Interlaced Knitted Footwear Upper Using Dual Tenacity Yarns

Solution Overview

Problem

Conventional knitted textiles for footwear uppers often compromise between breathability, lightweightness, and durability due to the complexity of knitting on multiple needle beds, which can result in less breathable and heavier textiles.

Innovation Solution

A knitted component for footwear uppers is developed using yarns of different tenacities with distinct knit stitch patterns, formed on a single needle bed. This approach creates interlaced knit structures that are breathable, lightweight, and strong, without the need for interlooping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple needle beds are used to knit layered constructions with different yarn types and stitch patterns, then flexibility in adjusting yarn and stitch types is improved, but the textile becomes less breathable and heavier due to additional knitted loops

Engineering Contradiction:

Improveflexibility in adjusting yarn and stitch typesVSAvoidbreathability

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The knitting machine is divided into two independent needle beds (first needle bed and second needle bed), each capable of knitting different yarn types and stitch patterns independently. This segmentation allows flexible adjustment of yarn and stitch types while avoiding the need for additional interlooping, thus maintaining breathability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines the knitting operations of multiple needle beds into a single integrated textile structure where the first and second knit structures are interlaced without additional interlooping. This merging approach achieves the flexibility of multiple yarn types while avoiding the harmful effect of reduced breathability.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If multiple needle beds are used to knit layered constructions, then flexibility in adjusting yarn and stitch types is improved, but the textile weight increases due to additional knitted loops

Engineering Contradiction:

Improveflexibility in adjusting yarn and stitch typesVSAvoidtextile weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The knitting machine is divided into two independent needle beds (first needle bed and second needle bed), each capable of knitting different yarn types and stitch patterns independently. This segmentation allows flexible adjustment of yarn and stitch types while avoiding the need for additional interlooping, thus maintaining breathability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines the knitting operations of multiple needle beds into a single integrated textile structure where the first and second knit structures are interlaced without additional interlooping. This merging approach achieves the flexibility of multiple yarn types while avoiding the harmful effect of reduced breathability.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If conventional knitting methods are used to provide containment around the foot, then durability is improved, but breathability and lightweightness are compromised

Engineering Contradiction:

Improvecontainment around footVSAvoidbreathability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The textile uses a composite construction with two different yarn types (first yarn and second yarn) having different tenacities, creating a knit structure that provides both durability for foot containment and breathability through the interlaced pattern without additional interlooping.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the textile can utilize different yarn types and stitch patterns optimized for specific functions - areas requiring durability for foot containment and areas requiring breathability, achieved through the flexible multi-yarn construction on separate needle beds.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250198059A1Interlaced knitted upper and methods of manufacture

Publication Date: 2025.06.19 NIKE INC

AI summary

Aspects herein are direct to, among other things, a knitted component, which may be incorporated into an upper for an article of footwear. The knitted component includes two interconnected knit structures. A first knit structure may form loops on a first set of wales and float across a second set of wales. A second knit structure may float across the first set of wales and form knit loops, tuck stitches, and held loops on the second set of wales. The two structures are not interlooped together, but are interconnected where the first yarn alternatively passes in front of and behind the second yarn. The first structure may be formed from a first yarn and the second structure may be formed from a second yarn, where the first yarn and the second yarn have different tenacities. The knit structures may incorporate various yarn types, knit stitch patterns, and/or constructions.