Integral Knit Ankle Cuff Upper for Seamless Foot Entry and Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional footwear uppers are formed from multiple material elements, each imparting different properties, leading to inconsistencies in flexibility, air-permeability, and wear-resistance, and lack a seamless, unitary construction that provides optimal comfort and support.
Innovation Solution
A knitted component with an integral knit ankle cuff is used, forming a one-piece element that includes a foot region and an ankle region, featuring a unitary knit construction, stretch padding zones, and tied-lace receiving apertures, enhancing comfort and support through seamless integration and adjustable fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional footwear uppers are composed of multiple material elements that require stitching or bonding, then the upper can provide different properties (wear-resistance, flexibility, air-permeability) in different areas, but the construction becomes cumbersome and lacks seamless integration
Solution Approach 1:
The patent merges multiple material elements into a single knitted component that is formed in one continuous knitting process. The knitted component integrates the upper, ankle cuff, and tongue into one seamless piece, eliminating stitching and bonding operations while maintaining area-specific properties through selective yarn placement and knitting pattern variation during manufacturing
Solution Approach 2:
The knitted component incorporates local quality by using different yarn types and knitting structures in different regions of the same component. The ankle cuff region uses a first yarn type with specific properties, while the foot region uses a second yarn type, allowing each area to have optimized properties without requiring separate material pieces
2Reliability
If the upper extends upward and around the ankle to provide support, then ankle support is enhanced, but the entry and removal of the foot becomes more difficult
Solution Approach 1:
The ankle cuff is designed with dynamic properties through the selection of elastic yarn types and knit structures that allow the material to stretch and recoil. This enables the ankle cuff to expand temporarily for easy foot insertion and then contract to provide continuous support around the ankle during wear
Solution Approach 2:
The patent changes the physical parameters of the ankle cuff region by selecting yarns with specific elastic properties and knitting densities that differ from the foot region. This creates a gradient of stiffness and elasticity that facilitates easy entry while maintaining support, with the ankle cuff being more compliant than traditional rigid ankle supports
3Adaptability or versatility
If various material elements are joined with adhesive or stitching, then the upper can be constructed with different functional zones, but the manufacturing process becomes more time-consuming and complex
Solution Approach 1:
The invention combines multiple functional zones (upper, ankle cuff, tongue) into a single knitted component manufactured in one continuous process. The knitting machine produces the entire assembly without interruption, eliminating the need for separate manufacturing and assembly operations for each component
Solution Approach 2:
The knitting process performs preliminary action by pre-forming the entire upper assembly with all necessary structural features, openings, and reinforcements during the single knitting operation. This eliminates subsequent assembly steps and post-processing operations that would otherwise be required to join separate components
Data Source
AI summary
An article of footwear with a knitted component including an upper and an integral knit ankle cuff is provided. The upper and the ankle cuff are formed as a one-piece knit element. The knit element forms a portion of an exterior surface of the upper and an opposite interior surface of the upper, with the interior surface forming a void for receiving a foot. The ankle cuff is formed of unitary knit construction with the upper as a one-piece knit element and extends above a throat area of the upper. The ankle cuff includes malleolus zones on medial and lateral sides to correspond with the ankle bones of a wearer. The knit component further incorporates features to assist with providing entry for a foot of a wear, providing comfort to a wearer, and to assist with orientation of the upper of the article of footwear when being worn.