Laminar Component Placement on 3D Shoe Uppers
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Solution Overview
Problem
Current manufacturing processes for sports articles, such as sports shoes, face challenges when placing components on two-dimensional objects that later become three-dimensional, leading to issues like buckling and the need for additional process steps to form the object, which can result in reduced fit and comfort and increased production complexity.
Innovation Solution
A method involving the use of a laminar component placed onto a three-dimensional object using a first roll, which moves relative to the object, allowing for precise placement on both convex and concave surfaces, potentially using a conveyor belt and air blasts for efficient application, and utilizing a liner for easy handling and separation of the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are placed on a two-dimensional shoe upper before lasting, then the placement process is simple, but the components buckle when the shoe upper is formed into three-dimensional shape
Solution Approach 1:
The patent applies preliminary action by pre-shaping the shoe upper into its three-dimensional form before placing the components. This allows the components to be positioned on the final three-dimensional surface rather than on a flat two-dimensional sheet that would later be deformed, thereby preventing buckling while maintaining placement simplicity.
2Manufacturing precision
If components are placed on a preformed three-dimensional object, then component flatness is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs dynamics by using a robot arm with multiple degrees of freedom to dynamically adapt to the three-dimensional surface of the preformed shoe upper. The robot arm can move in three-dimensional space and adjust its positioning to place components accurately on curved surfaces, thereby maintaining component flatness without requiring overly complex fixed manufacturing equipment.
3Measurement precision
If a robot arm is used to place components on three-dimensional objects, then placement precision is improved, but the device complexity increases
Solution Approach 1:
The patent introduces an intermediary coordinate transformation system that maps three-dimensional surface coordinates to robot arm control coordinates. This intermediary layer simplifies the control of the robot arm by providing a mathematical transformation rather than requiring complex direct control mechanisms, thereby achieving high placement precision while managing device complexity through software-based coordination.
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 automates the manufacturing process, reduces quality loss, and allows for late product modifications by enabling direct placement of components on preformed three-dimensional objects, avoiding wrinkles and seams, thus enhancing fit and comfort while simplifying the production process.
Implementation Method 1
placing the at least one laminar component onto the at least one three-dimensional object via a first roll, while the at least one three-dimensional object is simultaneously moved relative to the first roll
Implementation Method 2
The first roll may be a pulley of the conveyor belt and the conveyor belt may convey the laminar component to the first roll
Implementation Method 3
The method may further include pushing the laminar component in a direction of the object. The pushing of the laminar component may include pushing the laminar component via an air blast
Data Source
AI summary
A method for the manufacture of a sports article, in particular a sport shoe, can include the operations of: (a) providing at least one laminar component; (b) providing at least one three-dimensional object; and (c) placing the component onto the object by means of a first roll while simultaneously moving the object relative to the roll.