Knit Footwear Upper with TPU Overlay and Edge Piping
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Solution Overview
Problem
Footwear articles with knit uppers face challenges such as lack of structure, insufficient lateral support, and susceptibility to degradation, particularly in areas like the ankle region, where flexibility is desired but structural integrity is needed.
Innovation Solution
Incorporating unitary construction straps with edge piping and overlays made of thermoplastic polyurethane (TPU) or polyurethane (PU) to provide structural support while maintaining flexibility and comfort, with the overlays being glued, sewn, or molded onto the knit upper to prevent distortion and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If knit upper material is used for flexibility and comfort, then comfort and flexibility are improved, but structural integrity and lateral support deteriorate
Solution Approach 1:
The patent combines knit upper material with plastic overlay material to create a composite structure. The knit material provides flexibility and comfort, while the plastic overlay provides structural integrity and lateral support. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The plastic overlay is applied selectively to specific regions of the knit upper where structural support is needed, such as the eyelet regions and lateral areas. This local reinforcement maintains flexibility in non-overlay areas while providing strength where required.
2Ease of operation
If knit upper material is used for flexibility, then comfort is improved, but susceptibility to degradation worsens
Solution Approach 1:
The combination of knit material with plastic overlay creates a composite structure where the plastic layer protects the knit material from degradation. The overlay acts as a protective barrier that reduces wear and tear on the more susceptible knit fabric while maintaining its flexibility.
Solution Approach 2:
The plastic overlay is applied in advance to protect the knit upper from future degradation. This protective layer prevents direct exposure of the knit material to harmful factors such as friction, moisture, and UV radiation before degradation can occur.
3Ease of operation
If openings are formed in knit upper, then ventilation is improved, but structural stability worsens
Solution Approach 1:
The plastic overlay reinforces the areas around the openings in the knit upper. This composite structure allows the openings to provide ventilation while the surrounding plastic material maintains structural stability and prevents the openings from compromising the overall integrity of the upper.
Solution Approach 2:
The plastic overlay is strategically positioned around the openings to provide localized reinforcement. This allows maximum ventilation through the openings while concentrating structural support precisely where the openings create potential weakness points.
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 solution enhances the structural integrity and durability of knit uppers by providing additional support and preventing degradation, while maintaining the comfort and flexibility benefits of the knit material, thus improving the overall fit and longevity of the footwear.
Implementation Method 1
The overlays may be coupled to the knit upper via any one or more of gluing, sewing, or direct molding of the overlays onto the knit upper
Implementation Method 2
The overlays may be coupled to the knit upper via any one or more of gluing, sewing, or direct molding of the overlays onto the knit upper
Data Source
AI summary
A footwear article, comprising a single-piece knit upper that includes a medial portion and a plurality straps. The footwear article may further comprise one or more openings formed into the knit upper, a perimeter of the one or more openings defined at least in part by an edge of the knit upper, and a pipe edging may be fixed to the edge of the knit upper defining the openings. Further, a sole may be coupled to the knit upper. In at least one example, the footwear article may additionally comprise a lacing system that includes a plurality of cords, and strap of the knit upper may have a separate cord section of the lacing system attached therein. A plastic overlay may be positioned over the cords of the lacing system that are attached to the knit upper, in at least one example.