Integrally Knitted Eyelets for Shoe Upper Manufacturing
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Solution Overview
Problem
Existing shoe upper manufacturing methods require additional manufacturing steps to create eyelets, such as punching holes or attaching additional elements, which increase production complexity and costs.
Innovation Solution
Integrally knitted eyelets are formed using consecutive lines of loops that are interlooped within the set but not with external lines, allowing for eyelets to be created directly during the knitting process without additional steps, using partial knitting techniques and potentially incorporating fusible or elastic yarns for stability and shape retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If eyelets are provided as punched holes or additional elements attached to the shoe upper, then the shoe upper can receive laces properly, but additional manufacturing steps are required increasing production complexity
Solution Approach 1:
The patent merges the eyelet structure directly into the knitted upper by forming integral eyelet structures as part of the knitting process itself. The eyelets are created by specific needle arrangements and yarn paths during knitting, eliminating the need for separate eyelet components or post-knitting hole punching operations. This integration of the eyelet function into the base structure resolves the contradiction by reducing manufacturing steps while maintaining proper lace reception capability.
2Productivity
If additional elements are attached to create eyelets, then proper lace guidance is achieved, but production time and costs increase
Solution Approach 1:
The patent implements preliminary action by pre-forming the eyelet structures during the knitting process itself rather than adding them later. The knitting machine is programmed to create eyelet openings and reinforcement structures as part of the initial upper fabrication. This advance formation of eyelets eliminates subsequent attachment operations, thereby improving production efficiency while managing process complexity through integrated machine control.
3Strength
If punched holes are used for eyelets, then lace reception is enabled, but structural strength and tear resistance are reduced
Solution Approach 1:
The patent employs composite material strategies by incorporating reinforcement yarns or different yarn compositions in the eyelet regions during knitting. The eyelet structures are formed using yarns with enhanced strength properties or multi-component yarn constructions that provide both the necessary opening for lace passage and superior tear resistance. This composite approach maintains structural strength while preserving the simplicity of the integrated knitting process.
4Adaptability or versatility
If additional elements are attached for eyelets, then proper lace guidance is achieved, but the shoe upper loses uniform stretchability
Solution Approach 1:
The patent applies local quality by creating eyelet structures with localized structural characteristics only where needed for lace guidance, while maintaining the uniform stretchable knit structure in all other regions. The knitting process is programmed to modify yarn paths, needle selections, or stitch patterns specifically at eyelet locations to create openings and reinforcement, without affecting the overall fabric continuity and elasticity. This localized modification preserves the shoe upper's adaptability and stretchability while providing necessary lace reception functionality.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The present invention relates to a shoe upper (10) comprising a knitted component (11) comprising a plurality of integrally knitted lines of loops comprising a set of consecutive lines (31), wherein each line (31) in the set of consecutive lines (31) comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line (31) and not interlooped with loops of a line (32) which is not contained in the set, and wherein the set of consecutive lines (31) forms at least a portion of an eyelet (15) which is configured to receive a lace (16).