Knitted Component with Foamable Yarn for Lightweight Cushioning
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Solution Overview
Problem
Current knitting technologies face challenges in incorporating foamable materials into knitted components, particularly in footwear, to enhance cushioning and aesthetics while maintaining structural integrity and weight reduction.
Innovation Solution
Incorporating a foamable yarn with a thermoplastic polymer and blowing agent into knitted components, either through inlaying between loops or exposing on the surface, which expands post-knitting to form multicellular foam protrusions or surfaces, using a combination of chemical and physical blowing agents and controlled processing to achieve desired foam structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foamable material is incorporated into knitted components to enhance cushioning, then comfort and cushioning performance are improved, but weight and structural complexity increase
Solution Approach 1:
The patent utilizes foamable material that forms a porous, cellular structure when activated. This foam structure provides cushioning through its compressible cellular architecture while maintaining low density. The foamable yarn is integrated into the knitted fabric, and upon activation (typically through heat or moisture), it expands to form a lightweight foam structure that delivers cushioning performance without significant weight increase.
Solution Approach 2:
The patent creates a composite structure by integrating foamable material (containing thermoplastic polymer and blowing agent) with knitted fabric. This composite approach combines the structural integrity and breathability of the knitted textile with the cushioning properties of the foam, achieving weight reduction compared to using solid foam or dense materials alone.
2Strength
If foamable yarn is inlaid within knitted loops to maintain structural integrity, then fabric strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into a single yarn by integrating foamable material (thermoplastic polymer with blowing agent) directly into the yarn structure. This foamable yarn is then inlaid within the knitted loops using standard knitting machine infrastructure, merging the reinforcement function with the cushioning function in one integrated component rather than requiring separate layers or complex assembly processes.
Solution Approach 2:
The foamable yarn serves multiple functions simultaneously: it acts as a reinforcing element within the knitted structure, provides cushioning when activated, and can be processed using existing knitting machine feeders with minimal modification. This multi-functionality reduces the need for additional components or specialized manufacturing equipment.
3Shape
If foam protrusions are formed on the surface to enhance aesthetics and grip, then surface characteristics are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent controls foam protrusion formation by adjusting processing parameters such as activation temperature, exposure time, and blowing agent concentration. By carefully controlling these parameters, the foam expands to form protrusions of desired size and shape on the fabric surface, achieving aesthetic and functional goals while managing manufacturing precision requirements through parameter optimization rather than complex tooling.
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 allows for the creation of lightweight, breathable, and aesthetically enhanced knitted components with improved cushioning and surface characteristics, such as foam protrusions, that maintain structural integrity and can be tailored for specific functions like grip or comfort.
Implementation Method 1
the second yarn includes a foamable material that expands post-knitting to form a multicellular foam
Implementation Method 2
a foamable material that expands post-knitting to form a multicellular foam, using a combination of chemical and physical blowing agents and controlled processing
Data Source
Figure 1
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AI summary
A knitted component (200), comprising a first area having a first surface (112) at least partially formed by a knit course having a plurality of loops formed by a first yarn, and a multicellular foam material at least partially surrounding the first yarn in the first area, where the multicellular foam material forms a protrusion (212) extending from the first surface (112). Also a method of making the knitted component (200) comprising providing a foamable knitted component (100) including: at least one foamable yarn comprising a first thermoplastic material and a blowing agent, and a plurality of first yarns, and processing the foamable yarn to form the multicellular foam material.