Knit Footwear Uppers With Molded Thermoplastic Reinforcement
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Solution Overview
Problem
Conventional footwear uppers face challenges in combining durability and flexibility, particularly in athletic footwear where textile materials may not provide adequate support and stability.
Innovation Solution
The integration of discrete molded thermoplastic polymer elements linked by a knit element or vice versa, where the polymer elements are formed by melting and solidifying thermoplastic polymers within specific locations of the knit structure using a heated mold process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If textile materials are used for footwear uppers, then flexibility and comfort are improved, but durability and support are insufficient
Solution Approach 1:
The patent combines textile materials with thermoplastic polymer elements to create a composite upper structure. The textile provides flexibility and comfort while the thermoplastic polymer elements provide durability, support, and stability. This composite approach allows each material to contribute its advantageous properties to the overall footwear upper.
Solution Approach 2:
The thermoplastic polymer elements are strategically positioned at specific locations within the upper where enhanced durability and support are needed, such as around the toe box, heel counter, and midfoot areas. The knit textile remains in areas requiring flexibility and breathability. This localized application of different materials optimizes both flexibility and durability in their respective zones.
2Adaptability or versatility
If external components are bonded to the upper, then functionality is improved, but risk of detachment increases
Solution Approach 1:
The patent integrates external functional components directly into the knit upper structure during the knitting process. Thermoplastic polymer elements are incorporated as part of the knit pattern itself, creating a unified structure where functional features like toe caps, heel counters, and support elements are seamlessly integrated rather than separately bonded. This eliminates the risk of detachment while maintaining functionality.
3Strength
If thermoplastic polymer elements are integrated into knit upper, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The thermoplastic polymer elements are incorporated into the knit upper during the knitting process itself, before the upper is assembled with other footwear components. The knitting machine is configured to produce the upper with integrated thermoplastic elements, and the upper is then subjected to heat treatment to set the polymer elements in place. This preliminary integration simplifies subsequent manufacturing steps.
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 approach enhances the durability and stability of footwear uppers while maintaining flexibility, preventing the detachment of external components and ensuring a cohesive structure.
Implementation Method 1
places the upper in a heated mold for a period of time to melt at least a portion of the thermoplastic polymer
Implementation Method 2
the upper is cooled to solidify the melted portions and thereby form a plurality of molded thermoplastic polymer elements
Data Source
AI summary
An upper may include a plurality of knit elements linked together by a molded thermoplastic polymer element comprising a thermoplastic polymer, each of the knit elements being discrete, where each of the knit elements comprises a border that is at least partially surrounded by the molded thermoplastic polymer element. Further, an article of footwear may include a plurality of knit elements linked together by a molded thermoplastic polymer element comprising a thermoplastic polymer, each of the knit elements being discrete, where each of the knit elements comprises a border that is at least partially surrounded by the molded thermoplastic polymer element.