Knitted Sports Shoe Sole Structure for Low-Waste Assembly
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Solution Overview
Problem
Existing shoe manufacturing methods result in significant waste, complex connections between sole components, and increased production costs due to the use of materials like leather and rubber, which are difficult to glue together without adhesion promoters.
Innovation Solution
Utilizing knitwear for the outer sole, midsole, and upper, which can be manufactured in the required form without cutting and easily connected through sewing or heat fusion, allowing for functional areas to be formed during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If outer soles and midsoles are cut out from material webs or manufactured by casting, then manufacturing precision is improved, but waste is generated and connection complexity increases
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from cutting/casting to knitting, transforming the production method to create soles in their final shape without material removal, thereby eliminating waste while maintaining precision
Solution Approach 2:
The knitting process inherently produces the sole in its final shape and size, with the knitwear structure self-forming the required geometry without requiring subsequent cutting or shaping operations
2Adaptability or versatility
If outer sole and midsole are made from different materials (rubber and polyurethane), then functional properties are improved, but connection difficulty increases
Solution Approach 1:
The patent uses the same knitwear material for both the outer sole and midsole, eliminating the interface between different materials and thereby eliminating the connection step entirely, while still allowing functional differentiation through knitwear structure variations
Solution Approach 2:
The patent merges the outer sole and midsole into a single integrated knitwear component, eliminating the boundary between them and removing the need for connection processes while maintaining functional area differentiation
3Productivity
If functional areas are formed during manufacturing process, then production time is reduced, but additional processes and weight increase
Solution Approach 1:
The knitwear manufacturing process is made universal to simultaneously produce the sole structure and functional areas in one operation, with the knitting machine capable of creating varied densities, patterns, and properties within the same continuous process
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
Reduces waste, simplifies manufacturing, and lowers costs while providing customizable cushioning, stability, and traction properties through adaptable yarn thickness, material selection, and structural design.
Implementation Method 1
easily connected through sewing or heat fusion
Data Source
Figure 1a
Figure 1b~2
Figure 3~4
AI summary
The present invention relates to a shoe (71), particularly a sports shoe, comprising an upper (72) and an outer sole (73) and / or a midsole (121) which is connected to the upper (72), the outer sole (73) and / or the midsole (121) comprising knitwear.