Braided Footwear Upper with Variable Density Zones
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Solution Overview
Problem
Conventional athletic shoe uppers lack the ability to provide tailored performance and comfort characteristics across different regions of the foot, as they are often made from uniform materials that fail to adapt to specific stress points and activities.
Innovation Solution
The use of braided upper materials with varying braid angles, densities, and materials in different regions to create a unitary braided structure that offers customized support, stability, and comfort, with floating cables for additional tension and support where needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If uniform materials are used for the upper, then manufacturing is simple and cost-effective, but the shoe cannot provide tailored performance and comfort for different regions of the foot
Solution Approach 1:
The upper is constructed with multiple sections, each formed from different yarns with distinct physical properties (e.g., cushioning, support, breathability). These sections are positioned in specific regions of the foot to provide localized functionality - for example, more cushioning in high-impact areas and better breathability in warmer regions. This is achieved through a knitting process that incorporates multiple feeds, each providing different yarn types to create sections with varying characteristics throughout the upper.
2Adaptability or versatility
If multiple different materials and braid densities are used in different regions, then performance and comfort are optimized, but manufacturing complexity increases
Solution Approach 1:
Multiple feeds are integrated into a single circular knitting machine system, allowing different yarns to be knitted together in a unitary, seamless upper structure. The knitting process combines multiple material streams simultaneously, creating a unified garment with varied properties rather than assembling separate components. This merging approach enables customized regional properties while maintaining a streamlined single-step manufacturing process.
3Ease of operation
If a unitary seamless structure is created, then comfort and fit are improved, but manufacturing precision requirements increase
Solution Approach 1:
The knitting process dynamically adjusts parameters such as yarn selection, stitch type, and needle engagement across different sections of the upper. By varying these parameters during the knitting process, the system creates regions with different densities, elasticities, and physical properties within a single continuous structure. This parametric control allows precise regional customization while maintaining seamless construction, as each section's properties are programmed into the knitting pattern rather than requiring post-manufacturing assembly.
Data Source
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AI summary
An upper for an article of footwear. The upper includes, a unitary braided structure forming at least a toe region, a forefoot region, a midfoot region, a heel region, and an ankle region. The unitary braided structure comprises a first density of braids forming at least a portion of the midfoot region and forefoot region. The unitary braided structure further includes a first band of a second density of braids and a second band of the second density of braids. The first band and the second band each extending across a width of the upper over an instep of the upper. The second density of braids is higher than the first density of braids.