Knitted component having a foam surface feature
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Solution Overview
Problem
Current knitting technologies face limitations in creating knitted components with integrated foam structures that offer enhanced properties such as elasticity, breathability, and aesthetic appeal, particularly in footwear applications, where weight reduction and customizable surface features are desired.
Innovation Solution
Incorporating a foamable yarn with a thermoplastic polymer and blowing agent into the knitting process, allowing for the formation of multicellular foam structures within the knitted component, which can be strategically exposed or inlaid to create foam protrusions or surfaces, thereby enhancing the material's properties and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional knitting processes are used to create knitted components, then the manufacturing process is simple and well-established, but the components lack integrated foam structures with enhanced elasticity, breathability, and customizable surface features
Solution Approach 1:
The knitting process is segmented into multiple operational phases within a single continuous cycle: (1) forming knit loops with first yarn, (2) inlaying foamable yarn between specific loops, (3) tucking second yarn to secure the foamable yarn in position. This segmentation allows complex multi-material structures to be created through systematic, repeatable steps rather than requiring complex equipment modifications.
Solution Approach 2:
The invention combines multiple materials with different properties into a single knitted component: a first yarn for structural knit loops, a foamable yarn containing blowing agent for foam formation, and optionally a second yarn for securing. This composite approach integrates foam structures directly into the knitted fabric, providing enhanced elasticity, breathability, and customizable surface features while maintaining structural integrity.
2Reliability
If foamable yarn is inlaid within knit loops to create foam structures, then elasticity and breathability are enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The foamable yarn is inlaid into the knitted component in its unfoamed state during the knitting process, before the actual foam expansion occurs. The yarn is carefully positioned between specific knit loops and secured with tuck stitches, ensuring proper placement and structural integration. Only after the knitted component is formed does the foamable yarn expand when exposed to heat or moisture, creating the foam structures that enhance elasticity and breathability while maintaining structural integrity.
Solution Approach 2:
The invention utilizes parameter changes in the foamable yarn's physical state to achieve the desired effect. The foamable yarn contains a blowing agent that remains dormant during knitting, then activates upon exposure to heat or moisture, causing the yarn to expand and form foam structures. This parameter change from compact yarn to expanded foam provides enhanced elasticity and breathability without compromising the structural integrity established during the knitting process.
3Shape
If foam protrusions are created on the knitted surface, then aesthetic appeal and functional benefits are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention applies local quality by selectively inlaying the foamable yarn at specific locations within the knitted component rather than uniformly throughout. The foamable yarn is positioned between particular knit loops where foam protrusions are desired, and the knitting machine can adjust the inlay pattern to create different surface features in different areas. This localized approach allows precise control over where foam protrusions form, enabling customization of surface features for aesthetic appeal and functional benefits while managing manufacturing precision requirements through pattern design rather than tight tolerances.
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 integration of foamable yarns enables the creation of lightweight knitted components with improved elasticity, breathability, and customizable surface features, such as foam protrusions, that provide both functional benefits like cushioning and aesthetic appeal, while maintaining structural integrity.
Implementation Method 1
the foamable material expands when exposed to heat or moisture, forming multicellular foam structures
Implementation Method 2
the foamable material includes a blowing agent and a thermoplastic polymer
Data Source
AI summary
A knitted component may include a first area, where the first area includes a plurality of knit loops comprising a first yarn. The knitted component may also include a second yarn at least partially inlaid within the first area of the knitted component such that the second yarn extends between at least a first loop and a second loop of the plurality of knit loops. The second yarn may have a foamable material comprising a blowing agent and a thermoplastic polymer.