Multi-Layer Knit Footwear Upper Without a Strobel
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Solution Overview
Problem
Footwear components such as the strobel increase the height and weight of articles of footwear, necessitating additional manufacturing steps and costs.
Innovation Solution
A knitted component with multiple layers, including a first knit layer and a second knit layer, where the layers are fused using a thermoplastic material to form a thermoplastic layer, eliminating the need for a strobel and reducing manufacturing complexity and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a strobel is included to provide structural connection between upper and sole structures, then the structural integrity and connection strength are improved, but the height and weight of the footwear increase
Solution Approach 1:
The patent combines the strobel layer with the insole layer into a single integrated insole-strobel component. This merging eliminates the need for separate strobel and insole layers, reducing overall footwear weight and height while maintaining the structural connection function between the upper and sole structures through the integrated component's design
2Stability of the object's composition
If a strobel is included to connect upper and midsole/outsole, then the structural stability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the strobel and insole into a single integrated component that performs both structural connection and foot support functions. This reduces the number of separate parts and assembly steps, thereby decreasing manufacturing complexity while maintaining structural stability through the integrated design
Solution Approach 2:
The integrated insole-strobel component performs multiple functions simultaneously: it provides structural connection between upper and sole structures, offers foot support, and enables direct attachment of the midsole to the upper. This multi-functionality eliminates the need for separate strobel and insole components, simplifying manufacturing while maintaining structural stability
3Reliability
If a strobel is included to provide sufficient structure for connection, then the connection reliability is improved, but the footwear height increases
Solution Approach 1:
The patent combines the strobel and insole layers into a single integrated component with optimized thickness. This integration allows the component to provide sufficient structural connection reliability while minimizing the overall height contribution, as the merged structure can be designed with reduced thickness compared to separate layers
4Reliability
If multiple separate components are used including strobel, then the functional performance is improved, but the number of manufacturing steps increases
Solution Approach 1:
The patent merges the strobel and insole into a single integrated component manufactured in one piece. This eliminates the need for separate manufacturing and assembly steps for these components, thereby improving manufacturing efficiency and productivity while maintaining the functional performance through the integrated design that provides both structural connection and foot support
5Duration of action of stationary object
If a strobel is included to ensure sufficient structure, then the durability is improved, but the weight and height increase
Solution Approach 1:
The patent combines the strobel and insole into a single integrated component with optimized material distribution and thickness. This integration maintains the durability function by providing sufficient structural connection strength while reducing the overall weight compared to separate strobel and insole components
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 provides a thinner, lighter, and more durable footwear upper with enhanced containment and abrasion resistance, while simplifying manufacturing processes and increasing recyclability.
Implementation Method 1
heating and melting the thermoplastic material to form the thermoplastic layer
Implementation Method 2
the layers are fused using a thermoplastic material to form a thermoplastic layer
Data Source
AI summary
Uppers, articles of footwear, and methods of manufacturing uppers and articles of footwear. In aspects, an upper includes a first knit layer and a second knit layer joined by a thermoplastic polymer layer. The first knit layer may include a yarn with a thermoplastic polymer material that is melted and forms the thermoplastic polymer layer that at least partially encapsulates the yarn of the second knit layer and remaining yarn component(s) of the first knit layer. The first knit layer may have a different knit density than the second knit layer. The first knit layer and the second knit layer may both form sock-like constructions and be formed from opposite ends of a tubular knit structure. Knitted components with single or multi-layer knit structures that are manipulated to form an upper are also disclosed.