Stitched Polymer Thread Footwear Upper for Targeted Support
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Solution Overview
Problem
Existing footwear technologies face challenges in balancing durability, weight, breathability, stability, and propulsion while maintaining cost-effectiveness and customization for individual needs.
Innovation Solution
The integration of polymer threads with a core material and a coating material, where the melting point of the core is higher than the coating, stitched in various patterns on a base layer and bonded via the coating, providing targeted characteristics such as directional strength and stretchability to specific areas of the upper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional footwear materials and construction methods are used, then durability and structural integrity are maintained, but weight and breathability are compromised
Solution Approach 1:
The upper is constructed from multiple separate components (base layer, polymer thread sets, bonding agent layers) that are assembled together, allowing each component to be optimized independently for weight and function while maintaining overall structural integrity
Solution Approach 2:
The footwear upper combines different materials with complementary properties: a base layer material for structural support, polymer threads for reinforcement and breathability, and bonding agents for assembly, creating a composite structure that achieves durability without excessive weight
2Stability of the object's composition
If traditional footwear materials and construction methods are used, then structural integrity is maintained, but breathability is compromised
Solution Approach 1:
The polymer thread sets are configured to create porous or open structures within the upper that allow air circulation and moisture wicking, improving breathability while the base layer and bonding agents maintain structural integrity
Solution Approach 2:
The segmented construction with separate base layer, polymer threads, and bonding agents allows the polymer threads to be positioned to create breathable channels while the base layer provides structural support
3Ease of manufacture
If uniform material distribution is used throughout the upper, then manufacturing simplicity is maintained, but targeted performance characteristics cannot be achieved
Solution Approach 1:
Different regions of the upper are provided with different densities and patterns of polymer thread sets bonded to the base layer, allowing specific areas to have enhanced support or breathability characteristics tailored to local functional requirements
Solution Approach 2:
The bonding agent application parameters (amount, pattern, temperature) are varied in different regions to control the density and distribution of polymer threads, enabling customization of local properties while using the same basic materials throughout
4Strength
If extensive material layers are used to provide support and stability, then structural performance is improved, but weight and manufacturing cost increase
Solution Approach 1:
The support structure is created using a composite of base layer material and bonded polymer threads, where the polymer threads provide reinforcement along specific stress lines, allowing reduced material thickness while maintaining or improving support performance
Solution Approach 2:
The support function is segmented into discrete polymer thread sets positioned at specific locations and orientations, providing targeted support where needed rather than uniform material distribution, thereby reducing overall material usage and weight
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 enhances footwear performance by offering customizable support, stability, and propulsion while reducing material usage and manufacturing costs, and enabling efficient, reproducible production.
Implementation Method 1
the one or more polymer threads are bonded to the base layer via the coating of the polymer thread
Implementation Method 2
the melting point of the first material is higher than the melting point of the second material
Data Source
AI summary
An upper for an article of footwear, the upper including a base layer defining a least a portion of the upper and polymer threads stitched to the base layer. The polymer threads may include a core composed of a first material and a coating composed of a second material, where the melting point of the first material is higher than the melting point of the second material. The polymer threads may be bonded to the base layer by the coating of the polymer threads. The polymer threads may include one or more polymer thread sets stitched in pattern(s) on area(s) of an outer surface of the base layer to provide targeted characteristics to area(s) on the upper. In some embodiments, the polymer threads may be bonded to the base layer with heat and/or pressure.