Thread-Wound Shoe Upper Assembly Without Adhesive Bonding
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Solution Overview
Problem
Traditional shoe manufacturing methods using adhesives generate volatile organic gases, posing health and environmental risks, and require multiple assembly steps, contributing to a significant carbon footprint.
Innovation Solution
A shoe manufacturing method that integrates a sole and upper portion through 3D printing and winding threads around positioning structures on the sole perimeter, eliminating the need for adhesives and reducing assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesives are used to bond the upper portion and sole, then the bonding process is simple, but volatile organic gases are generated causing health and environmental issues
Solution Approach 1:
The invention extracts and eliminates the adhesive bonding process entirely from the shoe manufacturing system. Instead of using adhesives to bond the upper portion and sole, the patent uses mechanical interlocking through positioning structures (protrusions on the sole) that engage with corresponding recesses in the upper portion, completely removing the source of volatile organic gas emissions while maintaining effective bonding.
Solution Approach 2:
The invention replaces the chemical bonding mechanism (adhesives) with a mechanical interlocking system. The sole includes positioning structures with protrusions that fit into recesses of the upper portion, creating a mechanical connection that substitutes for the chemical adhesive bonding process, thereby eliminating harmful emissions while achieving secure attachment.
2Ease of manufacture
If multiple parts are purchased, manufactured, processed, shipped, and assembled, then the shoe can be produced with standard components, but the carbon footprint increases significantly
Solution Approach 1:
The invention merges the upper portion and sole into a more integrated assembly by eliminating separate adhesive bonding and assembly steps. The positioning structures are formed as integral parts of the sole, and the upper portion is directly attached through mechanical interlocking, reducing the number of discrete manufacturing and assembly operations required, thereby lowering the overall carbon footprint of production and logistics.
Solution Approach 2:
The positioning structures serve multiple functions: they provide mechanical interlocking between the upper and sole, act as alignment features during assembly, and eliminate the need for separate adhesive application processes. This multi-functionality reduces the number of manufacturing steps and components needed, contributing to reduced carbon emissions.
3Strength
If threads are wound around positioning structures multiple times, then the mechanical strength increases, but the manufacturing complexity increases
Solution Approach 1:
The winding process is designed to be self-aligning, where the thread automatically follows the positioning structures (protrusions) on the sole. This self-service mechanism reduces the need for complex positioning and alignment systems during manufacturing, as the thread naturally conforms to the predetermined path defined by the positioning structures, thereby maintaining simplicity while achieving high mechanical strength through multiple windings.
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 method produces a low-carbon, environmentally friendly shoe with reduced carbon footprint and simplified manufacturing, enhancing mechanical strength and durability through higher thread density in critical areas.
Implementation Method 1
producing positioning structures around the perimeter of the sole in a seamlessly integrated manner through 3D printing
Implementation Method 2
heating up the semi-finished product of the shoe to allow the at least one thread to be at least partially melted
Implementation Method 3
cooling down the semi-finished product of the shoe to form a shoe
Data Source
AI summary
The present disclosure provides a shoe, comprising: a shoe sole having a bottom surface, a sidewall surface, and a top surface opposite to the bottom surface; a plurality of positioning structures disposed on the perimeter of the sidewall surface; and a foot covering part comprising at least one thread, in which each thread extends from one of the positioning structures to another positioning structure to form a thread extension part, and the collection of a plurality of thread extension parts forms a configuration that fits a user's foot. The present disclosure also provides a manufacturing method of a shoe. The foot covering part of the shoe of the present disclosure comprises one or a plurality of threads.