Unitary Polymer Matrix Footwear Upper for Sizing and Breathability
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Solution Overview
Problem
Conventional athletic footwear upper materials often require multiple layers for optimal wear-resistance, flexibility, and air-permeability, leading to complexity and inefficiency in manufacturing and sizing adjustments.
Innovation Solution
A single unitary polymer matrix layer is used for the upper, incorporating a size adjustment mechanism and heel tongue element, providing a comfortable, flexible, and breathable structure that can accommodate various foot sizes and movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple material layers are used for the upper to achieve wear-resistance, flexibility, and air-permeability, then the desired functional properties are obtained, but the manufacturing complexity and number of components increase
Solution Approach 1:
The patent combines multiple material layers (exterior layer, intermediate layer, and interior layer) into a single unitary upper constructed from one or more polymer matrices. This merging eliminates the need for separate layers while maintaining the functional properties of wear-resistance, flexibility, and air-permeability that would otherwise require multiple distinct materials to achieve.
Solution Approach 2:
The patent utilizes polymer matrix materials that inherently possess composite properties, combining the characteristics of exterior, intermediate, and interior layers within a single material structure. The polymer matrix can be engineered to provide wear-resistance, flexibility, and air-permeability simultaneously, eliminating the need for separate material layers.
2Reliability
If multiple material layers are used for the upper to provide different functional properties in different areas, then the desired performance is achieved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the manufacturing of multiple material layers into a single unitary construction process. Instead of separately manufacturing and assembling exterior, intermediate, and interior layers, the upper is formed as one integrated component from polymer matrix material, significantly simplifying the manufacturing process and improving productivity.
Solution Approach 2:
The patent segments the upper construction into a unitary polymer matrix structure that can be manufactured in different sizes and configurations without requiring assembly of multiple layers. This segmentation approach allows for efficient production of uppers in various dimensions while maintaining functional properties throughout the single-piece construction.
3Duration of action of stationary object
If multiple material layers are used for the upper, then durability and functional performance are improved, but the number of components requires increases leading to more complex sizing adjustments
Solution Approach 1:
The patent combines multiple material layers into a single unitary upper constructed from polymer matrix material. This merging reduces the number of components that would otherwise need to be assembled and adjusted for different sizes, while maintaining the durability provided by the engineered polymer matrix structure.
Solution Approach 2:
The patent creates a universal upper construction from polymer matrix material that can be manufactured in various sizes and configurations to accommodate different foot dimensions. The single-piece design with integrated sizing adjustments (such as lacing systems) eliminates the need for complex assembly of multiple layers for each size variation.
Data Source
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AI summary
Articles of footwear, including athletic footwear, include one or more of: (a) a sole structure; (b) an upper having lateral and medial side elements engaged with the sole structure, the upper made from a polymer matrix structure that extends through at least a heel region; (c) a size adjustment mechanism located at the heel region; (d) a heel tongue element located adjacent the size adjustment mechanism; (e) a shoe securing mechanism; (f) an instep tongue member; and/or (g) a bootie member located at least partially within the foot-receiving chamber. Methods of manufacturing such articles of footwear also are disclosed.