Lightweight Textile Footwear Upper With Selective Support
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Solution Overview
Problem
Conventional methods for manufacturing footwear uppers lack efficiency in producing lightweight, form-fitting, and stable components that maintain shape, with existing processes being complex and time-consuming.
Innovation Solution
The method involves using a sock or sock-like structure as an upper base member, which is engaged with support members and reactive polymeric materials to provide structural support and shape, utilizing a jig and heating elements to bond the support members to the upper base member through a flat pressing process, allowing for the creation of a seamless and comfortable footwear upper with reduced manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to manufacture footwear uppers, then structural support and shape stability can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple manufacturing operations into a single flat pressing process. The upper base member, support members, and reactive polymeric materials are all processed simultaneously through one pressing operation, eliminating the need for separate stitching, bonding, and shaping steps that characterize conventional methods.
Solution Approach 2:
The invention divides the upper construction into modular components: an upper base member and separate support members. These segmented components can be independently manufactured and then selectively assembled through the flat pressing process, allowing for simplified production and easier customization of different upper configurations.
2Weight of moving object
If traditional upper construction methods are used, then durability and support can be achieved, but the upper becomes heavier and less form-fitting
Solution Approach 1:
The patent applies support members selectively at specific locations where structural reinforcement is needed, rather than using uniform thick materials throughout the entire upper. The reactive polymeric materials are also applied locally to provide shape stability only in critical areas, maintaining lightweight construction in non-critical regions.
Solution Approach 2:
The invention uses composite construction combining the upper base member material with reactive polymeric materials and support member materials. This composite approach creates a multi-material structure that provides both lightweight properties and localized structural support, achieving form-fitting characteristics while maintaining shape stability.
3Ease of manufacture
If reactive polymeric materials are used to bond support members, then seamless construction and comfort are achieved, but additional manufacturing steps are required
Solution Approach 1:
The reactive polymeric materials are applied to the support members or upper base member in advance of the final assembly. This preliminary application allows the bonding agent to be ready when the components are positioned, eliminating the need for separate bonding operations and reducing overall manufacturing time despite adding an initial application step.
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 results in a lightweight, form-fitting footwear upper that maintains shape and provides comfort, while simplifying the manufacturing process by eliminating the need for strobel members and heel stitching, and enabling easy integration with sole structures.
Implementation Method 1
utilizing a jig and heating elements to bond the support members to the upper base member through a flat pressing process
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Method of forming footwear components from lightweight textile structures (e.g., including circular knitted structures made from natural or synthetic fibers, such as socks or sock-type structures). The textile structures are selectively supported at various areas to provide desired local characteristics.