Thermoplastic Elastomer Shoe Upper Welding
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Solution Overview
Problem
Existing methods for producing shoe uppers struggle to efficiently influence material properties locally while maintaining breathability and economic feasibility, particularly in sports shoes where specific properties like breathability and water resistance are crucial.
Innovation Solution
A method involving a non-woven fabric made of thermoplastic elastomer, where specific areas are subjected to a welding beam to increase density, and layers of textile material are integrated between non-woven fabric layers to enhance surface properties, using techniques like high-frequency, ultrasonic, or laser welding to create defined, high-density areas without seam holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the non-woven fabric is exposed to a welding beam to increase density in specific areas, then water resistance and mechanical strength are improved, but breathability is reduced in those areas
Solution Approach 1:
The patent applies local quality by using a welding beam to treat only specific areas of the non-woven fabric (heel, toe, eyelets) while leaving other areas untreated. This creates zones with different properties: welded areas gain water resistance and strength, while non-welded areas maintain breathability, thus resolving the contradiction between these two requirements.
2Strength
If layers of textile material are added between non-woven fabric layers to enhance surface properties, then abrasion resistance is improved, but device complexity and production cost increase
Solution Approach 1:
The patent uses composite materials by combining non-woven fabric layers with textile material layers (such as knit or woven fabrics) to create a multi-layer structure. This composite approach enhances abrasion resistance and surface properties while maintaining flexibility and breathability, resolving the contradiction between strength and complexity through material selection.
3Strength
If the non-woven fabric is made from multiple layers using different methods (meltblown and spunbond), then mechanical properties and breathability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by varying the manufacturing method for different layers of the non-woven fabric. Some layers are produced using meltblown method while others use spunbond method, allowing optimization of mechanical properties and breathability for each layer. This resolves the contradiction by enabling tailored material properties despite increased manufacturing complexity.
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 allows for the production of breathable, water-resistant shoe uppers with improved fit and mechanical properties, maintaining breathability in non-welded areas and enhancing abrasion resistance, while reducing production costs and eliminating disruptive seams.
Implementation Method 1
at least partial areas of the surface of the non-woven fabric are exposed to a welding beam in this way that in these areas at least a partial melting out of the nonwoven takes place
Implementation Method 2
The welding beam is preferably generated by a high-frequency welding system, an ultrasonic welding system or a laser welding system
Implementation Method 3
The welding beam is preferably generated by a high-frequency welding system, an ultrasonic welding system or a laser welding system
Implementation Method 4
The welding beam is preferably generated by a high-frequency welding system, an ultrasonic welding system or a laser welding system
Data Source
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AI summary
The invention relates to a method for the production of at least one layer (1) of an upper shoe part, or of a part of an upper shoe part, wherein a non-woven fabric (2) made of thermoplastic elastomer (TPE) is utilized as the base material for at least one section of the layer (1) of the upper shoe part. In order to be able to specifically influence the material properties locally and in a cost-effective manner, the invention provides that a welding beam (4) is applied to at least partial regions (3) of the non-woven fabric surface such that at least a partial melting of the non-woven fabric (2) occurs in these regions (3) in order to increase the density of the material in the melted regions (3).