Multi-Layer Extruded Footwear Uppers for Zoned Support and Ventilation
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Solution Overview
Problem
Conventional footwear uppers lack the ability to efficiently control properties and performance characteristics in different regions or zones, leading to inconsistent comfort, support, and ventilation.
Innovation Solution
The use of multi-layer extruded filaments with non-intersecting, spaced apart path segments, where each layer is fused to the previous layer, allowing for precise control of filament size, material, spacing, and overlap to create zones with varying properties such as stretchability, breathability, and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional single-layer uppers are used, then manufacturing is simple, but the ability to control properties in different regions is poor
Solution Approach 1:
The upper is divided into multiple layers, each capable of being independently configured with different filament densities, materials, and patterns. This segmentation allows each layer to be optimized for specific regional requirements (e.g., high support zones vs. high ventilation zones) while maintaining overall control through the layered architecture.
Solution Approach 2:
Different regions of the upper can have different filament densities, materials, and configurations within their respective layers. The patent enables local optimization by allowing varying filament path patterns and densities in different zones, such as denser filaments in support-critical areas and sparser filaments in ventilation-principle areas.
2Strength
If filament density is increased for better support, then support is improved, but ventilation is reduced
Solution Approach 1:
The support and ventilation functions are separated across different layers. One layer can be configured with high filament density for support, while another layer uses lower density or different filament patterns for ventilation. This functional segmentation allows both requirements to be satisfied simultaneously without compromise.
Solution Approach 2:
The upper employs composite construction with multiple filament layers that can have different material properties, densities, and configurations. This composite approach enables the combination of support-providing filaments and ventilation-facilitating filaments within the same upper structure.
3Manufacturing precision
If multi-layer extruded filaments are used, then performance control is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical assembly processes with a computational/extrusion-based approach. Multiple layers of extruded filaments are deposited and fused in a controlled manufacturing process, allowing precise digital control of filament size, spacing, and overlap patterns without complex mechanical assembly steps.
Solution Approach 2:
The manufacturing process enables precise control over extrusion parameters (temperature, speed, filament diameter, layer spacing) to achieve the desired filament characteristics. By adjusting these parameters, the system can produce varied filament densities and patterns while maintaining manufacturing efficiency.
4Strength
If filaments are fused to create secure fit, then support is improved, but flexibility is reduced
Solution Approach 1:
The upper structure segments flexibility and support functions across different layers. Some layers can be fused with higher bonding strength for secure fit in high-support zones, while other layers maintain lower bonding strength or different filament configurations to preserve flexibility in areas requiring movement adaptability.
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 approach enables tailored performance characteristics in specific zones of the footwear upper, enhancing comfort, support, and ventilation by providing a secure fit and adaptive flexibility.
Implementation Method 1
each layer is fused to the previous layer
Data Source
AI summary
Upper components for footwear include: (a) a first layer including a first filament including first plural, non-intersecting, spaced apart path segments (wherein the first filament may have a width dimension of less than 3 mm wide); and (b) a second layer including a second filament including second plural, non-intersecting, spaced apart path segments (wherein the second filament may have a width dimension of less than 3 mm), wherein the second layer is fused to the first layer at locations where the layers contact one another. Additional layers of material, including additional layers with filament, may be included in the upper. The filament material in the different layers may be the same or different from one another (e.g., a thermoplastic material, a thermoplastic polyurethane material, a hydrophobic material, a water-repelling material, a non-water absorbing material, etc.). One or more layers each may be formed as a continuous extruded path of filament.