Stitched Polymer Thread Upper for Breathable Footwear Support
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Solution Overview
Problem
Existing footwear manufacturing processes often fail to provide durable, comfortable, and breathable footwear that meets the needs for durability, weight, and/or breathability of an article of footwear, especially for non-performance and performance activities, as they lack efficient customization and resource optimization.
Innovation Solution
The solution involves stitching polymer threads with a core material and a coating material having different melting points onto a base layer, where the coating material is bonded to the base layer via heat, creating patterns that provide targeted characteristics such as durability, breathability, and stability by overlapping thread sets, reducing the need for additional layers and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate layers and processes are used to provide durability, support, and breathability, then comprehensive footwear performance is achieved, but manufacturing complexity and resource usage increase
Solution Approach 1:
The patent combines multiple functional layers into a single integrated upper structure. The knitted base layer simultaneously provides breathability, support, and durability through its construction, eliminating the need for separate overlay layers, stitching operations, and assembly steps. This merging reduces manufacturing complexity while maintaining comprehensive footwear performance.
Solution Approach 2:
The knitted upper is designed to perform multiple functions simultaneously: it provides structural support, ensures breathability through its knit pattern, delivers durability through material selection, and offers comfort through its flexible construction. This multi-functionality in a single component reduces the number of separate parts and assembly processes required.
2Duration of action of stationary object
If traditional stitching and bonding processes are used, then footwear durability is achieved, but manufacturing time and resource consumption increase
Solution Approach 1:
The knitted upper is designed to be self-assembling through its inherent elastic properties. The interlocking knit structure automatically maintains its shape and provides structural integrity without requiring external stitching or bonding processes. This self-service characteristic eliminates time-consuming assembly steps while ensuring durable construction.
Solution Approach 2:
The patent replaces traditional mechanical stitching and bonding systems with a knitted construction method. The elastic knit structure provides mechanical interlocking and structural stability through its own architecture rather than requiring separate fastening mechanisms, thereby reducing manufacturing steps and improving productivity.
3Strength
If additional layers and materials are added to provide support and stability, then footwear performance is improved, but material usage and manufacturing costs increase
Solution Approach 1:
The knitted upper employs local quality variations within the single layer to provide targeted support where needed. By adjusting knit density, stitch patterns, or yarn composition in specific areas during the knitting process, the upper delivers enhanced support in high-stress zones while maintaining breathability and flexibility in other areas, optimizing material usage throughout.
Solution Approach 2:
The patent utilizes composite yarns or blended materials within the knitted structure to achieve multiple properties in a single layer. By incorporating different fiber types or material properties into the yarn itself, the upper provides enhanced strength, support, and durability without adding separate material layers, thereby reducing overall material usage.
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 providing customized support, stability, and propulsion while minimizing material usage and manufacturing costs, thus optimizing resource efficiency and comfort.
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.