Reinforced Shoe Upper Using Solid PSA Adhesive Tape

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Solution Overview

Problem

The manufacturing of reinforced shoe uppers faces challenges in achieving both aesthetic value and breathability, as reinforcement layers applied with liquid glues create a waterproof barrier, hinder deformation, and complicate the shaping process, while also requiring long drying times and posing health risks due to volatile substances.

Innovation Solution

A reinforced shoe upper design using solid Pressure Sensitive Adhesives (PSA) gluing material in the form of adhesive tape, applied between breathable outer and inner layers, allowing for breathable channels and easier shaping without the need for liquid glues, which simplifies the manufacturing process and maintains breathability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If liquid gluing material is used to apply reinforcement layers, then the reinforcement layers are firmly fixed to the outer layer and lining, but breathability is strongly compromised and annulled in the reinforced zones

Engineering Contradiction:

Improvefixing strength of reinforcement layerVSAvoidbreathability

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The gluing material is applied in a discontinuous, segmented manner rather than as a continuous layer. The spraying system deposits glue in separate zones or spots, leaving gaps between reinforcement layers that preserve breathability while maintaining sufficient fixing strength in the bonded areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different zones of the reinforcement assembly have different gluing characteristics. Some areas receive gluing material for strong fixation, while other areas remain free of glue to maintain breathability. This local differentiation allows simultaneous achievement of both fixation strength and breathability.

Inventive Principle:

Principle #3Local quality

2Strength

If liquid gluing material is sprayed to fix reinforcement layers, then the reinforcement is firmly attached, but the gluing material flows between layers and creates a continuous waterproof barrier

Engineering Contradiction:

Improveadhesion of reinforcement layerVSAvoidwaterproof barrier effect

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of applying gluing material excessively to ensure complete coverage and strong adhesion, the system applies glue partially - only in specific zones where fixation is needed. This partial application prevents the formation of continuous waterproof barriers while achieving adequate adhesion in the glued areas.

Inventive Principle:

Principle #16Partial or excessive action

3Strength

If liquid glues are used for reinforcement, then the reinforcement layers are firmly fixed, but hardenings are caused by crystallization which modify the natural Hand and complicate fixing

Engineering Contradiction:

Improvefixing strength of reinforcement layerVSAvoidnatural Hand and flexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent changes the physical-chemical parameters of the gluing material by using thermoplastic materials instead of liquid glues that crystallize. The thermoplastic material remains flexible and does not undergo harmful crystallization, preserving the natural Hand of the materials while providing sufficient fixing strength through melting and bonding.

Inventive Principle:

Principle #35Parameter changes

4Strength

If liquid gluing material is used, then the reinforcement layers are fixed, but long drying time is required which hinders rise in production rate

Engineering Contradiction:

Improveadhesion of reinforcement layerVSAvoidproduction rate

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the chemical bonding mechanism of liquid glues with a thermal-mechanical process. Thermoplastic material is melted using heat (from pressing or body heat) and then bonds through mechanical interlocking and cooling, eliminating the need for long drying times and enabling faster production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Strength

If liquid gluing materials are sprayed, then the reinforcement layers are fixed, but vapours or mists are formed which require protective masks

Engineering Contradiction:

Improveadhesion of reinforcement layerVSAvoidvapours and mists

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses thermoplastic material that can be applied in a controlled manner and then melted and bonded in place. This eliminates the need for spraying liquid glues that generate harmful vapors, as the thermoplastic material is applied as a solid or semi-solid that does not volatilize during application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 solution enables quick and cost-effective production of breathable, aesthetically pleasing shoe uppers with improved comfort and reduced health risks, as the solid adhesive material preserves breathability and allows for easier shaping, eliminating the need for complex gluing processes and hazardous fumes.

Implementation Method 1

A reinforced shoe upper (2) comprises an outer layer (5), an inner layer (6) or lining and a reinforcement layer (9) interposed between the outer layer (5) and the inner layer (6), which is firmly connected to both the outer layer (5) and the inner layer (6) by means of a Pressure Sensitive Adhesive (PSA) gluing material

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentEP4193871A1Reinforced shoe upper, reinforcement element for a shoe upper and method for forming a reinforced shoe upper

Publication Date: 2023.06.14 ALC FLENCO GRP

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Figure 3~4
Figure 5

AI summary

A reinforced shoe upper (2) for a footwear (1) has an outer layer (5), an inner layer (6) which at least partially lines the outer layer (5), at least one reinforcement layer (9) interposed between the outer layer (5) and the inner layer (6), and a gluing material interposed between the reinforcement layer (9) and the outer (5) and inner (6) layers; the shoe upper (2) is reinforced using a reinforcement element (20) provided with the reinforcement layer (9) and with a plurality of solid gluing material portions (13), which protrude on opposite sides of the reinforcement layer (9), are spaced apart from one another, delimit between one another breathable zones (16,21) without gluing material and are protected by protection films (18,19) which are removed before forcing the outer layer (5) and the inner layer (6) against the gluing material.