Knit Footwear Upper With Integrated Tensile Force Transfer
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Solution Overview
Problem
Conventional footwear uppers are complex, requiring multiple material elements that increase manufacturing time, cost, waste, and reduce recyclability, while also complicating the integration of desired properties like stretch-resistance, wear-resistance, flexibility, and comfort.
Innovation Solution
The footwear upper incorporates a textile component with a tensile element formed of unitary knit construction, which includes a knit element and tensile elements that are integrated through a knitting process, allowing for efficient force transfer and distribution across the upper, reducing the number of material elements and seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material elements are used in the upper, then desired properties like stretch-resistance, wear-resistance, flexibility, and comfort can be imparted to different areas, but manufacturing time, cost, and complexity increase
Solution Approach 1:
The patent merges multiple material elements into a single textile component formed from one piece of material. The textile component includes a textile element and integrated tensile elements that are joined together through a knitting process, eliminating the need for separate material elements and their associated joining operations.
Solution Approach 2:
The textile component serves multiple functions simultaneously: it provides stretch-resistance, wear-resistance, flexibility, and comfort across different areas of the upper. The tensile elements are integrated throughout the textile component to provide structural support and force distribution while maintaining the textile's inherent flexibility and comfort properties.
2Adaptability or versatility
If multiple material elements are joined together, then desired properties can be imparted to different areas, but manufacturing time and expense increase
Solution Approach 1:
The textile component is formed as a single integrated piece through a knitting process that combines the textile element and tensile elements into one continuous structure. This eliminates multiple joining operations and reduces manufacturing steps while maintaining all desired functional properties.
Solution Approach 2:
The knitting process itself creates the integrated textile component with embedded tensile elements, eliminating the need for separate joining operations. The structure is self-formed during manufacturing rather than requiring post-assembly joining operations.
3Adaptability or versatility
If multiple material elements are used, then desired properties can be imparted to different areas, but waste material accumulates to a greater degree
Solution Approach 1:
By forming the textile component from one piece of material through a knitting process, the design eliminates the waste that would result from cutting and joining multiple separate material elements. The integrated structure allows for efficient material utilization with minimal off-cut waste.
4Adaptability or versatility
If multiple material elements are incorporated into the upper, then desired properties can be imparted to different areas, but the upper becomes more difficult to recycle
Solution Approach 1:
The textile component is formed from a single material type through a knitting process, creating a homogeneous structure that is easier to recycle compared to multi-material constructions. The integrated tensile elements are formed from the same material as the textile element, eliminating the complexity of separating different materials for recycling purposes.
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
This design enhances manufacturing efficiency, reduces waste, and improves fit and comfort by distributing forces effectively, while maintaining flexibility and support during various activities.
Implementation Method 1
The tensile element is configured to transfer at least a portion of an input force applied to the first side of the upper across the heel region, to the lower portion of the upper on the second side
Implementation Method 2
the textile component can provide advantageous fit and flexibility for the wearer's foot
Data Source
AI summary
An article of footwear includes a textile component. The textile component of the upper includes a textile element and a tensile element. The tensile element defines a first segment disposed on a first side of the upper. The first segment of the tensile element is configured to attach the securement device to the textile element on the first side of the upper. The tensile element further includes a second segment that is disposed proximate the lower portion of the upper on the second side. The second segment is fixed relative to the lower portion of the upper on the second side. The tensile element further includes an intermediate segment that extends continuously from the first segment, across the heel region, to the second segment.