Footwear Upper Thread Structure for Lightweight Stretch Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional footwear upper constructions often result in superfluous material layers that do not contribute to desired properties, such as stretch-resistance, wear-resistance, and air-permeability, leading to increased mass without enhanced performance.
Innovation Solution
The method involves an embroidery process to strategically locate and orient threads on a base layer to form structural elements that provide specific properties, such as stretch-resistance, in the upper, minimizing unnecessary material and optimizing the distribution of threads to achieve desired performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple material layers are used to form the upper, then wear-resistance and flexibility are improved, but the mass of the upper increases
Solution Approach 1:
The upper is divided into functional zones with different thread densities and orientations. High-density thread regions provide wear-resistance in high-stress areas, while low-density regions maintain flexibility and reduce mass in areas requiring stretch or breathability.
Solution Approach 2:
Different properties are assigned to different regions of the upper based on functional requirements. Thread structural elements are concentrated in areas needing reinforcement, while other areas maintain base layer properties for flexibility and air-permeability.
2Strength
If multiple material layers are used to form the upper, then stretch-resistance is improved, but the mass of the upper increases
Solution Approach 1:
The upper is segmented into regions with different thread orientations and densities. Thread elements are strategically placed to provide stretch-resistance in specific directions where needed, while leaving other directions flexible for natural foot movement.
Solution Approach 2:
Stretch-resistance properties are localized to specific areas of the upper rather than uniformly applied. Thread structural elements create anisotropic properties where the base layer provides stretch in certain directions while threads provide resistance in perpendicular directions.
3Object-affected harmful factors
If multiple material layers are used to form the upper, then air-permeability is improved, but the mass of the upper increases
Solution Approach 1:
The upper structure is segmented into breathable zones and structural zones. Thread elements are arranged to maintain open spaces and air channels in regions requiring ventilation, while providing structural support in areas where mass reduction is prioritized over maximum breathability.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An article of footwear (10) includes an upper (30) that is at least partially formed from a base layer (41) and thread sections (42) that lie adjacent a surface of the base layer. The thread sections are positioned to provide structural elements that, for example, restrain stretch in directions corresponding with longitudinal axes of the thread sections. In some configurations of the footwear, a first portion of the thread sections may extend between forefoot (11) and heel regions (13) of the footwear, and a second portion of the thread sections may extend vertically. An embroidering process may be utilized to position the thread sections on the base layer.