Loop-Fused Thermoplastic Shoe Upper for Flexible Mass Production
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Solution Overview
Problem
Existing textile production methods, particularly for shoe uppers, face challenges in achieving flexibility and durability while being cost-effective and sustainable, as traditional methods like 3D printing often result in fibers sticking together and are not suitable for mass production, and alternative methods like melt blown processes can only produce nonwovens.
Innovation Solution
A method involving the application of thermoplastic filament on a shaping carrier to form loops, which are then fused to create a textile element with varying mesh geometries and properties, using techniques like robotic winding, nozzle application, and stitching, allowing for flexible and durable shoe uppers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If 3D printing is used to produce textile elements, then individual adaptation to foot contours is improved, but fibers stick together and flexibility is reduced
Solution Approach 1:
The patent changes the physical state and arrangement parameters of the filament during deposition. By controlling the filament deposition to form loops with specific geometric parameters (openings between loops, loop size, density), the textile achieves both adaptability for foot contours and flexibility for wear, resolving the contradiction between 3D printing capability and flexibility.
Solution Approach 2:
The textile structure is segmented into discrete loops with spaces between them, rather than continuous fused fibers. This segmentation allows the material to conform to complex foot shapes while maintaining flexibility through the spaced arrangement, solving the contradiction between adaptability and flexibility.
2Adaptability or versatility
If 3D printing is used for mass production, then customization is improved, but production time and cost efficiency deteriorate
Solution Approach 1:
The patent enables continuous deposition of filament forming loops across the entire textile surface in a single pass, rather than traditional 3D printing layer-by-layer construction. This continuous action dramatically reduces production time while maintaining customization capability, resolving the contradiction between customization and productivity.
Solution Approach 2:
The textile element is pre-formed with its final loop structure and geometry during the deposition process, eliminating subsequent processing steps. This preliminary formation of the complete textile structure with its functional loop pattern reduces overall production time while preserving customization.
3Ease of operation
If traditional textile production methods are used, then flexibility is maintained, but significant amounts of cuttings are produced reducing sustainability
Solution Approach 1:
The filament self-forms into loops with appropriate spacing and geometry during the deposition process without requiring cutting or trimming operations. The continuous deposition creates the final textile structure directly, eliminating waste from cuttings and improving sustainability while maintaining flexibility.
Solution Approach 2:
By controlling deposition parameters (filament diameter, loop size, spacing between loops, density), the process creates flexible textiles directly without traditional cutting operations. This parameter control enables waste-free production while maintaining the flexibility needed for comfortable shoe wear.
4Productivity
If melt blown process is used to produce nonwovens, then production speed is improved, but mesh-like or loop-like textile elements cannot be formed
Solution Approach 1:
The patent segments the filament into distinct loops with openings between them during deposition, creating the desired mesh-like structure. This segmentation is achieved through controlled deposition patterns that form discrete loop units, enabling both high production speed and the formation of functional mesh structures.
Solution Approach 2:
The loop structure is pre-formed during the deposition process itself, with loops being created as they are deposited. This preliminary formation of the mesh structure eliminates the need for subsequent processing steps, maintaining high production speed while achieving the desired loop-like geometry.
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 enables the production of flexible, durable, and lightweight textile elements with enhanced tear and wear resistance, reducing production time and energy consumption, suitable for mass production.
Implementation Method 1
fusing the applied thermoplastic filament into the textile element
Implementation Method 2
By melting or at least softening the thermoplastic filament, the overlapping sections of the thermoplastic filament can be joined together
Data Source
AI summary
A method for producing a textile element (1), in particular a shoe upper, including at least the steps of providing a shaping carrier (2), in particular a last; providing a thermoplastic filament (3), in form of a continuous thermoplastic filament; applying the thermoplastic filament (3) on the shaping carrier (2) such that it forms a plurality of loops (4) on the shaping carrier (2) and fusing the applied thermoplastic filament (3) into one fabric. An article of apparel, in particular a shoe, including the textile element, in particular a shoe upper, may be produced by the method.