Footwear Upper Ribbon Structure and Embroidered Border
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Solution Overview
Problem
Current methods for creating decorative and functional embroidery on footwear lack efficient techniques for integrating ribbon structures with embroidered borders, resulting in uneven surfaces and potential discomfort due to lack of flexibility and support.
Innovation Solution
A method involving a ribbon structure with a continuous ribbon pattern, including straight and curved sections, is used to create an upper for footwear, where the ribbon is laid down on a backing layer and stitched in place, with an embroidered border element covering the curved sections to enhance flexibility and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a ribbon structure is used to create the footwear upper, then flexibility and comfort are improved, but structural support and durability may be compromised
Solution Approach 1:
The patent combines multiple ribbons in a triaxial pattern (three directions) to create a unified structure that distributes mechanical loads across all three orientations, providing both flexibility and structural support simultaneously
Solution Approach 2:
The footwear upper uses a composite construction combining ribbons with an embroidered border layer and backing layer, creating a multi-layer composite structure that integrates flexibility (ribbons) with durability (embroidered border and backing)
2Shape
If embroidered border elements are added to cover curved ribbon sections, then aesthetics and structural integrity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the border embroidery process with the ribbon attachment process, using the same embroidery machine to both attach ribbons to the backing and create the border pattern in a single integrated operation
Solution Approach 2:
The embroidery machine performs multiple functions: it attaches ribbons to the backing layer and simultaneously creates the decorative border pattern, eliminating the need for separate border application equipment
3Strength
If a continuous ribbon pattern is used, then flexibility and stress distribution are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical state of the ribbon from rigid to flexible by using materials that can be easily manipulated and stitched, allowing for continuous curves and intersections while maintaining placement precision through the embroidery process
Solution Approach 2:
The backing layer serves as an intermediary substrate that holds the continuous ribbon pattern in place during manufacturing, providing a stable base that facilitates precise ribbon placement and curvature
Data Source
AI summary
An article of footwear with an upper including a ribbon structure is disclosed. The ribbon structure comprises ribbon sections winding back and forth between the peripheral edges of the upper. At the peripheral edges, the ribbon loops around and some portions along the loops may raise up from a backing layer. An embroidered border element is applied over the peripheral edges to tack down or cover the raised portions of ribbon. The loops of ribbon may also be used as lace loops.