Knitted Shoe Upper with Integrated Polyurethane Waterproof Layer
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Solution Overview
Problem
Current knitted shoe uppers lack waterproof functionality, making them unsuitable for outdoor use, and existing waterproof solutions compromise portability by adding heavy sewn covers.
Innovation Solution
A method for manufacturing waterproof and breathable shoes involving the production of a shoe sole and upper through specific processing steps, including knitting a sock knitted fabric with tuck stitches, applying a polyurethane layer, and bonding with adhesive glue, while incorporating a pretreated fabric with a micro-nano hierarchical structure for enhanced hydrophobicity and breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sewn waterproof shoe cover is added to make shoes waterproof, then waterproof function is improved, but weight increases and portability deteriorates
Solution Approach 1:
The patent merges the waterproof membrane directly into the knitted shoe upper structure, combining the waterproof function with the shoe upper itself rather than adding a separate waterproof cover. This integration eliminates the need for additional heavy waterproof layers while maintaining waterproof performance.
Solution Approach 2:
The patent uses a thin waterproof membrane integrated into the knitted fabric structure, replacing traditional heavy sewn waterproof covers. This thin film approach provides waterproof protection while maintaining light weight and flexibility of the shoe upper.
2Strength
If traditional cutting and stitching methods are used to make shoe uppers, then structural integrity is improved, but processing complexity and labor cost increase
Solution Approach 1:
The patent merges multiple shoe upper components into a single integrated knitted structure, eliminating the need for separate cutting and stitching operations. The knitted shoe upper is formed as one piece with the waterproof membrane integrated throughout, significantly reducing processing steps while maintaining structural integrity.
Solution Approach 2:
The patent replaces traditional mechanical cutting and stitching processes with a knitting process that forms the shoe upper structure directly through interlocking loops. This substitution eliminates complex cutting and sewing equipment while achieving equivalent or superior structural integrity.
3Weight of moving object
If knitted shoe uppers are used to improve portability and comfort, then weight is reduced, but waterproof function is lost
Solution Approach 1:
The patent creates a composite structure by integrating a waterproof membrane within the knitted fabric layers. The composite construction combines the lightness and breathability of knitted materials with the waterproof properties of the membrane, achieving both weight reduction and waterproof function simultaneously.
Solution Approach 2:
The patent applies waterproof properties locally at critical interfaces where water penetration would occur, such as the interface between the shoe upper and sole, while maintaining the overall lightweight knitted structure. This targeted approach provides waterproof protection without requiring the entire shoe upper to be heavy waterproof material.
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 method results in lightweight, comfortable, and functionally superior waterproof and breathable shoes with reduced production steps and costs, maintaining flexibility and breathability while ensuring waterproof performance.
Implementation Method 1
incorporating a pretreated fabric with a micro-nano hierarchical structure for enhanced hydrophobicity and breathability
Implementation Method 2
the tuck stitch enables a more compact structure of the knitted fabric, prevents outward expansion and deformation of the shoe upper that compromises the wearing comfort, and enhances the waterproofness of an interface between the shoe sole and the shoe upper
Implementation Method 3
bonding the shoe upper and sole for the waterproof and breathable shoes with an adhesive glue
Data Source
AI summary
A method for manufacturing waterproof and breathable shoes is provided. The method includes subjecting shoe sole materials to plastication and mixing, followed by cutting into pieces to be mold to form a shoe sole; stacking a knitted fabric as an outer layer, a polyurethane layer as a middle layer, and a knitted fabric as an inner layer sequentially into a mold for hot-pressing and shaping to form a shoe upper; and bonding the shoe upper to the shoe sole with an adhesive glue so as to form a shoe. The shoe is made flexible and light as the shoe upper is made up of two layers of knitted fabric bonded to a polyurethane layer. Moreover, the middle layer of the shoe upper includes a wavy structure, which is stretchable and helps improve waterproofness and breathability of the shoe upper.