Bag-Like Shoe Upper Assembly to Prevent Shell Displacement

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Solution Overview

Problem

Existing shoe manufacturing methods face challenges in ensuring a secure fit and preventing position displacement of the upper body within the shell, leading to poor fit and impaired function, while also requiring a lengthy and complex manufacturing process.

Innovation Solution

A method involving a flexible shell with an internal space, a bag-like upper body with a topline opening, and a sole body, where the upper body is partially fixed to the shell using a sewn portion, allowing for easy assembly and preventing displacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the upper body is accommodated in the shell without being fixed, then the manufacturing process is simpler, but the upper body may significantly be displaced in position resulting in poorer fit

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidupper body position accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The upper body is preliminarily formed with a bag-like structure including an opening at the topline portion before being accommodated in the shell. This preliminary formation allows the upper body to be easily inserted into the shell while maintaining its shape, and subsequent partial fixing at specific locations prevents displacement without requiring complex manufacturing processes

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fixing between the upper body and shell is segmented rather than continuous. The upper body is fixed at specific discrete locations (such as the topline portion and heel portion) rather than along the entire perimeter, which simplifies the manufacturing process while still preventing significant displacement of the upper body within the shell

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the upper body and the shell are fixed to each other in their entirety with an adhesive, then position displacement is prevented, but the manufacturing process becomes significantly more complicated and time-consuming

Engineering Contradiction:

Improveupper body position accuracyVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Instead of fixing the upper body and shell in their entirety with adhesive, the invention applies fixing only at partial critical locations such as the topline portion and heel portion. This partial fixing action is sufficient to prevent significant displacement of the upper body while dramatically reducing the time and complexity of the manufacturing process compared to complete surface bonding

Inventive Principle:

Principle #16Partial or excessive action

3Adaptability or versatility

If the upper body is made from a flexible member for better fit, then comfort is improved, but the upper body may significantly be displaced in position when accommodated in the shell without being fixed

Engineering Contradiction:

Improvefit to footVSAvoidupper body position accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The upper body is preliminarily formed with a bag-like structure including an opening at the topline portion before being accommodated in the shell. This preliminary formation allows the flexible upper body to be easily inserted into the shell while maintaining its shape, and subsequent partial fixing at specific locations prevents displacement without restricting the flexibility needed for good fit

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The upper body is constructed from a flexible member that can conform to the shape of the foot for better fit. The flexible material is formed into a bag-like structure that can be easily accommodated in the shell, and when partially fixed at critical locations, it maintains both flexibility for comfort and positional stability within the shell

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS12533862B2Method of manufacturing shoe and shoe

Publication Date: 2026.01.27 ASICS CORP

AI summary

A method of manufacturing a shoe includes preparing a flexible shell having an internal space, preparing an upper body in a form of a bag, the upper body being provided with an opening in a portion corresponding to a topline, preparing a sole body, accommodating the upper in the shell, partially fixing the shell and the upper body, and forming the upper body with a last being located in the upper body accommodated in the shell, taking the last out of the formed upper body, and inserting the sole body in the shell.