Knitted Footwear Upper with Thermoplastic Window Regions

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Solution Overview

Problem

Conventional footwear uppers lack the necessary combination of strength, water resistance, and aesthetic appeal while maintaining comfort and breathability, particularly in athletic footwear where durability and moisture management are crucial.

Innovation Solution

A knitted component comprising a first yarn with a lower melting temperature and a second yarn with a higher melting temperature, where the first yarn is fused to form translucent or semi-transparent window regions and surrounding areas, providing thermal bonding and structural reinforcement without the use of adhesives or stitching, and enhancing visual aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional footwear uppers are constructed to provide strength and water resistance, then durability is improved, but breathability and comfort deteriorate

Engineering Contradiction:

Improveupper strengthVSAvoidbreathability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The upper is constructed from a composite knitted material comprising thermoplastic polymer fibers mixed with other fibers. The thermoplastic fibers fuse during heating to create bonded regions that provide strength and water resistance, while non-fusing regions maintain porosity for breathability. This composite structure allows simultaneous achievement of durability and comfort.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The upper exhibits spatially varying properties through selectively fused regions. Bonded areas provide strength and water resistance where needed, while non-bonded areas maintain breathability and comfort. The pattern of fused and non-fused regions creates local quality variations that satisfy different functional requirements within the same upper structure.

Inventive Principle:

Principle #3Local quality

2Reliability

If thermoplastic yarn is fused to create bonded regions, then water resistance and structural integrity are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvewater resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The manufacturing process utilizes parameter changes by heating the knitted upper to a specific temperature range that melts the thermoplastic polymer fibers. This thermal parameter change causes the fibers to fuse and bond, creating water-resistant regions. The process then involves cooling to solidify the bonds. These parameter changes (heating and cooling) provide a relatively simple method to achieve complex bonding patterns without requiring multiple manufacturing steps.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple yarn types with different melting temperatures are used, then functional regions can be differentiated, but material selection and processing difficulty increase

Engineering Contradiction:

Improveregion differentiationVSAvoidmaterial processing ease

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The knitted upper incorporates yarns with different melting temperatures to create local quality variations. Regions containing lower melting temperature thermoplastic fibers are heated to fuse and provide bonding, while regions with higher melting temperature fibers remain unbonded to maintain breathability. This differentiation of material properties at local levels enables functional zoning within the upper structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The manufacturing process exploits parameter changes by controlling the heating temperature to selectively melt specific thermoplastic fiber types. By adjusting the temperature parameter, the process differentiates between yarn types based on their melting characteristics, enabling automatic region differentiation without complex material handling or additional processing steps.

Inventive Principle:

Principle #35Parameter changes

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 achieves a balance of strength, water resistance, and visual appeal while maintaining comfort and breathability, offering improved durability and moisture management in athletic footwear.

Implementation Method 1

the thermoplastic polymer material may be melted and/or softened to form the fused area when heated to a temperature at or above the melting point of the thermoplastic polymer material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

the thermoplastic polymer material may be melted and/or softened to form the fused area when heated to a temperature at or above the melting point of the thermoplastic polymer material and then pressed

Methodology Applied

Scientific EffectThermal bonding:

Implementation Method 3

Methodology Applied

Scientific EffectCooling and solidification: Freezing

Data Source

PatentUS12012675B2Knitted component comprising a window

Publication Date: 2024.06.18 NIKE INC

AI summary

The present disclosure provides a knitted component having a first yarn and a second yarn, where the first yarn comprises a thermoplastic material having a melting temperature. The knitted component includes window regions substantially or exclusively formed of the first yarn, such that melting the first yarn in these window regions form at least a semi-transparent window allowing a viewer to see through the knitted component.