Knitted Footwear Upper with Floating Yarns
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Solution Overview
Problem
Conventional footwear manufacturing processes are inefficient and wasteful due to the use of multiple material elements in the upper, leading to increased waste and reduced recyclability, particularly in athletic footwear where multiple layers and stitching are required to achieve desired properties.
Innovation Solution
The use of knitted components with unitary knit construction for the upper, including compressible areas and flange areas, which are formed through circular or flat knitting processes, reducing the number of material elements and seams, and allowing for the incorporation of floating yarns to enhance compressibility and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple material elements are used in the upper to achieve desired properties (stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, moisture-wicking), then the functional performance of the footwear is improved, but the manufacturing complexity, waste, and expense increase
Solution Approach 1:
The patent merges multiple material elements into a single integrated knitted upper that provides stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, and moisture-wicking properties through a unified knitting structure with varied yarn compositions and knit patterns, eliminating the need for separate material layers and reducing manufacturing complexity
Solution Approach 2:
The knitted upper serves multiple functions simultaneously by incorporating different yarn types and knit structures within a single component, providing structural support, comfort, breathability, and durability all in one element rather than requiring separate specialized components
2Reliability
If multiple material elements are joined together with stitching or adhesive bonding to impart different properties to different areas, then the functional performance is improved, but the manufacturing time and expense increase
Solution Approach 1:
The patent combines multiple functional material elements into a single knitted upper constructed through knitting processes that integrate varied yarns and stitch patterns, eliminating the need for separate stitching or adhesive bonding operations and significantly improving manufacturing efficiency
3Reliability
If multiple material elements are cut and joined in a layered configuration, then the desired properties are achieved, but waste material accumulates to a greater degree
Solution Approach 1:
The patent merges multiple material functions into a single knitted upper that is constructed without cutting operations, using knitting processes to create the final shape and integrate different yarn types, thereby eliminating waste material that would normally result from cutting and joining separate layers
4Reliability
If the number and type of material elements incorporated into the upper increases, then the functional performance is improved, but the recyclability of the upper decreases
Solution Approach 1:
The patent combines multiple material elements into a single knitted upper constructed from yarns that can be recycled together as one component, simplifying the recycling process compared to separating and recycling multiple different material layers and types
Data Source
AI summary
A method of manufacturing a collar element for an article of footwear is disclosed. The method comprises knitting the collar element comprising a tubular structure defining an interior cavity and a plurality of floating yarns within the cavity. The method further comprises securing the collar element to an upper of the article of footwear. A method of manufacturing an upper for an article of footwear having a collar element is also disclosed.