Shoe Upper With Selective Welding For Flex Zones
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Solution Overview
Problem
The complexity and weight of footwear increase with the number of material elements used in the upper, leading to higher manufacturing costs, waste generation, and reduced recyclability, while existing solutions do not effectively address the need for both structural support and flexibility in athletic footwear.
Innovation Solution
A shoe upper design featuring multiple welds in selected areas for structural support and unwelded flex zones to mimic foot movement, using thermal or high-frequency welding methods to fuse materials like thermoplastics or natural fibers coated with thermoplastics, reducing the number of material elements while maintaining comfort and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple material elements are used in the upper, then structural support and functionality are improved, but mass and manufacturing complexity increase
Solution Approach 1:
The patent merges multiple material elements into a single integrated upper structure with selective welding. Instead of using separate components that need stitching or adhesion, the design uses one piece of material with strategically placed weld zones to create the necessary structure, thereby reducing manufacturing complexity while maintaining strength.
Solution Approach 2:
The patent applies local quality by implementing selective welding only in specific zones where structural support is needed, while leaving other areas unwelded to maintain flexibility. This localized approach allows the structure to be strong where required without compromising overall manufacturability or creating unnecessary complexity throughout the entire upper.
2Strength
If multiple material elements are used in the upper, then structural support and functionality are improved, but mass of the footwear increases
Solution Approach 1:
By consolidating multiple material elements into a single upper structure with selective welding, the design eliminates redundant materials and reduces the total mass of the footwear while still providing the necessary structural support through strategic weld placement.
Solution Approach 2:
The selective welding approach applies material and structural properties only locally where needed for support, rather than throughout the entire upper. This localized reinforcement reduces overall material usage and consequently reduces the mass of the footwear while maintaining necessary strength.
3Strength
If multiple material elements are used in the upper, then structural support and functionality are improved, but waste material increases
Solution Approach 1:
The integration of multiple material elements into a single upper structure with selective welding reduces the number of separate components that require cutting and joining, thereby minimizing off-cut waste material while still achieving the necessary structural support through strategic weld zones.
Solution Approach 2:
By implementing welding only in specific local zones rather than throughout the entire upper, the design optimizes material usage and reduces waste from cutting and joining processes, while still providing structural support where absolutely necessary.
4Strength
If multiple material elements are used in the upper, then structural support and functionality are improved, but manufacturing time and expense increase
Solution Approach 1:
The patent merges multiple material elements into a single integrated upper that requires fewer assembly steps. By using one piece of material with selective welding rather than multiple components needing stitching or adhesion, the design significantly reduces manufacturing time and expense while maintaining structural support.
Solution Approach 2:
The selective welding approach requires fewer manufacturing operations than would be needed for multiple separate material elements, thereby reducing both manufacturing time and expense. The localized nature of the welding allows for more efficient production processes and higher productivity.
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 design reduces the mass and waste of footwear, increases manufacturing efficiency, and enhances recyclability while providing necessary support and flexibility, ensuring the foot remains properly positioned and comfortable during various activities.
Implementation Method 1
using thermal or high-frequency welding methods to fuse materials like thermoplastics or natural fibers coated with thermoplastics
Implementation Method 2
using thermal or high-frequency welding methods to fuse materials
Data Source
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Figure 3
AI summary
A shoe having a shoe upper including multiple unwelded flex zones in selected locations on the shoe upper. The flex zones may be selectively located on the upper to flex when the shoe is in use.