Printed Functional Shoe Upper for Precise Zone-Specific Properties
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Solution Overview
Problem
Existing shoe manufacturing processes require complex and labor-intensive assembly of multiple parts to achieve zone-specific functionalities, leading to inefficient and imprecise adjustment of shoe upper properties.
Innovation Solution
A direct printing process is used to apply a functional second layer onto a first layer of the shoe upper, allowing for precise and flexible manufacturing of shoes with locally adapted functionalities without the need for assembly or transfer processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple individual parts are assembled to form functional zones in the upper, then the functionality can be provided in different zones, but the manufacturing process becomes complex and labor-intensive
Solution Approach 1:
The patent combines multiple individual functional parts into a single integrated upper structure. The functional zones are created by directly forming different materials or properties within different zones of the same upper component, eliminating the need to assemble multiple separate parts. This merging approach maintains the adaptability of having functional zones while significantly simplifying the manufacturing process.
Solution Approach 2:
The patent applies local quality by providing different materials, densities, or structural properties in specific zones of the upper without requiring separate parts. Each zone of the upper can have tailored properties (e.g., different breathability, support, or flexibility) directly integrated into the single upper structure, achieving zone-specific functionality through localized material or structural variations rather than through assembly of multiple components.
2Adaptability or versatility
If multiple parts are assembled to form functional zones, then different functionalities can be provided, but the precision of adjusting functionalities is limited due to larger part areas
Solution Approach 1:
The patent enables precise functionality adjustment by implementing local quality variations within a single integrated upper. Different zones can have precisely controlled material properties, densities, or structural characteristics at the zone level without being constrained by the size and shape of separate assembled parts. This allows for fine-tuned functionality adjustment in each zone with higher manufacturing precision.
3Adaptability or versatility
If casting process is used to deposit polymer layer on substrate layer, then functional zones can be created, but the process becomes energy-intensive and time-consuming
Solution Approach 1:
The patent changes the parameters of the material deposition process from high-energy casting to lower-energy methods. Instead of using energy-intensive casting processes that require melting and pouring molten polymer, the invention employs methods such as extrusion, injection molding, or direct forming techniques that operate at lower temperatures and consume less energy while still creating the desired functional zones with different material properties.
4Strength
If meltable plastic powder is used with screen printing and melting process, then reinforcing elements can be created, but the process becomes energy-intensive and involves shrinking
Solution Approach 1:
The patent changes the state and processing parameters of the plastic material from powder form requiring melting to forms that can be directly formed or extruded. By using plastic compounds in pellet, granule, or semi-solid forms that can be processed through extrusion or injection molding without complete melting, the invention maintains the strength of reinforcing elements while eliminating the energy-intensive melting process and associated shrinking problems.
Solution Approach 2:
The patent employs composite materials that combine plastic with other materials or use specially formulated plastic compounds that provide the desired reinforcing properties without requiring high-temperature melting. These composite materials can be processed at lower temperatures through extrusion or direct forming, maintaining structural strength while reducing energy consumption and minimizing shrinkage during processing.
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 method enables faster, less costly, and more precise production of shoes with finely tuned functional zones, improving comfort, durability, and performance by precisely adjusting mechanical properties such as elasticity, cushioning, and abrasion resistance.
Implementation Method 1
using methods like screen printing or ink-jet printing to apply the second layer directly onto the first layer
Implementation Method 2
using methods like screen printing or ink-jet printing to apply the second layer directly onto the first layer
Data Source
AI summary
Described are shoes, in particular a sports shoe, wherein at least a portion of an upper of the shoe includes a first layer and a functional second layer, wherein the functional second layer is directly printed onto the first layer.