Knitted Footwear Net Layer for Containment and Weight Reduction
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Solution Overview
Problem
Conventional articles of footwear with knitted uppers face challenges in maintaining foot containment during movement, leading to performance and comfort issues. Additionally, post-knitting processes used to enhance containment and durability increase weight, production time, and reduce recyclability.
Innovation Solution
The article of footwear incorporates a knitted component comprising a knitted base layer and a knitted net layer securely attached to each other. The knitted net layer, formed with yarns defining a plurality of cells, provides containment without relying on post-knitting components, while inlaid strands offer additional support and containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-knitting components (synthetic leather textiles, laminate film layers) are added and secured to a knitted upper, then foot containment and durability are improved, but weight increases
Solution Approach 1:
The patent combines the knitted base layer and knitted net layer into a single integrated knitted component structure. The net layer is formed as part of the knitting process itself, with yarns defining cells that provide containment while remaining integrated with the base layer, eliminating the need for separate post-knitting components
Solution Approach 2:
The patent changes the structural parameters of the knitted material by incorporating a net layer with specific cell structures (open centers surrounded by yarn perimeters). This structural parameter change provides containment functionality inherently within the knitted fabric, replacing the need for additional heavy materials
2Reliability
If post-knitting components are added and secured through post-knitting processes, then foot containment and durability are improved, but production time increases
Solution Approach 1:
The patent performs the containment function through the knitting process itself rather than adding components afterward. The knitted net layer with its cell structure is formed during the initial knitting process, providing containment functionality before the upper is completed and assembled, thereby reducing subsequent production steps
Solution Approach 2:
The patent merges the containment function with the primary knitting process. The knitted component with its net layer structure is created as a single integrated element during knitting, combining structure formation and containment functionality into one process step rather than requiring separate post-knitting operations
3Reliability
If post-knitting components are added to a knitted upper, then foot containment and durability are improved, but recyclability is reduced
Solution Approach 1:
The patent uses homogeneous knitted material throughout the upper structure. Both the base layer and net layer are made from yarns that can be knitted together, creating a uniform material composition that is easier to recycle compared to composite structures with multiple different materials bonded together
Solution Approach 2:
The patent combines the containment function into the knitted material itself rather than adding separate components. This creates a unified structure made from a single material type (yarns), which maintains recyclability better than multi-material constructions that require separation and different recycling processes
Data Source
AI summary
Aspects herein are directed to, among other things, a knitted component for an article of footwear. The knitted component includes a knitted base layer secured to a knitted net layer. The knitted net layer may have a yarn defining cells with openings through which the knitted base layer is exposed. A thermoplastic polymer material, which may initially form yarn that forms the knitted net layer or the knitted base layer, may at least partially fuse the knitted base layer to the knitted net layer. In some aspects, the knitted component further includes one or more inlaid strands at least partially arranged between the knitted base and net layers. The inlaid strands may also include a thermoplastic polymer material that is at least partially melted during heating of the knitted component and, when cooled, fuses the inlaid strands to the knitted base layer and knitted net layer.