Woven Shoe Upper With 3D Patterning Without Separate Sewing
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Solution Overview
Problem
Existing methods for incorporating three-dimensional patterns into shoe uppers require separate sewing processes, increasing manufacturing complexity and cost.
Innovation Solution
A shoe upper is woven using a combination of high-stretch and regular weft yarns, with the high-stretch yarns disposed on the rear surface and regular yarns on the outer surface to form three-dimensional patterns, and plain weave and leno weave fabrics are continuously woven without sewing, allowing for complex patterns to be integrated during the weaving process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate sewing operation is used to attach a three-dimensional pattern member to the shoe upper, then the three-dimensional pattern can be inserted into the shoe upper, but the manufacturing process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent merges the pattern formation process with the shoe upper weaving process by integrating the three-dimensional pattern directly into the fabric structure during weaving. This is achieved by using a combination of warp yarns and weft yarns with different elasticity properties, where the pattern-forming yarns are woven into the fabric in specific sequences to create raised three-dimensional patterns that are inherently part of the shoe upper material, eliminating the need for separate sewing operations.
Solution Approach 2:
The patent applies preliminary action by pre-forming the three-dimensional pattern within the fabric structure during the weaving process itself. The pattern-forming yarns are positioned and arranged in three-dimensional configurations before the final shoe upper assembly, allowing the pattern to be built into the fabric as it is being woven rather than added afterward through separate attachment operations.
2Ease of manufacture
If a separate sewing operation is used to attach a three-dimensional pattern member to the shoe upper, then the three-dimensional pattern can be inserted into the shoe upper, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single weaving process. The three-dimensional pattern formation, fabric creation, and pattern integration are all accomplished simultaneously during the weaving operation, eliminating the need for separate cutting, sewing, and attachment operations that would increase manufacturing costs.
Solution Approach 2:
The weaving process itself performs the pattern formation function that would otherwise require separate sewing operations. The loom and weaving mechanism automatically create the three-dimensional pattern as part of the fabric structure through the arrangement and interlacing of yarns with different elastic properties, making the system self-sufficient for pattern creation.
3Adaptability or versatility
If plain weave fabric and leno weave fabric are continuously woven through a jacquard process, then various and complicated three-dimensional patterns are provided, but the weaving process becomes more complex
Solution Approach 1:
The patent applies local quality by using different weave structures (plain weave and leno weave) in different regions of the fabric to achieve specific pattern effects. The jacquard process controls individual yarns or small groups of yarns to create locally varied three-dimensional patterns with different heights, densities, and textures, allowing complex overall patterns to be built from simpler local weave variations.
Solution Approach 2:
The patent uses composite yarn structures combining yarns with different elasticity properties (stretch yarns and non-stretch yarns) to create the three-dimensional patterns. The jacquard weaving process manipulates these composite yarns to produce varied three-dimensional patterns where different yarn combinations create different pattern characteristics, enabling pattern variety without proportionally increasing process 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 method simplifies the manufacturing process by integrating three-dimensional patterns without sewing, reducing costs and enhancing pattern complexity and visibility.
Implementation Method 1
a first weft yarn which is a high-stretch yarn and a second weft which is a regular yarn overlap each other to form the weft yarn, and the shoe upper comprises a three-dimensional pattern region in which the first weft yarn is disposed on a rear surface and the second weft yarn is disposed on a surface to form the three-dimensional pattern on the surface
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
The present disclosure provides a shoe upper woven using a warp yarn and a weft yarn, having the weft yarn formed so that a first weft yarn which is a high-stretch yarn and the second weft which is a regular yarn overlap each other, and including a three-dimensional pattern region in which the first weft yarn is disposed on a rear surface and the second weft yarn is disposed on a surface to form the three-dimensional pattern on the surface.