Inlaid Knitted Footwear Upper for Single-Material Support

Solution Overview

Problem

Conventional footwear uppers are formed from multiple material elements that require significant manufacturing steps, leading to increased waste, complexity, and reduced recyclability, while existing knitting machines with inlay feeders occupy two attachment points, limiting efficiency.

Innovation Solution

A knitted component formed with a unitary knit construction and an inlaid strand that extends through the knit element, providing support and stability, and a knitting machine with a combination feeder that occupies a single attachment point, allowing for efficient production of footwear uppers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate components (upper, midsole, outsole, lacing system) are used to provide structural support and functionality, then the desired structural integrity and functional performance are achieved, but the number of manufacturing steps increases and production time is extended

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines multiple separate components (upper, midsole, outsole, lacing system) into a single integrated knitted component formed by one continuous knitting process. The first yarn provides structural support while the second yarn forms functional elements like lacing channels and reinforcement zones, all in one piece without assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses different yarns (first yarn for structure, second yarn for function) knitted in the same fabric to create functionally segmented zones within a single component. The lacing system includes different zones: eyelet zones for lace passage, reinforcement zones for durability, and flexible zones for comfort, all integrated into one knitted structure.

Inventive Principle:

Principle #1Segmentation

2Reliability

If traditional multi-component construction methods are used, then functional zones (lacing systems, reinforcement areas) can be achieved, but material waste increases due to separate manufacturing and assembly processes

Engineering Contradiction:

Improvefunctional performanceVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent combines multiple separate components (upper, midsole, outsole, lacing system) into a single integrated knitted component formed by one continuous knitting process. The first yarn provides structural support while the second yarn forms functional elements like lacing channels and reinforcement zones, all in one piece without assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the manufacturing process parameters by using a single knitting machine to produce the entire component in one operation, eliminating cutting, sewing, and assembly steps that generate material waste in traditional multi-component construction.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If complex assembly processes are used to integrate multiple components, then desired functionality is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvefunctional performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (upper, midsole, outsole, lacing system) into a single integrated knitted component formed by one continuous knitting process. The first yarn provides structural support while the second yarn forms functional elements like lacing channels and reinforcement zones, all in one piece without assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single knitted component performs multiple functions simultaneously: structural support from the first yarn, lacing system functionality from the second yarn, reinforcement zones, flexible areas, and drainage channels, all integrated into one multi-functional component that eliminates the need for separate parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces manufacturing waste, simplifies production, and enhances recyclability by using a single material for footwear uppers, while maintaining structural integrity and fit, and improves manufacturing efficiency by utilizing a single-attachment-point feeder.

Implementation Method 1

The plurality of intermeshed loops are formed with a first yarn comprising a thermoplastic polymer material

Methodology Applied

Scientific EffectThermoplastic molding: Melting

Data Source

PatentEP4488432B1Knitted component, article of footwear, and method of froming a knitted komponent

Publication Date: 2026.04.29 NIKE INNOVATE CV

Figure 1
Figure 2
Figure 3

AI summary

A knitted component, an article of footwear, and a method of forming the knitted component are disclosed. The knitted component comprises a knit element being formed of courses comprising a plurality of intermeshed loops, and an inlaid strand. The plurality of intermeshed loops are formed with a first yarn comprising a thermoplastic polymer material. The inlaid strand extends through at least a portion of the plurality of intermeshed loops along a first path passing therebetween. The plurality of intermeshed loops extend along courses that alternate behind and in front of the path of the inlaid strand.