Shoe Upper with Continuous String-Like Body for Fitting
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Solution Overview
Problem
Existing shoes face challenges in achieving a high fitting function while reducing the number of parts and improving recyclability, as forming all parts from a single material compromises fitting and increases manufacturing energy and environmental burden.
Innovation Solution
A shoe design featuring an upper member and a string-like body formed continuously with the same thread as the upper member, incorporating shoelaces and eyelets with varying tensile rigidity and stretchability to enhance fitting and reduce parts, with the string-like body being used to fix the sole member to the upper member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If all parts are formed from a single material to reduce the number of parts and improve recyclability, then manufacturing energy is reduced and environmental burden is decreased, but the fitting function is compromised
Solution Approach 1:
The upper member is segmented into multiple regions with different knitting densities and structures. High-density knit regions provide close contact and support, while low-density regions provide breathability and flexibility. This segmentation allows a single-material construction to achieve differentiated functional zones that collectively deliver high fitting performance without requiring multiple separate components.
Solution Approach 2:
Different regions of the upper member are constructed with different knitting patterns, stitch types, and yarn arrangements to create local variations in properties such as elasticity, density, and stretchability. For example, toe and heel areas use tighter knitting for durability and fit, while instep areas use looser knitting for comfort. This local quality differentiation enables high fitting function within a unified single-material structure.
2Reliability
If multiple parts are used to ensure high fitting function, then fitting performance is improved, but manufacturing energy increases and recyclability deteriorates
Solution Approach 1:
Multiple functional elements that would traditionally be separate parts (eyelets, shoelaces, upper member) are merged into a single integrated construction formed from one continuous yarn. The eyelets are formed as integral features of the knitted upper, and the shoelaces are extensions of the same yarn, eliminating the need for separate manufacturing processes and assembly steps, thereby reducing manufacturing energy while maintaining fitting function.
Solution Approach 2:
The single yarn material serves multiple functions simultaneously: it forms the structural upper member, creates the eyelets for lacing, provides the shoelaces themselves, and enables the differential density regions for fitting. This multi-functionality eliminates the need for multiple specialized components, reducing manufacturing complexity and energy consumption while achieving high fitting performance.
3Reliability
If multiple materials are used to achieve high fitting function, then fitting performance is improved, but recyclability is reduced
Solution Approach 1:
The entire upper member, eyelets, and shoelaces are constructed from a homogeneous single yarn material, enabling the entire assembly to be recycled together as one material type. The yarn may contain blended fibers (e.g., polyester and spandex) for functional properties, but the uniform composition throughout allows for simplified recycling processes compared to multi-material constructions that require separation.
Solution Approach 2:
The integrated single-material construction facilitates easier recovery and recycling of the upper member components. Since all elements are made from the same material, they can be processed together through recycling streams without requiring complex separation procedures, thereby reducing environmental burden while maintaining the high fitting function achieved through sophisticated single-yarn knitting techniques.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A shoe includes an upper member (6) covering a foot, and a string-like body (10) formed continuously with the upper member (6) by the same thread as a thread forming the upper member (6).