3D Printed Traced Element Footwear Upper
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Solution Overview
Problem
Existing three-dimensional printing technologies face challenges in creating complex structures with integrated textile strands and polymer layers that provide both strength and flexibility, while also ensuring efficient manufacturing processes.
Innovation Solution
The development of a three-dimensional printing system that deposits a first polymer layer, positions a textile strand along a strand-trace path, and then deposits a second polymer layer that overlaps both the first polymer layer and the strand, creating a traced element with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers of polymer material are deposited around a textile strand, then the strength and structural integrity of the traced element is improved, but the device complexity and manufacturing process difficulty increase
Solution Approach 1:
The traced element is constructed by segmenting the deposition process into distinct layers: a first polymer layer is deposited along a first trace path, followed by a second polymer layer along a second trace path that overlaps the first. This segmentation allows each layer to be optimized independently while contributing to the overall structural integrity of the traced element.
Solution Approach 2:
The patent employs multi-layer deposition in three-dimensional space, where polymer layers are built up around the textile strand in different spatial dimensions. The first and second polymer layers are deposited at different heights and orientations, creating a complex three-dimensional structure that enhances strength while managing manufacturing complexity through controlled layering.
2Ease of operation
If the traced element extends over a large portion of the upper (at least 50% horizontal and vertical extent), then the flexibility and comfort of the footwear are improved, but the amount of material and manufacturing time increase
Solution Approach 1:
The traced element is designed with varying properties across its extent, with different polymer layers providing different functional characteristics in different regions. The first and second polymer layers can have different material compositions, thicknesses, and deposition parameters optimized for local requirements, allowing the traced element to provide flexibility where needed while maintaining structural integrity elsewhere.
Solution Approach 2:
The traced element extends over at least 50% of the horizontal and vertical extent of the upper, providing sufficient flexibility and comfort coverage without requiring complete coverage of the entire footwear upper. This partial action approach achieves the necessary functional benefits while limiting material consumption and manufacturing time.
3Reliability
If overlapping trace paths are used to create multi-layer polymer structure, then the reliability and durability of the traced element are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The first polymer layer is deposited along a first trace path before the second polymer layer is deposited along the second trace path. This preliminary action allows the first layer to serve as a foundation and guide for the second layer, with the overlapping regions pre-positioned to ensure proper alignment and bonding between layers, thereby improving reliability while managing precision requirements.
Solution Approach 2:
The overlapping regions between the first and second polymer layers act as intermediaries that bond the layers together, creating a durable multi-layer structure. These overlapping zones provide a transition region that accommodates minor misalignments while ensuring strong inter-layer adhesion, thereby enhancing reliability without requiring extremely high manufacturing precision.
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 creation of articles of footwear with traced elements that extend over at least 50% of the horizontal and vertical extent of the upper, providing improved strength, flexibility, and manufacturing efficiency.
Implementation Method 1
a first layer of polymer material is deposited on a receiving layer and along a polymer-trace path, a textile strand is positioned along a strand-trace path and over the first layer of polymer material, and a second layer of polymer material is deposited along the polymer-trace path and over both the first layer of polymer material and the textile strand
Data Source
AI summary
A method of forming a traced element is disclosed. The method may include printing layers of a traced element and incorporating a textile strand in overlapping polymer layers of the traced element. In some embodiments, the traced element may be formed on a base layer. The traced element may be incorporated into an upper for an article of footwear.