Knit Wingtip Shoe Upper with Integrated Broguing
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Solution Overview
Problem
Existing shoe manufacturing methods fail to produce seamless, unitary knit uppers with integrated design elements like wingtip patterns and broguing, which compromise on aesthetics and structural integrity.
Innovation Solution
A method of knitting a shoe upper using a knitting machine to create a unitary one-piece construction with distinct regions, including heel, midfoot, metatarsal, ball, and toe areas, seamlessly integrating wingtip patterns and broguing lines formed during the knitting process, utilizing different knit structures and yarn combinations for enhanced durability and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional shoe manufacturing methods are used to create uppers with wingtip patterns and broguing, then these design elements can be achieved, but the upper requires multiple separate pieces that need stitching and post-processing, compromising structural integrity and aesthetic appeal
Solution Approach 1:
The patent merges multiple separate upper pieces into a single integrated knitted upper that is formed as one continuous piece during the knitting process. The wingtip patterns and broguing lines are incorporated directly into the knit structure through programmed needle selection, eliminating the need for separate pieces, stitching, and post-processing operations. This single-piece construction inherently improves structural integrity while the knitting process itself provides the manufacturing capability.
Solution Approach 2:
The patent applies preliminary action by forming the wingtip patterns and broguing lines during the initial knitting process itself, rather than adding them later through post-processing. The knitting machine program pre-defines the stitch patterns and hole formations (broguing) as the upper is being constructed, so these design elements are built-in from the start rather than requiring subsequent manufacturing steps.
2Shape
If traditional manufacturing methods with multiple pieces and stitching are used, then production can proceed with standard processes, but the aesthetic appeal and seamless integration of design elements are compromised
Solution Approach 1:
The patent combines multiple manufacturing operations (knitting, pattern formation, broguing hole creation) into a single integrated process. The knitting machine simultaneously produces the upper structure and incorporates the wingtip patterns and broguing lines through programmed stitch selection, eliminating separate operations for each design element and achieving both aesthetic appeal and manufacturing efficiency.
Solution Approach 2:
The patent changes the manufacturing parameters by using a computer-controlled knitting machine that can programmatically vary stitch types, needle selection, and yarn insertion patterns during the knitting process. This allows dynamic parameter changes to create different regions (wingtip patterns, broguing lines, structural areas) within a single continuous operation, achieving complex aesthetics without sacrificing productivity.
3Ease of manufacture
If separate pieces are used to create wingtip patterns and broguing, then these design elements can be added, but additional stitching and post-processing are required, increasing manufacturing steps
Solution Approach 1:
The patent merges the creation of wingtip patterns, broguing lines, and upper structure into a single knitting operation. The knitting machine program controls which needles are activated to form different patterns and holes directly during the knitting process, consolidating what would traditionally require multiple separate manufacturing steps into one integrated process.
Solution Approach 2:
The knitting machine performs self-service by automatically forming the broguing holes and wingtip patterns through programmed needle selection without requiring external intervention or separate operations. The machine itself creates the design elements as part of the knitting process, eliminating the need for additional post-processing steps that would otherwise be required.
Data Source
AI summary
A shoe includes a knit upper and a sole secured to the knit upper. The knit upper has a first area of a jersey stitch knit and a second area of a pointelle stitch knit, a boundary line between the first and second areas, and a line of broguing adjacent the boundary line.