Flat Weft-Knitted Sports Shoe Upper for Lightweight Support
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Solution Overview
Problem
Conventional sports shoes struggle to balance the requirements of providing good support while maintaining a low weight, as reducing weight typically compromises support, and enhancing support often increases weight through additional materials or fastening elements.
Innovation Solution
A sports shoe upper made of flat weft-knitted knitwear, comprising a top portion as tube weft-knitted knitwear to surround the shank and a bottom portion to cover the foot, connected by linking, weft-knitting, or ultrasonic welding, with optional adhesive covering, and featuring elastic cuffs and adjustable pressure for anatomical fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional materials or fastening elements are applied to enhance support, then support is improved, but weight increases
Solution Approach 1:
The upper is divided into multiple knitwear portions (first knitwear portion, second knitwear portion, third knitwear portion) with different structural characteristics. Each portion provides specific support functions through its knitting pattern without requiring additional fastening elements, thus maintaining low weight while achieving comprehensive support.
Solution Approach 2:
Different areas of the upper have different knitting densities and structural properties. The first knitwear portion has a first knitting pattern, the second has a second knitting pattern, and the third has a third knitting pattern, allowing each region to provide optimized support locally without uniformly increasing weight across the entire upper.
2Weight of moving object
If material is dispensed with to reduce weight, then weight is reduced, but support deteriorates
Solution Approach 1:
The knitting parameters (density, stitch type, yarn weight) are varied across different portions of the upper. This allows optimization of material usage in each region - using lighter knitting where less support is needed and denser knitting where support is critical - achieving weight reduction without compromising overall support performance.
Solution Approach 2:
The upper combines multiple knitwear portions with different structural properties formed from yarns with varying characteristics. This composite structure allows light areas and support areas to coexist within a single integrated upper, eliminating the need to choose between weight and support.
3Ease of manufacture
If conventional shoe construction methods are used, then manufacturing is simple, but support and fit are compromised
Solution Approach 1:
Multiple functional elements that would traditionally require separate components (upper, tongue, heel counter, support structures) are merged into a single integrated knitwear construction. The first, second, and third knitwear portions are formed in one piece, eliminating the need for additional fastening elements and simplifying manufacturing while providing comprehensive support.
Solution Approach 2:
The knitwear portions serve multiple functions simultaneously - providing structural support, anatomical fit, weight reduction, and integration with the midsole. The single-piece construction performs what would traditionally require multiple separate components, achieving multi-functionality without increasing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides lightweight support with reduced pressure sores and chafe marks, adjustable fit, and integrated features like pockets and lace bars, while allowing customization and improved proprioception.
Implementation Method 1
the top portion is formed as tube weft-knitted knitwear such that it is configured to surround a part of a shank of a wearer
Implementation Method 2
adjustable pressure for anatomical fit
Implementation Method 3
connected by linking, weft-knitting, or ultrasonic welding
Data Source
AI summary
Described are uppers for a sports shoe with flat weft-knitted knitwear. The flat weft-knitted knitwear forms a top portion and a bottom portion of the upper. The top portion is formed as tube weft-knitted knitwear such that it is configured to surround a part of a shank of a wearer of the sports shoe when worn. The bottom portion is configured to cover at least a part of a foot of the wearer of the sports shoe when worn.