Knitted Footwear Upper Thermoforming With Perforated Foot Preform
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Solution Overview
Problem
Existing footwear manufacturing processes are time-consuming, prone to assembly errors, generate significant waste, and are difficult to recycle due to the large number of components, with limited functionalization capabilities and potential damage to components during thermoforming.
Innovation Solution
A method involving a first knitted tubular part with heat-fusible portions and functional components, thermoformed onto a preform with perforations to allow even heat distribution, enabling simultaneous bonding and functionalization of all surfaces, reducing assembly steps and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional multi-component assembly methods are used to manufacture footwear uppers, then functional components can be added, but the manufacturing process becomes time-consuming and error-prone
Solution Approach 1:
The patent merges multiple separate components (upper body, sole section, functional components) into a single integrated three-dimensional knitted tube. This eliminates the need for time-consuming assembly of multiple parts while maintaining the ability to incorporate functional elements such as reinforcement zones, lacing systems, and closure mechanisms directly into the knitted structure during manufacturing.
Solution Approach 2:
The three-dimensional knitted tube serves multiple functions simultaneously: it forms the upper body, incorporates sole sections, integrates functional components, and provides structural support. This multi-functional design eliminates the need for separate assembly steps for each function, thereby increasing manufacturing productivity.
2Adaptability or versatility
If multiple separate components are assembled to form the upper, then functional components can be integrated, but assembly errors increase and manufacturing complexity rises
Solution Approach 1:
By combining all components into a single knitted tube manufactured in one continuous process, the patent eliminates multiple assembly operations that could introduce errors. The integrated structure ensures proper alignment and connection of functional components without the risks associated with manual or automated assembly of separate parts.
3Ease of manufacture
If traditional cutting and assembly processes are used, then various components can be created, but material waste increases significantly
Solution Approach 1:
The patent uses selective reinforcement zones and localized knitting patterns within the continuous tubular structure to create different functional areas (upper body, sole sections, reinforcement zones) without cutting or assembling separate components. This segmented design approach within a unified structure maintains component versatility while eliminating material waste from cutting and assembly processes.
4Shape
If conventional thermoforming processes are used on assembled footwear, then shaping is achieved, but functional components may be damaged
Solution Approach 1:
The patent performs thermoforming on the three-dimensional knitted tube before attaching functional components or assembling the final footwear structure. This preliminary shaping action ensures the base structure is properly formed without exposing delicate functional components to high temperatures that could cause damage.
5Adaptability or versatility
If numerous separate components are used in footwear construction, then functional requirements can be met, but recyclability becomes difficult
Solution Approach 1:
By merging all functional components into a single integrated knitted tube structure, the patent creates a unified material composition that is significantly easier to recycle. The monolithic structure eliminates the need to separate and sort multiple different materials and components, thereby enhancing recyclability while maintaining all necessary functional performance through strategic placement of reinforcement zones and functional elements within the knit 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
This method significantly reduces manufacturing time, minimizes assembly errors, enhances recyclability, and improves the quality and appearance of the upper by allowing full three-dimensional functionalization without component degradation.
Implementation Method 1
the preform includes an inner volume and perforations opening onto its outer surface, said inner volume and the perforations are in fluidic connection
Implementation Method 2
provide a first knitted tubular part comprising at least one heat-fusible portion and one or more functional component(s)... joining the functional component(s), to at least one, of the first knitted tubular part and the second knitted tubular part, and joining the first and second knitted tubular parts together
Data Source
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AI summary
The present invention relates to a method for manufacturing a footwear article, comprising the provision (i) of a first knitted tubular portion (20) comprising at least one hot-melt portion and one or more functional components (60;70;75), the formation (ii) of a footwear set (40) comprising the first knitted tubular portion (20) and one or more functional components (60;70;75), and finally the transformation of the footwear set (40), which has previously been placed against the outer surface (51) of a preform (50) in the form of a foot, into a rod. The transformation step comprises thermoforming of the footwear set (40) according to the shape of the foot of the preform (50). The preform (50) comprises an inner volume (56) and perforations (55) opening on its outer surface (51), said inner volume (56) and the perforations (55) being fluidically connected.