Thermally Bonded Ribbon Footwear Upper
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Solution Overview
Problem
Conventional methods for manufacturing footwear uppers often rely on stitching and adhesives, which can increase rigidity, weight, and manufacturing time, while also compromising flexibility and comfort.
Innovation Solution
The use of a ribbon structure formed by overlapping ribbon sections with thermal joints, where the ribbon sections are arranged in a pattern and fixedly attached to each other and an underlying material using thermal joining techniques, such as ultrasonic welding, to create a lightweight, flexible, and comfortable footwear upper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stitching and adhesives are used to join material elements, then the structural strength and reliability are improved, but the weight and rigidity increase, and flexibility decreases
Solution Approach 1:
The patent removes traditional joining methods (stitching and adhesives) from the material elements and replaces them with thermal bonding. This extraction of harmful joining methods reduces weight while maintaining structural integrity through direct thermal fusion of the material elements themselves.
Solution Approach 2:
The patent replaces mechanical joining systems (stitching needles and threads, adhesive application systems) with a thermal bonding system. The thermal bonding process uses heat and pressure to fuse material elements directly, eliminating the need for separate mechanical fastening components and reducing overall weight.
2Strength
If stitching and adhesives are used to join material elements, then the structural strength and reliability are improved, but the manufacturing time increases
Solution Approach 1:
The patent merges the joining function into the material elements themselves through thermal bonding. Instead of separate stitching or adhesive application steps, the material elements are directly fused together in a single thermal bonding process, reducing the number of manufacturing steps and overall production time.
Solution Approach 2:
The patent replaces time-consuming mechanical joining operations (stitching, adhesive application and curing) with a faster thermal bonding process. The thermal bonding system can join multiple material elements simultaneously through controlled heat and pressure, significantly reducing manufacturing cycle time.
3Stability of the object's composition
If stitching and adhesives are used to join material elements, then the structural integrity is improved, but the flexibility and comfort decrease
Solution Approach 1:
The patent extracts rigid joining elements (stitches and adhesive layers) from the footwear upper construction and replaces them with thermal bonding. This removal of stiff intermediate joining layers allows the material elements to move more freely relative to each other, improving flexibility and comfort while maintaining structural integrity through the bonded joints.
4Weight of moving object
If thermal bonding is used to join material elements, then the weight and flexibility are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent replaces complex mechanical joining systems with a thermal bonding system. While thermal bonding requires heat and pressure control, it eliminates the complexity of stitching mechanisms (needles, threads, tension control) and adhesive systems (application, positioning, curing), potentially simplifying the overall manufacturing process.
5Productivity
If thermal bonding is used to join material elements, then the manufacturing efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes parameter changes in the thermal bonding process (temperature, pressure, time) to achieve efficient joining. By precisely controlling these thermal parameters, the process can rapidly bond material elements together, improving manufacturing efficiency while maintaining consistent joint quality through controlled parameter variations.
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 reduces the weight and rigidity of the footwear upper, enhances manufacturing efficiency, and improves comfort by allowing the upper to conform to the foot, while maintaining strength and durability.
Implementation Method 1
one or more of the material elements to be joined may be at least partially softened or melted such that the materials of the elements are secured to each other when cooled
Implementation Method 2
fixedly attaching a first ribbon section to an underlying material with thermal joining
Data Source
AI summary
A method of manufacturing an upper for an article of footwear includes dispensing ribbon in an overlapping pattern of ribbon sections to form a ribbon structure; and fixedly attaching a first ribbon section to an underlying material with thermal joining.