Footwear Upper Incised Layer Design for Flexibility
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Solution Overview
Problem
Conventional footwear upper configurations often compromise between flexibility, wear-resistance, and breathability due to the use of multiple material layers, which can limit comfort and adjustability, especially in athletic footwear where varying foot dimensions and activities require adaptable fit and performance.
Innovation Solution
A layered and incised configuration for the footwear upper, comprising a substrate layer and an incision layer, where the incision layer is formed with precise cuts or separations to expose the substrate layer, allowing for enhanced stretchability and adjustability, achieved through methods like laser cutting or die cutting, enabling specific properties in different areas for improved comfort and fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple material layers are used to form the upper, then wear-resistance is improved, but flexibility and breathability deteriorate
Solution Approach 1:
The upper is divided into multiple independent layers (exterior layer, intermediate layer, interior layer) that can be selectively applied to different areas. This segmentation allows each layer to provide specific functions - the exterior layer provides wear-resistance while the interior and intermediate layers provide flexibility and breathability, resolving the contradiction between durability and flexibility.
Solution Approach 2:
Different material layers are applied to different areas of the upper based on local requirements. High-wear areas like the toe and heel receive the durable exterior layer, while areas requiring flexibility and breathability use the intermediate and interior layers. This local differentiation resolves the contradiction by providing wear-resistance where needed without compromising flexibility elsewhere.
2Strength
If multiple material layers are used to form the upper, then wear-resistance is improved, but breathability deteriorates
Solution Approach 1:
The upper is segmented into multiple layers with the interior and intermediate layers providing breathability pathways. This segmentation allows the exterior layer to provide wear-resistance while the inner layers maintain air permeability and moisture wicking, resolving the contradiction between durability and breathability.
Solution Approach 2:
The upper uses a composite structure combining different material types - the exterior layer provides wear-resistance while the intermediate polymer foam layer and interior textile layer provide breathability and moisture management. This composite approach resolves the contradiction by integrating materials with complementary properties.
3Duration of action of stationary object
If conventional layered configuration is used, then durability is improved, but adjustability deteriorates
Solution Approach 1:
The upper is segmented into multiple detachable layers that can be independently adjusted or removed. This segmentation enables the wearer to modify the upper's properties by adding or removing layers, providing adjustability while maintaining the durability of the exterior layer.
Solution Approach 2:
The upper transitions from a static conventional layered structure to a dynamic configurable structure where layers can be added, removed, or adjusted. This dynamic capability allows the upper to adapt to different foot dimensions and activities while maintaining durability through the robust exterior layer.
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 layered and incised configuration provides improved flexibility, comfort, and adjustability by selectively stretching in specific areas, accommodating various foot dimensions and activities while maintaining durability and breathability, enhancing the overall performance and fit of athletic footwear.
Implementation Method 1
A laser apparatus removes material from an incision layer to form incisions
Data Source
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AI summary
A manufacturing method may include forming incisions through an incision layer (150'') that is secured to a transfer layer (53''). After defining the incisions, the incision layer (50") is secured to a substrate layer (40"), and the transfer layer (53") is then separated from the incision layer (50"). The manufacturing method may be applied to elements used in footwear, apparel, or a variety of other products.