Footwear Upper Layered Structure Bonding
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Solution Overview
Problem
Conventional athletic footwear upper layers often require multiple materials with different properties, such as wear-resistance, flexibility, and air-permeability, which can lead to inconsistencies in performance and comfort, particularly in areas like the toe and heel where leather or rubber may not provide adequate flexibility and air-permeability.
Innovation Solution
A footwear design featuring a layered upper structure comprising a textile interior layer, a polymer intermediate layer molded between the interior and exterior layers, and a stitchless or adhesive bonding method to secure these layers, allowing the polymer material to infiltrate the textile for enhanced bonding and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple materials (leather, rubber, synthetic textile) are used for different areas of the exterior layer to provide wear-resistance, then wear-resistance is improved, but flexibility and air-permeability deteriorate in toe and heel areas
Solution Approach 1:
The upper is divided into multiple layers (exterior layer, intermediate layer, interior layer) with each layer serving specific functions. The exterior layer provides wear-resistance while the intermediate layer provides flexibility and air-permeability, resolving the contradiction by separating these functions into different segments.
Solution Approach 2:
The upper is constructed as a composite structure combining different materials (exterior layer material, intermediate layer material, interior layer material) to achieve multiple properties simultaneously. The composite structure allows wear-resistance from the exterior layer while maintaining flexibility and air-permeability through the intermediate and interior layers.
2Strength
If multiple materials with different properties are used for the exterior layer, then wear-resistance is improved, but consistency in performance and comfort across different areas deteriorates
Solution Approach 1:
The upper is segmented into three distinct layers, each with uniform properties throughout. This segmentation allows each layer to consistently provide its specific function (wear-resistance, cushioning, moisture management) across all areas of the footwear, eliminating performance inconsistencies.
Solution Approach 2:
The composite layer structure ensures that each material layer maintains consistent properties across the entire upper surface. The exterior layer uniformly provides wear-resistance, the intermediate layer uniformly provides flexibility and air-permeability, and the interior layer uniformly manages moisture, achieving overall performance consistency.
3Strength
If adhesive or stitching is used to join layers, then bonding strength is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The intermediate layer serves multiple functions simultaneously: it provides cushioning, enhances flexibility, ensures air-permeability, and acts as an adhesive bonding layer. By merging these functions into a single layer, the number of separate components and joining operations is reduced, improving manufacturing efficiency.
Solution Approach 2:
The intermediate layer acts as an intermediary between the exterior and interior layers, providing both structural functions (cushioning, flexibility) and bonding functions. This intermediary layer simplifies the overall construction by eliminating the need for separate adhesives or stitching in many cases, thereby improving productivity.
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
This design improves comfort and durability by providing consistent cushioning, flexibility, and air-permeability across the upper surface, while maintaining durability and wear-resistance, with the polymer intermediate layer enhancing the bonding between layers and distributing forces effectively.
Implementation Method 1
The first layer may be a textile material such that the polymer material of the second layer infiltrates the textile material of the first layer to secure the second layer to the first layer
Data Source
AI summary
An article of footwear and a method of manufacturing the footwear are disclosed. The footwear has an upper and a sole structure. The upper is secured to sole structure and the upper is formed from three layers: a first layer, a second layer, and a third layer. The second layer is formed from a polymer material and molded to the first layer, but the second layer may alternately be molded to the third layer. The third layer is joined with at least one of the first layer and the second layer such that the second layer is positioned between the first layer and the third layer.