Shoe Upper Stretch-Locking Structure for Multi-Size Fit
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Solution Overview
Problem
Existing methods for manufacturing shoe uppers are labor-intensive and complicated, and fail to provide the desired stability and comfort, especially for sports applications, due to the use of hook and loop fasteners and stiff leather, while varying sizes across different countries increase manufacturing costs.
Innovation Solution
A method involving stretchable portions on the shoe upper, which are stretched and permanently locked with rigid elements to create adjustable sizes, allowing for reduced manufacturing of different sizes and improved stability and comfort, using techniques like circular knitting and integrating stretch yarns for enhanced flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sizes of shoe uppers are manufactured to meet different sizing requirements, then customer fit and comfort are improved, but manufacturing costs and complexity increase
Solution Approach 1:
The shoe upper incorporates stretchable portions that can be dynamically adjusted during manufacturing to achieve different final sizes. A single upper design is stretched to fit multiple size requirements, eliminating the need to manufacture separate uppers for each size while maintaining size adaptability.
Solution Approach 2:
The invention changes the physical state of the shoe upper material by applying stretch to transform a standard-sized upper into larger sizes. This parameter change (dimensional expansion through stretching) allows one upper design to serve multiple size requirements, reducing manufacturing complexity.
2Stability of the object's composition
If traditional manufacturing methods with hook and loop fasteners and stiff leather are used, then structural stability is improved, but comfort and ease of manufacture deteriorate
Solution Approach 1:
The shoe upper combines stretchable material with rigid elements to create a composite structure. The stretchable portions provide comfort and ease of manufacture, while the rigid elements (such as toe caps, heel counters, or reinforcement panels) maintain structural stability in critical areas.
Solution Approach 2:
The upper is divided into functional zones: stretchable portions for comfort and adaptability, and rigid elements for structural support. This segmentation allows each zone to perform its specific function optimally while simplifying the manufacturing process for each component.
3Productivity
If stretchable portions are used to reduce manufacturing of different sizes, then productivity is improved, but stability may deteriorate
Solution Approach 1:
By combining stretchable portions with rigid elements, the invention maintains structural stability while utilizing the efficiency benefits of stretchable materials. The rigid elements provide the necessary stability, allowing productivity gains from reduced size variations to be realized without compromising upper stability.
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 manufacturing costs and time by minimizing the need for multiple shoe sizes, enhances stability and comfort, and allows for seamless integration with the shoe sole, providing a more attractive and blister-free fit.
Implementation Method 1
stretching the at least one stretchable portion of the shoe upper for adapting a size of the shoe upper
Implementation Method 2
permanently attaching at least one rigid element at least partly on the stretched stretchable portion so that the stretched stretchable portion is locked
Data Source
Figure 1
Figure 2a~2b
Figure 2c
AI summary
The present invention relates to a method (100) for manufacturing a shoe upper (200; 305), comprising the steps of: (a.) providing (110) at least one stretchable portion (210; 310) on the shoe upper (200; 305); (b.) stretching (120) the at least one stretchable portion (210; 310) of the shoe upper (200; 305) for adapting a size of the shoe upper (200;305); and (c.) permanently attaching (130) at least one rigid element (220; 320) at least partly on the stretched stretchable portion (210; 310) so that the stretched stretchable portion (210; 310) is locked.