Dual-Layer Knitted Footwear Upper for Seamless Functional Integration

The patent combines the manufacturing of inner and outer layers into a single integrated knitting process. The knitted upper is formed as one continuous structure where the inner layer and outer layer are knitted simultaneously, eliminating the need for separate manufacturing processes while maintaining the ability to integrate functional elements (like sensor pockets) with aesthetic features throughout the entire upper structure.

The single knitting process is segmented into distinct functional zones: an inner layer portion, an outer layer portion, and intermediate portions connecting them. The knitting machine selectively forms different knit structures in different zones - for example, forming sensor pockets in the inner layer, aesthetic patterns in the outer layer, and structural connections in the intermediate portions. This segmentation allows complex functionality to be achieved through a relatively simple continuous process.

The knitting process applies local quality by creating different knit structures at different locations within the upper. The inner layer uses knit structures optimized for comfort and flexibility, the outer layer uses structures optimized for durability and aesthetics, and the intermediate portions use structures optimized for structural integrity. This localized differentiation of knit structures provides superior flexibility and comfort compared to uniform separate-layer manufacturing.