Shoe Upper Reinforcement Using Thermoplastic Resin Powder

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Solution Overview

Problem

Existing methods for manufacturing shoe uppers with reinforcing portions using thermoplastic resin often result in unintentional tension and inadequate reinforcement at joints, leading to compromised fitting performance and reinforcing effectiveness.

Innovation Solution

A method involving three-dimensional formation of the shoe upper before applying thermoplastic resin powder, pre-heating specific areas to melt the resin, and adhering it to the upper member to create a firmly bonded reinforcing portion that extends over joints, ensuring adequate coverage and thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the reinforcing portion is provided in the upper member before three-dimensional formation, then the reinforcing effect is enhanced, but unintentional tension occurs in the shoe upper deteriorating fitting performance

Engineering Contradiction:

Improvereinforcing effectVSAvoidfitting performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The upper member is three-dimensionally formed first, and then the reinforcing portion is provided on the formed upper member. This preliminary formation of the three-dimensional structure before adding the reinforcing portion prevents unintentional tension while maintaining the reinforcing effect.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the upper member is three-dimensionally formed before providing the reinforcing portion, then fitting performance is improved, but it becomes difficult to adhere thermoplastic resin powder with excellent reproducibility

Engineering Contradiction:

Improvefitting performanceVSAvoidadhesion reproducibility

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The upper member is pre-heated to a temperature equal to or higher than the melting point of the thermoplastic resin powder before adhesion. This parameter change (temperature increase) enables the thermoplastic resin powder to melt and adhere firmly to the three-dimensionally formed upper member, achieving excellent reproducibility.

Inventive Principle:

Principle #35Parameter changes

3Shape

If the reinforcing portion is formed after three-dimensional formation, then the upper member can be shaped properly, but the reinforcing portion cannot extend over joints formed during three-dimensional formation

Engineering Contradiction:

Improvethree-dimensional formationVSAvoidjoint reinforcement

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The upper member is three-dimensionally formed first to establish the proper shape and create joints, and then the reinforcing portion is provided that extends over these pre-formed joints. This preliminary formation allows the reinforcing portion to be strategically placed across joint areas for enhanced strength.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If thermoplastic resin powder is adhered to the three-dimensionally formed upper member without pre-heating, then the process is simpler, but the adhesion is insufficient and the reinforcing effect is reduced

Engineering Contradiction:

Improveprocess simplicityVSAvoidadhesion strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The upper member is pre-heated to a temperature equal to or higher than the melting point of the thermoplastic resin powder. This parameter change ensures that the thermoplastic resin powder melts and adheres firmly to the upper member, achieving sufficient adhesion strength while maintaining process simplicity.

Inventive Principle:

Principle #35Parameter changes

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 approach enhances the reinforcing effect while improving fitting performance by preventing unintentional tension and ensuring consistent adhesion of the thermoplastic resin, resulting in a shoe upper with improved durability and comfort.

Implementation Method 1

pre-heating the three-dimensionally formed upper member such that a portion-to-be-reinforced of the three-dimensionally formed upper member is heated to a temperature equal to or higher than a melting point of the thermoplastic resin powder

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

further heating the upper member to which the thermoplastic resin powder is adhered, and melting the thermoplastic resin powder adhered to the upper member

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentEP3858181B1Method for manufacturing shoe upper, shoe upper, and shoe

Publication Date: 2023.04.19 ASICS CORP

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AI summary

A method of manufacturing a shoe upper according to the present invention includes: three-dimensionally forming an upper member (11); pre-heating the upper member (11) such that a portion-to-be-reinforced of the three-dimensionally formed upper member (11) is heated to a temperature equal to or higher than a melting point of thermoplastic resin powder (200); adhering the thermoplastic resin powder (200) to the upper member (11) so as to at least cover the portion-to-be-reinforced of the pre-heated upper member (11); further heating the upper member (11) to which the thermoplastic resin powder (200) is adhered and melting the thermoplastic resin powder (200) adhered to the upper member (11); and hardening the melted thermoplastic resin powder (200) to firmly adhere the reinforcing portion (13) to the upper member (11).