Flat Knit Footwear Upper Construction
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Solution Overview
Problem
Conventional athletic footwear manufacturing processes require multiple steps, including cutting and sewing, which lead to waste, increased time, and cost, while also limiting the ability to create footwear with enhanced properties like stretchability, wear resistance, and breathability in a single, unitary construction.
Innovation Solution
The use of a flat-knitting process to create a unitary, three-dimensional upper structure with uncut finished edges, where different yarns and stitch patterns can be selectively placed to achieve varied properties across different zones, eliminating the need for additional support structures and seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting and sewing processes are used to manufacture footwear uppers, then manufacturing precision and structural support are achieved, but manufacturing time increases, waste is generated, and production cost increases
Solution Approach 1:
The patent merges multiple separate upper components into a single unitary flat-knitted element that is constructed in one continuous knitting process. This eliminates the need for separate cutting and sewing operations, directly resolving the contradiction by reducing manufacturing time while maintaining structural integrity through the integrated design of the upper including toe box, vamp, quarter, and tongue portions all formed as one piece
Solution Approach 2:
The flat-knitting process performs preliminary shaping and structure formation during the knitting itself, creating three-dimensional contours and structural features directly in the flat fabric before any assembly operations. This preliminary action eliminates subsequent cutting and sewing steps, reducing manufacturing time while ensuring precision is built-in rather than added later
2Strength
If conventional cutting and sewing processes are used to manufacture footwear uppers, then structural support is achieved, but material waste increases and production cost increases
Solution Approach 1:
The patent combines multiple upper components into one unitary flat-knitted element, eliminating material waste associated with cutting separate pieces and joining them. The continuous knitting process uses material efficiently without the offcuts and waste generated by conventional cutting operations, while maintaining structural support through the integrated construction
Solution Approach 2:
The patent changes the manufacturing parameters from discrete cutting and sewing operations to a continuous flat-knitting process. This parameter change enables the formation of complex three-dimensional upper structures directly in the knitting process, eliminating material waste while maintaining or enhancing structural support through the inherent properties of the knitted construction
3Reliability
If multiple separate upper components are used, then structural support and durability are improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent merges multiple upper components into a single unitary flat-knitted element, simplifying the manufacturing process to one continuous knitting operation rather than multiple separate steps involving cutting, sewing, and assembly. This reduction in manufacturing complexity maintains durability through the integrated construction that eliminates seams and weak points from joining operations
4Strength
If conventional textile materials are used for upper construction, then wear resistance is achieved, but flexibility and air permeability are reduced
Solution Approach 1:
The patent changes the material parameters by using flat-knitted textile materials with specific yarn constructions and stitch patterns that inherently provide both wear resistance and flexibility. The knitting structure allows for controlled elasticity and movement, while the material selection maintains durability, resolving the contradiction between strength and ease of operation
5Stability of the object's composition
If conventional textile materials are used for upper construction, then structural integrity is achieved, but air permeability and breathability are reduced
Solution Approach 1:
The patent changes the material parameters by selecting flat-knitted textile materials with open stitch patterns and yarn configurations that provide air permeability while maintaining structural integrity. The knitting structure allows for controlled porosity that enables breathability without compromising the strength and stability of the upper construction
Data Source
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AI summary
An article of footwear (10) comprises an upper (30) including a flat-knitted element (40,50,60) formed from at least one yam mechanically manipulated in a flat-knitting process, wherein the flat-knitted element includes a forefoot region, a midfoot region and a heel region, the forefoot, midfoot and heel regions being unitarily and seamlessly knit with one another during the flat-knitting process, wherein the flat-knitted element has a first area with a first type of knit structure and a second area with a second type of knit structure, and wherein the flat-knitted element has a final shape that is formed with uncut finished edges during the flat-knitting process.