Tensioned Elastic-Yarn Woven Upper for Regional Stretch Control
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Solution Overview
Problem
Existing methods for creating shoe uppers with regions of differing physical characteristics, such as elasticity, require additional processing and the application of a second functional layer, which is inefficient and complex.
Innovation Solution
A woven upper formed of warp and weft yarns with controlled proportions of elastic and inelastic yarns, woven under tension to achieve anisotropic elasticity, allowing regions of the upper to have varying elastic properties without additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a second functional layer is printed onto the upper material to create regions of different physical characteristics, then the elasticity and physical properties can be varied in different regions, but the manufacturing process becomes more complex and requires additional processing steps
Solution Approach 1:
The patent applies local quality by varying the proportion of elastic yarns in specific regions (first area vs second area) of the woven upper. The first area contains a higher proportion of elastic yarns to provide greater elasticity, while the second area contains fewer elastic yarns for different physical characteristics. This regional variation in yarn composition allows different physical properties in different areas without requiring additional processing layers or steps.
Solution Approach 2:
The patent changes the parameter of elastic yarn proportion to control elasticity in different regions. By adjusting the percentage of elastic yarns in the warp and/or weft directions for different areas of the upper, the patent achieves varying physical characteristics throughout the material. This parameter-based approach enables regional elasticity control through the weaving process itself, avoiding complex post-processing operations.
2Adaptability or versatility
If regions of different material are used to achieve different stiffness and elasticity, then the physical characteristics can be optimized for specific shoe regions, but the upper construction becomes more complex
Solution Approach 1:
The patent uses composite materials by combining elastic yarns and inelastic yarns within the same woven structure. Different regions of the upper contain different proportions of these yarn types, creating regions with distinct physical characteristics. This composite approach allows optimization of stiffness and elasticity in specific shoe regions while maintaining a unified upper construction without requiring multiple separate material components.
Solution Approach 2:
The patent implements local quality by controlling the distribution of elastic and inelastic yarns in specific regions. The first area contains a higher proportion of elastic yarns for flexibility, while the second area contains fewer elastic yarns for structural support. This localized yarn composition achieves region-specific physical characteristics through the weaving pattern itself, simplifying the overall upper construction.
3Adaptability or versatility
If elastic yarns are woven in tension to provide elasticity, then the elastic properties are enhanced, but the manufacturing process requires precise tension control
Solution Approach 1:
The patent applies preliminary action by pre-tensioning the elastic yarns during the weaving process. The elastic yarns are extended from their rest length by at least 5% (and potentially 20%, 50%, or 100%) while being woven into the upper. This preliminary extension establishes the elastic properties during manufacturing, allowing the upper to achieve the desired elasticity without requiring complex post-processing tension adjustments.
Solution Approach 2:
The patent changes the physical state parameter of the elastic yarns by extending them from their rest length during weaving. By controlling the extension percentage (at least 5%, with embodiments specifying 20%, 50%, or 100%), the patent optimizes the elastic properties of the upper. This parameter adjustment during the weaving process enables precise elasticity control while maintaining manufacturing efficiency.
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
The woven upper provides a simple and efficient method to control elasticity in different directions by varying the proportion of elastic yarns, enabling regions with distinct elastic properties through a single weaving process.
Implementation Method 1
an elastic yarn is one that is capable of elastically deforming to at least 150% of a rest length
Implementation Method 2
the elastic yarns are woven in tension. That is, during weaving the elastic yarns are elastically extended such that an elastic tension is present in the elastic yarns
Data Source
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AI summary
The present invention provides a woven upper formed of warp yarns and weft yarns comprising a first area that is elastic in at least one of the warp or weft direction. The warp yarns and/or the weft yarns comprise at least 5% elastic yarns. The woven upper being characterised in that the elastic yarns are woven in tension. The upper may also comprise a second area having a different elasticity to the first area, wherein the the warp yarns and/or weft yarns of the second area comprise at least 5% fewer elastic yarns than the equivalent yarns of the first area. Advantageously the woven upper is woven using a jacquard machine. The present invention also provides a method of weaving the woven upper.