Shoe Upper Functional Printing for Zoned Performance Control
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Solution Overview
Problem
Existing shoe manufacturing processes require complex and labor-intensive assembly of multiple parts to achieve varied functionalities in different zones, limiting the precision and scalability of functional adjustments.
Innovation Solution
A direct functional printing process is used to apply a second layer onto a first layer, eliminating the need for assembly and enabling precise, scalable, and cost-effective manufacturing of shoes with varied functionalities by printing functional zones directly onto the first layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple parts are assembled to form an upper with different functionalities in different zones, then the functionality requirements can be met, but the manufacturing process becomes complex and labor-intensive
Solution Approach 1:
The patent merges multiple separate functional parts into a single integrated upper by directly printing different functional layers onto one substrate. Instead of assembling multiple components with different properties, the invention combines them into one homogeneous structure where each zone has its required functionality through selective printing, thereby simplifying the manufacturing process while maintaining adaptability.
Solution Approach 2:
The patent applies local quality by directly printing specific functional materials only in the zones where they are needed on the upper. This allows each zone to have the exact functionality required (e.g., cushioning, stabilization, breathability) without requiring separate parts, reducing assembly complexity while preserving localized functional adaptability.
2Adaptability or versatility
If multiple parts are assembled by sewing or gluing, then different functionalities can be provided in different zones, but the number of parts is limited and functionality adjustment is coarse
Solution Approach 1:
The patent enables precise functionality adjustment by directly printing functional materials with specific properties (e.g., elasticity, cushioning, breathability) only in the exact zones where they are needed. This continuous, localized application allows for fine-grained control of functionality across the upper, far exceeding the coarse adjustment possible with discrete assembled parts.
Solution Approach 2:
The patent replaces the mechanical assembly process (sewing or gluing of discrete parts) with a direct printing process. This substitution eliminates the need for labor-intensive assembly operations while enabling continuous, precise deposition of functional materials in any desired pattern, significantly reducing manufacturing effort and improving functionality precision.
3Manufacturing precision
If casting process is used to deposit polymer layer on substrate layer, then functional layers can be created, but the process becomes energy-intensive and time consuming
Solution Approach 1:
The patent replaces the energy-intensive casting process with a direct printing process that deposits functional materials layer by layer in the desired zones. This printing approach achieves precise layer deposition control without requiring the high energy input and long processing times associated with casting, thereby maintaining manufacturing precision while dramatically reducing energy consumption.
Solution Approach 2:
The patent applies partial action by directly printing functional materials only in the specific zones where they are needed, rather than casting a complete layer across the entire surface. This selective deposition reduces material usage and processing time/energy while maintaining the precision of layer placement in the functional zones.
4Strength
If meltable plastic powder is used with screen printing and heating, then reinforcing elements can be created, but the process requires lots of energy and comprises complex melting
Solution Approach 1:
The patent replaces the complex melting and heating process with a direct printing process that deposits functional materials in their final functional state. Instead of printing plastic powder and then melting it through heating, the invention directly applies the functional material (e.g., elastic polymer, cushioning material) in the desired zones, eliminating the melting step and associated energy requirements while maintaining the strength and functionality of the reinforcing elements.
5Strength
If stability ribs are attached to outer parts at desired positions, then stabilization can be provided, but the assembly process becomes labor-intensive
Solution Approach 1:
The patent merges the stabilization function into the upper itself by directly printing stabilizing materials in the required zones during the same process that creates the upper. Instead of separately manufacturing stability ribs and then attaching them through labor-intensive assembly, the stabilization functionality is integrated into the upper manufacturing process, dramatically improving productivity while maintaining the required stabilization strength.
Solution Approach 2:
The patent provides stabilization through local printing of functional materials with stabilizing properties (e.g., elastic polymers, rigid structures) directly in the zones where stabilization is needed on the upper. This localized application eliminates the need for separate stabilization components and their attachment, reducing labor intensity while maintaining effective stabilization at the required positions.
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 allows for faster, less labor-intensive production of shoes with precisely adjusted functionalities, reducing material waste and enabling fine structural adjustments, enhancing comfort and performance by adapting to specific zones and user needs.
Implementation Method 1
the functional second layer is directly printed onto the first layer by means of a screen printing process
Implementation Method 2
the functional second layer is directly printed onto the first layer by means of an inkjet-printing process
Data Source
Figure 1a~1c
Figure 2
Figure 3a~3d
AI summary
The present invention relates to a method of direct printing onto a first layer of at least a portion of an upper of a shoe. The method comprises providing the first layer and printing a functional second layer directly onto the first layer. Printing the functional second layer directly onto the first layer comprises printing a first sublayer of the functional second layer directly onto the first layer, drying at least a surface of the first sublayer, and printing a second sublayer of the functional second layer directly onto at least a portion of the first sublayer.