Woven Shoe Upper with Integrally Stitched Yarn for Bias Stability

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Solution Overview

Problem

Conventional weaving techniques for shoe uppers lack flexibility and accuracy in engineering mechanical properties, particularly in providing sufficient stability along bias directions, and often result in increased weight and complexity due to waste yarns and additional handling steps.

Innovation Solution

A woven shoe upper with an integrally woven stitching yarn that is laterally displaced during the weaving process, allowing for localized reinforcement and pattern incorporation without additional steps, using an open reed system and electronic or mechanical control for precise placement, reducing waste and complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional weaving techniques are used to produce woven shoe uppers, then the fabric has lighter weight and higher tensile strength than knits, but the flexibility for engineering mechanical properties is reduced and stability along bias directions is insufficient

Engineering Contradiction:

Improvetensile strengthVSAvoidflexibility for engineering mechanical properties

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The invention divides the weaving process into distinct functional zones: a first zone for the base woven fabric and a second zone for integrated stitching yarn reinforcement. This segmentation allows different mechanical properties to be engineered in different regions of the same fabric, providing both strength and flexibility without requiring separate components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention merges the base fabric construction and reinforcement stitching into a single integrated weaving process. The stitching yarn is incorporated during the weaving operation itself rather than as a separate post-processing step, combining multiple functions (structural support and reinforcement) into one unified fabric structure.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If additional yarns are incorporated by embroidery after weaving, then functional zones can be added, but the process requires additional handling and is time-consuming with limited accuracy and reproducibility

Engineering Contradiction:

Improvefunctional zonesVSAvoidproduction time and efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The invention performs the reinforcement stitching action during the initial weaving process rather than as a subsequent operation. The stitching yarn is fed and integrated into the fabric structure simultaneously with the warp and weft yarns, eliminating the need for separate embroidery or reinforcement steps and significantly improving production efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention combines multiple yarn feeding operations (warp, weft, and stitching yarn) into a single integrated weaving process. This merging of operations allows functional zones to be created during the primary manufacturing step, reducing total production time and improving consistency.

Inventive Principle:

Principle #5Merging (Combining)

3Shape

If conventional Jacquard loom techniques are used to form intricate patterns, then patterns can be created on woven fabric, but the techniques are technically complex, produce waste yarns, and increase area weight significantly

Engineering Contradiction:

Improveintricate patternsVSAvoidweaving technique complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The invention applies stitching yarn reinforcement only in specific local zones where functional support is needed, rather than using complex Jacquard techniques that create patterns across the entire fabric. This localized approach achieves the desired functional effect with simpler equipment and without generating waste yarns from unused pattern elements.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention extracts only the essential reinforcement function from complex pattern-making techniques. Instead of using Jacquard looms to create intricate designs, the stitching yarn is selectively placed only where structural support is needed, removing unnecessary complexity and waste while maintaining the essential functional benefit.

Inventive Principle:

Principle #2Taking out (Extraction)

4Strength

If reinforcement is achieved by using stronger yarns along warp or weft direction, then tensile strength is improved, but the woven material becomes unstable along bias directions at +/−45° to the warp direction

Engineering Contradiction:

Improvetensile strength along warp/weftVSAvoidstability along bias direction

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The invention adds a third dimensional element to the traditional two-directional (warp and weft) weaving structure by incorporating stitching yarn that runs perpendicular to the weave direction. This additional dimension provides reinforcement that complements the warp and weft yarns, improving overall fabric stability including along bias directions without compromising the strength along the primary directions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20240016258A1Woven shoe upper

Publication Date: 2024.01.18 ADIDAS AG

AI summary

The present invention concerns a shoe upper comprising a woven portion, wherein the woven portion comprises a plurality of warp yarns; a plurality of weft yarns; at least one stitching yarn, wherein the stitching yarn is integrally woven into the fabric during the weaving process by laterally displacing the stitching yarn substantially along the weft direction and moving the stitching yarn in and out of at least one open reed gap in a reed.