Adjustable Inlaid Strand Knitted Footwear Upper
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Solution Overview
Problem
Conventional footwear uppers require multiple material elements, leading to increased manufacturing time, waste, and reduced recyclability due to complex cutting and stitching processes, and lack an adjustable inlaid strand for enhanced fit and functionality.
Innovation Solution
A knitted component with a unitary knit construction incorporating an adjustable inlaid strand that extends through the knit element, providing support, stability, and stretch-resistance, and can be independently tensioned for a customizable fit, reducing the need for multiple material elements and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material elements are used in the upper, then different properties (stretch-resistance, wear-resistance, flexibility) can be imparted to different areas, but manufacturing time and expense increase
Solution Approach 1:
The patent combines multiple material elements into a single knitted component formed by continuous knitting processes. Different yarns with different properties (stretch-resistant yarn, wear-resistant yarn, flexible yarn) are integrated during knitting to create a unified upper that provides area-specific properties without requiring separate material pieces and their associated cutting and joining operations
Solution Approach 2:
The knitted component serves multiple functions simultaneously: it provides structural support, stretch-resistance, wear-resistance, and flexibility all in one element. The inlaid strand further enhances this by providing additional support and adjustability, allowing a single component to replace what would traditionally require multiple specialized material elements
2Adaptability or versatility
If multiple material elements are used in the upper, then different properties can be imparted to different areas, but waste material from cutting and stitching processes accumulates
Solution Approach 1:
By merging multiple material elements into a single knitted component constructed from the beginning, the patent eliminates the need for cutting and stitching operations that generate waste. The continuous knitting process integrates different yarns directly into the final product without requiring separate material pieces to be joined, thereby preventing waste accumulation
Solution Approach 2:
The patent creates a homogeneous structure in terms of construction method - the entire upper is formed through a unified knitting process rather than assembling heterogeneous cut pieces. This homogeneous approach to manufacturing eliminates the waste associated with cutting and joining different material types
3Adaptability or versatility
If multiple material elements are incorporated into the upper, then different properties can be achieved, but the upper becomes more difficult to recycle
Solution Approach 1:
The patent merges multiple material properties into a single knitted component that can be processed as one unit. By integrating different yarns during the knitting process rather than assembling separate pieces, the upper becomes easier to recycle because it can be treated as a single material stream rather than a complex assembly of different materials requiring separation
4Strength
If a conventional inlaid strand is used, then support and stability are provided, but the fit cannot be adjusted by the wearer
Solution Approach 1:
The patent transforms the static inlaid strand into a dynamic, adjustable element. The inlaid strand is configured to extend outwardly from the knitted component, allowing it to be manipulated by the wearer. This dynamic configuration enables the strand to be tensioned or loosened according to individual fit preferences while maintaining its structural support function
Data Source
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AI summary
An article of footwear may include an upper incorporating a knitted component. The knitted component includes a knit element and an inlaid strand formed of unitary knit construction with the knit element. The inlaid strand extends through the knit element. A portion of the inlaid strand may extend into the heel region and may be external to the heel region. Pulling on the external portion may tension the inlaid strand.