Knit Heel Element with Zonal Rigidity and Cushioning

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Solution Overview

Problem

Traditional heel elements in footwear are often made from rigid materials, leading to discomfort due to sharp edges, increased manufacturing complexity and cost, and a higher carbon footprint.

Innovation Solution

A knit heel element with zonally varying amounts of cushioning and rigidity, achieved through different knit structures, yarn types, and processing techniques, allowing for integration into the upper without separate manufacturing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional rigid heel elements are used, then structural support is provided, but comfort deteriorates due to sharp edges

Engineering Contradiction:

Improvestructural supportVSAvoidcomfort

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The knit heel element incorporates zones with different knit structures where certain zones provide rigidity for structural support while other zones provide cushioning for comfort. This local differentiation allows the single component to simultaneously achieve both structural integrity and comfort without sharp edges.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heel element uses composite knit structures combining different yarn types and knit patterns within a single integrated component. The composite nature allows rigid zones for support and soft zones for comfort to coexist in one element that replaces traditional separate rigid and cushioning components.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If separate cushioning elements are added to heel elements, then comfort is improved, but manufacturing complexity increases

Engineering Contradiction:

ImprovecomfortVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The cushioning zones are integrated directly into the knit heel element through the knitting process itself, merging what were traditionally separate components (rigid heel element and separate cushioning elements) into a single integrated part. This eliminates the need for additional attachment steps and reduces manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The knitting machine directly produces the heel element with embedded cushioning zones in a single operation, allowing the manufacturing process to create both structural and comfort functions simultaneously without requiring external assembly operations or additional manufacturing steps.

Inventive Principle:

Principle #25Self-service

3Reliability

If multiple manufacturing steps are used for heel elements, then functional requirements are met, but production time increases

Engineering Contradiction:

Improvefunctional requirementsVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The cushioning zones are built into the heel element structure during the initial knitting process rather than being added afterward. This preliminary integration of comfort functions into the base manufacturing process eliminates subsequent assembly steps and reduces overall production time while maintaining all functional requirements.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If traditional heel elements with separate cushioning are manufactured, then performance requirements are met, but carbon footprint increases

Engineering Contradiction:

Improveperformance requirementsVSAvoidcarbon footprint

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

By combining the rigid heel element and cushioning elements into a single integrated knit component, the number of manufacturing steps and material layers is reduced. This merging decreases the overall material consumption and manufacturing energy requirements, thereby reducing the carbon footprint while still meeting all performance requirements for support and comfort.

Inventive Principle:

Principle #5Merging (Combining)

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 knit heel element enhances comfort, reduces manufacturing complexity and cost, and minimizes the carbon footprint by eliminating additional manufacturing steps and integrating components seamlessly into knit footwear.

Implementation Method 1

a first knit layer and a second knit layer that are integrally knitted with each other in a single knitting event

Methodology Applied

Scientific EffectKnitting (interlooping):

Implementation Method 2

Heat and pressure are applied to a first knit zone of the knit heel element

Methodology Applied

Scientific EffectThermal energy application: Heating

Data Source

PatentUS20250040650A1Knit element with cushioning and rigidity zones, uppers and footwear with the same, and methods of manufacturing the same

Publication Date: 2025.02.06 NIKE INC

AI summary

Knit elements, including knit heel elements, configured with cushioning and rigidity features, along with uppers and footwear having the same, and methods of manufacturing and integrating the same in footwear. The cushioning and rigidity features may be provided in a knit element by positioning cushioning yarns and yarns comprising a thermoplastic material in selected zones and/or knit layers. Heat and pressure may be selectively applied to knit zones to melt the thermoplastic material and form a thermoformed layer that has a desired degree of hardness and/or rigidity. The thermoformed layer can form at least part of an integrally knit heel-counter of an upper for an article footwear, e.g., without introducing separate components traditionally attached or integrated to form the heel-counter.