Knit Shoe Upper With Selective Melting for Patterned Sole Bonding
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Solution Overview
Problem
Existing shoe manufacturing methods face challenges in creating a seamless and structurally integrated knit upper with distinct visual and functional regions, particularly in achieving a visually discernible pattern and ensuring secure attachment of the sole without compromising the integrity of the knit structure.
Innovation Solution
A method involving a knitting process that forms a unitary one-piece knit upper with different types of yarns and knit structures, where a first yarn with a lower melting temperature is selectively melted post-knitting to create a wingtip pattern and secure the sole, while a second yarn with a higher melting temperature remains intact, ensuring seamless integration and visual differentiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a seamless knit upper is manufactured as a unitary one-piece construction, then manufacturing efficiency and structural integration are improved, but visual differentiation and pattern definition become difficult to achieve
Solution Approach 1:
The patent applies local quality by incorporating thermoplastic yarns at specific locations within the knit upper to create distinct visual patterns (such as wingtip patterns) while maintaining the overall seamless construction. The thermoplastic yarns are selectively placed in certain knit structures to provide localized visual differentiation without disrupting the unitary one-piece manufacturing process.
2Shape
If thermoplastic yarn is melted post-knitting to create patterns, then visual differentiation is achieved, but structural integrity of the knit upper may be compromised
Solution Approach 1:
The patent uses composite materials by combining thermoplastic yarns with conventional yarns in the knit structure. The thermoplastic yarns are integrated into specific knit structures (such as knit structures 104, 106, 108) to create visual patterns when melted, while the conventional yarns maintain the overall structural integrity of the knit upper. This composite approach allows pattern creation without compromising the strength of the knit structure.
3Shape
If multiple yarn types with different melting temperatures are used, then selective melting for pattern creation is enabled, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by utilizing yarns with different melting temperatures to enable selective melting during post-knitting heat treatment. The thermoplastic yarns have lower melting temperatures than the conventional yarns, allowing them to be selectively melted to create visual patterns while the conventional yarns remain intact. This parameter-based differentiation enables pattern creation without requiring complex additional 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
The solution results in a shoe with a visually distinct knit upper and secure sole attachment, enhancing structural integrity and aesthetic appeal while maintaining the knit's functional properties.
Implementation Method 1
The knitted element is heated after the knitting process at a temperature no lower than the first yarn melting temperature and lower than the second yarn melting temperature, to melt the first yarn without melting the second yarn
Data Source
AI summary
A shoe includes a knit upper and a sole secured to the knit upper. The knit upper is formed with a first type of knit structure knitted with a thermoplastic yarn in a first area. The first area is in at least the toe region of the knit upper. In a second area including at least the medial and lateral metatarsal regions of the knit upper, the knit upper is formed with a second type of knit structure knitted with a second yarn having a higher melting temperature than the thermoplastic yarn. A rear boundary line of the first area and a forward boundary line of the second area define a boundary line between the first and second areas.