Knit Footwear Upper With Invertible Cuff and Ankle Support
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Solution Overview
Problem
Conventional footwear uppers lack innovative design features that provide both functional support and aesthetic appeal, particularly in athletic footwear, while also ensuring a secure and comfortable fit.
Innovation Solution
The development of a knit element for footwear uppers featuring a ribbed knit structure with elastic yarns, hidden and revealed yarns for visual effects, and a cuff that can invert for different functions, along with a multi-layer knit structure for enhanced support and breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional upper structure is used, then the footwear provides basic coverage and support, but it lacks innovative design features and aesthetic appeal
Solution Approach 1:
The upper is divided into multiple knit elements with different knit structures (first knit structure, second knit structure, third knit structure) that can be selectively applied to different regions. This segmentation allows design versatility without requiring a completely complex new structure, as each segment can be independently designed and combined.
Solution Approach 2:
The cuff component serves multiple functions: it provides ankle support, enables dynamic visual effects through hidden/revealed yarns, and can be configured in different states (inverted or non-inverted). This multi-functionality increases design versatility without proportionally increasing overall complexity.
2Reliability
If a simple knit structure is used, then the manufacturing process is easier, but the footwear lacks enhanced support and breathability
Solution Approach 1:
Different knit structures are applied to different regions of the upper. The first knit structure provides breathability in certain areas, the second knit structure provides support in others, and the ribbed knit structure with elastic yarns provides ankle support where needed. This local differentiation achieves enhanced support and breathability without requiring the entire upper to be complex.
Solution Approach 2:
The upper combines multiple knit structures and yarn types (including elastic yarns) into a single integrated component. This composite approach provides enhanced support and breathability through material diversity while maintaining manufacturing efficiency by knitting the entire upper as a single piece on a knitting machine.
3Adaptability or versatility
If a static cuff design is used, then the manufacturing process is simpler, but the footwear lacks dynamic visual effects and adaptability
Solution Approach 1:
The cuff incorporates hidden yarns and revealed yarns that create dynamic visual effects as the cuff moves or stretches. The cuff can also be configured in different states (inverted or non-inverted), providing adaptability. These dynamic features are achieved through knit structure design rather than mechanical components, avoiding excessive complexity.
4Strength
If uniform material distribution is used, then the manufacturing process is easier, but the footwear lacks enhanced support in specific regions
Solution Approach 1:
The first side of the upper is formed with at least 50% more material than the second side, with the first area (toe region) receiving additional material for enhanced support. This local material differentiation provides regional support where needed while maintaining relatively simple manufacturing through the knitting process.
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 element provides enhanced ankle support, breathability, and dynamic visual effects, while ensuring a secure and comfortable fit, making it suitable for various types of footwear, including athletic and non-athletic shoes.
Implementation Method 1
The ribbed knit structure may include a yarn formed of an elastic material
Data Source
Figure 1
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Figure 3A~3D
AI summary
In one aspect, the present disclosure provides an upper for an article of footwear and a method of manufacturing the same. The upper may include a knit element having a first area, the first area including a first side and a second side opposite the first side. The first side may be formed of at least 30% more material than the second side such that the first area is configured to curve convexly away from the first side.