Double-Layer Shoe Upper Structure for Wrinkle-Free Shape Holding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacture of shoe uppers with double textile layers often results in wrinkles, folds, and creases due to disconnected inner and outer layers, necessitating costly additional manufacturing steps like heat treatments or stabilizing parts to maintain shape.
Innovation Solution
Incorporating a first tubular textile layer with a polygonal-shaped zone made of a more resilient yarn into the shoe upper, surrounded by a second layer, which is knitted or woven, to stabilize and maintain the shape without additional reinforcement materials, using intarsia knitting techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a double textile layer construction is used for shoe uppers, then comfort and flexibility are improved, but wrinkles, folds, and creases occur due to disconnected inner and outer layers
Solution Approach 1:
The patent introduces a first zone with specific yarn composition and polygonal shape as an intermediary element between the inner and outer textile layers. This zone acts as a mediator that connects the two layers structurally, preventing relative displacement and the formation of wrinkles and folds while maintaining the comfort and flexibility benefits of the double layer construction
2Stability of the object's composition
If additional stabilizing parts or heat treatments are applied to prevent wrinkles, then shape stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent incorporates the stabilizing function directly into the first tubular textile layer during the knitting process itself. The first zone with polygonal shape and specific yarn composition is created in advance during manufacturing, eliminating the need for subsequent heat treatments or addition of separate stabilizing parts. This preliminary integration of the stabilizing mechanism simplifies the overall manufacturing process while maintaining shape stability
3Stability of the object's composition
If low melting point yarns are used for fusion, then shape holding is improved, but comfort is reduced due to stiffness
Solution Approach 1:
The patent applies different yarn properties in different zones of the textile layer. The first zone, which requires shape holding, uses yarn with specific resilience properties and polygonal configuration. The rest of the textile layers maintain their original yarn composition for comfort. This local differentiation allows shape holding where needed while preserving comfort in other areas, avoiding the need to make the entire upper stiff
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 reduces wrinkles and creases, provides a comfortable and sportive silhouette, and enhances stability while maintaining flexibility, reducing production costs and waste.
Implementation Method 1
The first tubular textile layer includes a first zone (130), wherein the first zone includes a first yarn (1030). The first tubular textile layer includes a second yarn, wherein the first yarn is more resilient than the second yarn
Data Source
AI summary
An upper for a shoe includes a first tubular textile layer and a second tubular textile layer. The first tubular textile layer is at least partially surrounded by the second tubular textile layer thus forming an internal textile layer and an external textile layer. The first tubular textile layer includes a first zone. The first zone includes a first yarn and the first tubular textile layer includes a second yarn. The first yarn is more resilient than the second yarn, and the first zone includes a polygonal shape.