Leno-Jacquard Shoe Upper Weave for 3D Pattern Integration
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Solution Overview
Problem
Existing shoe upper manufacturing processes require separate sewing steps to insert patterns, especially with multi-color warps, leading to complexity and increased costs.
Innovation Solution
A multiple woven leno-jacquard fabric with a ground weave and pattern weave, where the pattern weave includes multiple layers, allowing for the expression of various patterns without separate sewing processes, and providing a three-dimensional pattern effect in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate sewing work is used to insert patterns into the shoe upper, then pattern insertion is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the pattern insertion function directly into the weaving process by incorporating pattern yarns (different from ground yarns) into the jacquard weaving loom. This allows patterns to be woven directly into the shoe upper fabric during the main manufacturing process, eliminating the need for separate sewing operations and reducing manufacturing complexity while maintaining pattern quality
Solution Approach 2:
The patent performs pattern insertion in advance during the weaving process itself, rather than as a subsequent separate operation. By pre-planning and pre-positioning pattern yarns in the warp or weft during fabric construction, the pattern is already integrated into the shoe upper before any assembly or finishing operations, thereby simplifying the overall manufacturing process
2Adaptability or versatility
If multi-color warp is used to produce patterns, then various patterns can be inserted, but the process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent uses a single jacquard weaving loom that can handle multiple yarn types (ground yarns and pattern yarns) and produce both ground fabric and pattern elements in one continuous process. The loom is configured to universally manage different yarn colors and types without requiring separate specialized equipment for each pattern type, thereby achieving pattern variety without proportionally increasing device complexity
Solution Approach 2:
The patent employs composite yarn structures where pattern yarns (with different properties such as color, material composition, or elasticity) are integrated with ground yarns in the same fabric structure. This allows various patterns to be created using different yarn combinations within a unified weaving process, achieving versatility while maintaining process simplicity through standardized multi-yarn handling
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
Enables efficient display of three-dimensional patterns without additional manufacturing steps, reducing complexity and cost by integrating pattern insertion into the weaving process.
Implementation Method 1
the first weave is leno weave in which a pair of two warps including a first warp and a second warp is twisted while crossing each other centered on the weft to form an opening
Data Source
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AI summary
The present disclosure relates to a multiple woven fabric including a ground weave and a pattern weave, in which the ground weave and the pattern weave are arranged to be neighboring, the ground weave includes a plain weave woven so that a warp and a weft participate in weaving, and the pattern weave is a multi-layer weave including a first weave forming a first layer and a second weave separated from the first layer to form a second layer.