer shoes.
Innovation Solution
A composite material process involving a carbon fiber weave bonded with a flexible substrate and a thin protective coating, allowing for increased flexibility and durability by using a hot melt adhesive and industrial heating for bonding, and applying the adhesive and coating using hoses or other methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional composite materials are used for footwear uppers, then durability is improved, but flexibility is reduced
Solution Approach 1:
The patent applies composite materials by bonding carbon fiber weave with a flexible substrate using hot melt adhesive. This composite structure combines the durability and strength of carbon fiber with the flexibility of the substrate material, resolving the contradiction between durability and flexibility in footwear uppers
Solution Approach 2:
The patent changes the physical parameters of the composite material system by using hot melt adhesive applied through heating. The thermal parameters are controlled to bond the materials while preserving the flexibility characteristics of the substrate, achieving both durability and flexibility
2Reliability
If carbon fiber layers are applied to increase durability, then weight is reduced, but flexibility is further reduced
Solution Approach 1:
The patent uses thin carbon fiber weave layers bonded to a flexible substrate, creating a thin-film composite structure that provides durability protection while maintaining flexibility and minimizing weight addition. The thin film approach avoids the stiffness and weight of traditional thick composite materials
3Productivity
If hot melt adhesive is used for bonding, then manufacturing efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical bonding methods with thermal bonding using hot melt adhesive. This substitution allows for automated adhesive application through heating systems and hoses, improving manufacturing efficiency while the complexity is managed through standardized thermal processing procedures
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
The composite material provides a lightweight, flexible, and durable upper that can bend, fold, and deform elastically without structural failure, reducing weight and enhancing performance in flexible footwear applications.
Implementation Method 1
bonded with a flexible substrate and a thin protective coating, allowing for increased flexibility and durability by using a hot melt adhesive and industrial heating for bonding
Implementation Method 2
using a hot melt adhesive and industrial heating for bonding
Implementation Method 3
The composite material provides a lightweight, flexible, and durable upper that can bend, fold, and deform elastically without structural failure
Data Source
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AI summary
An upper including a flexible composite material is disclosed. The flexible composite material includes a sheet of carbon fiber weave material (102) attached to a flexible substrate (202) and a coating (402) applied to an exposed side of the sheet of carbon fiber weave material. The exposed side includes a plurality of exposed ends associated with the carbon fiber weave material and at least a portion of the plurality of exposed ends are covered by the coating.