Multilayered Shoe Upper With Unidirectional Fibers
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Solution Overview
Problem
Existing materials with high performance fibers for shoe uppers face issues with crimping, stress concentrations, lack of elasticity, and inability to form three-dimensional shapes due to rigid structures, leading to poor seam strength, UV resistance, and stretchability.
Innovation Solution
A multilayered composite material with unidirectionally oriented fibers in specific angled configurations and a matrix material, such as thermoplastic polyurethane, allowing for elasticity and deformation to form three-dimensional shapes without compromising tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If woven configuration of high performance fibers is used, then tensile strength is improved, but fiber crimping occurs causing stress concentrations and wear points that reduce long term performance
Solution Approach 1:
The patent combines unidirectionally oriented high performance fibers with a thermoplastic elastomer matrix to create a composite material that maintains the fibers' high tensile strength while eliminating the crimping issues inherent in woven configurations. The matrix binds the fibers together without inducing bends or stress concentrations.
Solution Approach 2:
The patent changes the structural parameter from woven to unidirectionally oriented fiber arrangement, and selects a thermoplastic elastomer with specific elasticity parameters (Shore A 40-80) to achieve the desired performance characteristics without fiber crimping.
2Strength
If unidirectional extruded fibers are used with low elasticity to resist stretch, then stretch resistance is improved, but the material cannot be deformed to form three dimensional objects
Solution Approach 1:
The patent selects a thermoplastic elastomer with specific elasticity parameters (Shore A 40-80) that provides optimal balance between stretch resistance and deformability. This elasticity parameter range allows the material to be formed into three-dimensional shapes while maintaining adequate stretch resistance for the application.
Solution Approach 2:
The thermoplastic elastomer matrix serves as an intermediary that allows controlled deformation during manufacturing while transferring and distributing loads to the high performance fibers during use, achieving both formability and structural integrity.
3Ease of operation
If multilayered composite material with thermoplastic elastomer is used, then elasticity and ability to form three dimensional shapes is improved, but seam strength and stitch sheer strength may be reduced
Solution Approach 1:
The patent creates a composite material where unidirectionally oriented high performance fibers are embedded in a thermoplastic elastomer matrix, combining the elasticity and formability of the elastomer with the high strength and seam integrity of the oriented fibers.
Solution Approach 2:
The patent uses unidirectionally oriented fiber layers that can be strategically positioned to reinforce areas requiring high seam strength and stitch sheer strength, while allowing areas requiring elasticity to have lower fiber density or different orientation.
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 material achieves low weight, high tensile strength, and elasticity, enabling the formation of complex shapes without wrinkles or folds, while maintaining strength and stability in strategic locations within the shoe upper.
Implementation Method 1
a matrix material, wherein the multilayered material comprises elastic properties that allow the multilayered material to deform when stretched over a three dimensional mold
Data Source
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AI summary
Described are shoe uppers in which at least a portion thereof is formed of a multilayered material. The multilayered material includes at least one nonwoven fiber layer with unidirectionally oriented fibers and a matrix material, wherein the multilayered material has elastic properties that allow the multilayered material to deform when stretched over a three dimensional mold.