Shoe Upper Zonal Contouring via Internal Adhesive Bonding
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Solution Overview
Problem
Adding contours to shoe uppers, especially those made from thin, lightweight materials, is challenging due to attachment issues which can lead to separation and increased manufacturing costs, and may detract from the aesthetic appearance.
Innovation Solution
A composite panel is formed by assembling a backing, a bonding agent, contouring elements, and an outer panel, which is then heated and compressed to create a raised contour, securely attaching the contouring elements to the interior side of the panel, reducing the risk of separation and enhancing the appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If contouring elements are attached to the outside of the upper, then raised contours are formed for aesthetic and functional purposes, but the elements tend to separate from the upper and manufacturing cost increases
Solution Approach 1:
The contouring element is merged with the upper by bonding it to the interior surface of the upper, creating a unified structure where the contouring element becomes an integrated part of the upper rather than a separate attachment. This resolves the separation issue by eliminating the interface between separate components.
Solution Approach 2:
Instead of attaching the contouring element to the exterior surface (2D attachment), the element is positioned in the 3D space between the insole and the outer panel, creating a multi-layered composite structure. This dimensional transition allows the contouring element to maintain its raised profile while being securely embedded within the upper assembly.
2Reliability
If stitching is used to reinforce the attachment of contouring elements, then attachment stability improves, but manufacturing cost increases and aesthetic appearance deteriorates
Solution Approach 1:
The mechanical stitching system is replaced with a chemical bonding system using adhesive. The adhesive is applied to the contouring element and bonded to the insole and/or outer panel, providing secure attachment without the need for needles, threads, or stitching machines. This substitution eliminates the associated manufacturing costs and aesthetic drawbacks of visible stitching.
3Reliability
If stitching is used to reinforce the attachment of contouring elements, then attachment stability improves, but the shoe appearance deteriorates
Solution Approach 1:
The visible mechanical stitching is replaced with invisible chemical bonding using adhesive. The adhesive bonds the contouring element to the upper components without creating visible external features, preserving the clean aesthetic appearance of the shoe while maintaining secure attachment through the bonded joints.
Solution Approach 2:
The attachment interface is moved from the exterior surface to the interior layers of the upper. By bonding the contouring element between the insole and outer panel, the attachment mechanism becomes hidden within the multi-layered structure, eliminating visible stitching or fasteners on the shoe's exterior surface.
4Weight of moving object
If thin, lightweight material is used for the upper, then weight is reduced, but attachment of contouring elements becomes more challenging
Solution Approach 1:
The contouring element is merged with the thin upper material through adhesive bonding, creating a composite structure where the lightweight upper and contouring element become a unified component. This merging approach avoids the need for additional mechanical fasteners or reinforcement that would add weight or complexity to the attachment process.
Solution Approach 2:
Mechanical attachment methods that would require additional hardware or complex stitching processes are replaced with adhesive bonding. This allows the contouring element to be securely attached to the thin, lightweight upper material without compromising the material's weight advantages or requiring complex manufacturing operations.
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 securely attaches contouring elements to the shoe upper, minimizing separation risks and providing a more aesthetically pleasing finish while maintaining the lightweight and ventilated properties of the material.
Implementation Method 1
The outer panel can be, e.g., a mesh or other flexible porous material and can be bonded to portions of the backing adjacent to the contouring element
Implementation Method 2
The assembled stack may then be heated and compressed so as to form a composite panel having a contour corresponding to the contouring element
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A composite panel portion of an upper (11) includes a contouring element (31-34) located between a backing (29) and an outer panel (19). The outer panel (19) conforms to the contouring element (31-34) and the backing (29) so as to form a raised contour.