TPU Infused Mesh for Rigid Breathable Shoe Uppers
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Solution Overview
Problem
Traditional shoe uppers, primarily made from materials like leather and canvas, lack the necessary rigidity, breathability, and durability to provide optimal support and comfort, especially in high-performance footwear applications.
Innovation Solution
The use of thermoplastic polyurethane (TPU) infused mesh material is molded to form a portion of the shoe upper, providing a rigid, breathable, and lightweight structure that can be heat molded and coupled with the sole, offering enhanced support and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional materials like leather and canvas are used for shoe uppers, then the upper can be manufactured with conventional processes, but the structural integrity, rigidity, and durability are insufficient for high-performance footwear
Solution Approach 1:
The patent uses TPU-infused mesh as a composite material that combines the breathability of mesh with the structural integrity and rigidity of thermoplastic polyurethane. This composite provides both the mechanical strength needed for high-performance footwear and the manufacturing advantages of a unified material system that can be heat-molded and thermally bonded to the sole.
Solution Approach 2:
The patent applies thermal energy to the TPU-infused mesh to activate the thermoplastic properties of the TPU. By heating the material above its glass transition temperature, the mesh becomes pliable for molding and bonding, then cools to set the desired shape and create permanent bonds with the sole, enabling efficient manufacturing with high structural integrity.
2Reliability
If traditional shoe uppers are constructed, then the manufacturing process is straightforward, but breathability and comfort are compromised
Solution Approach 1:
The TPU-infused mesh composite maintains the open-knit structure of the mesh for breathability while infusing it with TPU strands that provide structural support. This composite structure delivers both comfort through air permeability and performance through enhanced durability and shape retention.
3Strength
If TPU infused mesh is used to form the shoe upper, then structural integrity, breathability, and durability are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent leverages the thermal properties of TPU to simplify manufacturing. By controlling temperature parameters during assembly, the TPU-infused mesh transitions from a rigid state during handling to a pliable state during bonding, then returns to rigid upon cooling. This thermal cycling enables complex structural integration through simple heating and cooling steps rather than complex mechanical assembly processes.
Data Source
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AI summary
Embodiments of the present invention relate to a thermoplastic polyurethane ("TPU") infused mesh material that is molded to form at least a portion of a shoe. The TPU infused mesh may be formed as an upper, a portion of sole or other components of a shoe. The TPU infused mesh is formed, in an exemplary embodiment, through the application of liquid TPU to a surface of a spacer mesh. The liquid TPU infused spacer mesh is then cured, cut to a pattern, and heat molded to form a desired portion of the shoe. The heat molded TPU mesh is coupled to other portions of the shoe (e.g., sole) to form an article footwear in an exemplary embodiment.