Knitted Shoe Upper With Membrane Element For Structural Support
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Solution Overview
Problem
Shoes with knitted uppers face issues of limited flexibility, poor protection, and breathability due to the use of heat-setting yarns, leading to rigidity and discomfort, along with problems in assembly methods like gluing and sewing which cause wear and loss of shape over time.
Innovation Solution
A procedure involving the construction of a double-layered knitted upper with a thermoplastic polymer yarn and a membrane element that provides elasticity, breathability, and structural support, combined with a polyurethane injection method to create a single, homogeneous shoe body with improved dimensional stability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If heat-setting yarns are used in the knitted upper to provide structure and shape retention, then dimensional stability is improved, but flexibility and breathability deteriorate
Solution Approach 1:
The patent applies different types of yarns to different regions of the knitted upper. Heat-setting yarns are strategically placed in areas requiring structural support (like the heel counter and ankle support), while elastic yarns are used in areas requiring flexibility (like the forefoot and toe box). This local differentiation allows the upper to maintain dimensional stability where needed while preserving flexibility where required for natural foot movement.
Solution Approach 2:
The knitted upper is constructed as a composite structure combining multiple yarn types with different properties. The composite includes heat-setting yarns for structural stability, elastic yarns for flexibility and recovery, and breathable knitted fabric for air permeability. This composite approach allows the upper to simultaneously achieve dimensional stability, flexibility, and breathability by leveraging the complementary properties of different materials working together.
2Ease of manufacture
If the upper is assembled with the sole by gluing to simplify construction, then manufacturing ease is improved, but grip and flexibility deteriorate
Solution Approach 1:
The patent merges the upper and sole into a single integrated knitted structure rather than assembling separate components. The upper is knitted directly onto the sole or the sole is knitted as an integrated part of the upper structure, eliminating the need for separate gluing or sewing operations. This merging approach maintains manufacturing simplicity while ensuring optimal grip and flexibility through continuous material construction without adhesive layers or stitching seams.
3Strength
If the upper is assembled with the sole by sewing to improve grip, then bond strength is improved, but wear and complexity increase
Solution Approach 1:
The patent eliminates the sewing process by merging the upper and sole into a single knitted structure. The integration is achieved through continuous knitting where the upper and sole are formed as one piece or through interlocking knitted loops that mechanically bind the components together without requiring separate stitching. This approach provides strong bond strength through the inherent structural integration while avoiding the wear issues associated with sewn seams and reducing overall construction complexity.
4Ease of manufacture
If a single-layer knitted upper is used to simplify construction, then manufacturing ease is improved, but protection and structure deteriorate
Solution Approach 1:
The knitted upper is segmented into multiple functional layers, each with specific properties. The structure includes an outer layer for protection and aesthetics, an inner layer for comfort and breathability, and intermediate layers for structural support and shaping. This segmentation allows each layer to be optimized for its specific function while maintaining overall construction simplicity through a systematic multi-layer knitting process that integrates all layers into a unified structure.
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 that is lightweight, flexible, and comfortable, offering enhanced protection and breathability while maintaining shape and reducing muscle fatigue during prolonged use, with improved construction efficiency and reduced production time.
Implementation Method 1
a first upper shaping step in which the two stockings have the appearance of a sort of 'tube' which is sealed at one part (the toe), while the other end of the tube remains open
Implementation Method 2
A procedure involving the construction of a double-layered knitted upper with a thermoplastic polymer yarn and a membrane element that provides elasticity, breathability, and structural support
Implementation Method 3
combined with a polyurethane injection method to create a single, homogeneous shoe body with improved dimensional stability and protection
Data Source
AI summary
A procedure for making a shoe with a knitted upper, including a series of steps in which—during an upper shaping step—once the internal stocking has been placed on the shoe tree, a membrane element (3) is placed in position, which covers the portion corresponding to the sole of the shoe tree and a lateral portion. The membrane element is a single-body element formed of a polymer membrane that has adhesive material on both sides thereof and features a series of suitable shaped and positioned perforations (30). The membrane element is designed to create a support structure for the two stockings so that the shoe obtained has and maintains a structured shape. Once the upper is complete, a sole is constructed by injection moulding in order to create a shoe that is a single, homogeneous, compact, and structured body.