Tubular Knitted Shoe Upper Integrally Formed Aperture
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Solution Overview
Problem
Current methods for producing knitted shoe uppers are limited in terms of comfort, fit, support, and breathability, and involve inefficient processes that result in unnecessary waste and additional steps, such as cutting collars and sealing edges, which restrict design possibilities.
Innovation Solution
The method involves creating a tubular knitted element with an integrally formed aperture using casting-off or binding-off techniques on a circular or flat knitting machine, allowing for reduced waste and efficient production, with the aperture serving for breathability and flexibility, and the use of different yarn thicknesses and types for varying support and comfort, along with melt and elastic yarns for reinforcement and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a collar opening is cut into an upper after knitting, then the aperture can be created for breathability and flexibility, but this produces unnecessary waste and requires an additional process step
Solution Approach 1:
The aperture is formed during the knitting process itself rather than being cut afterward. The knitting machine creates the opening as part of the tubular knitted element's construction, eliminating the need for subsequent cutting operations and preventing material waste.
Solution Approach 2:
The aperture creation is merged with the knitting process. The same knitting machine that forms the tubular knitted element also creates the aperture through selective casting-off or binding-off of stitches, combining two operations into one continuous process.
2Ease of operation
If a collar opening is cut into an upper after knitting, then the aperture can be created for breathability and flexibility, but this requires an additional process step in the production
Solution Approach 1:
The aperture is formed during the knitting process itself rather than being cut afterward. The knitting machine creates the opening as part of the tubular knitted element's construction, eliminating the need for subsequent cutting operations and preventing material waste.
Solution Approach 2:
The aperture creation is merged with the knitting process. The same knitting machine that forms the tubular knitted element also creates the aperture through selective casting-off or binding-off of stitches, combining two operations into one continuous process.
3Ease of operation
If different yarn thicknesses and types are used for varying support and comfort, then the comfort and functionality of the knitted upper can be improved, but the construction and design possibilities are currently limited
Solution Approach 1:
Different yarn types and thicknesses are used in different regions of the tubular knitted element. The knitting machine can selectively change yarns at specific locations to create zones with different properties - for example, thicker yarns for support in heel areas and thinner yarns for breathability in toe areas.
Solution Approach 2:
The invention combines multiple yarn types and thicknesses within a single knitted structure. This creates a composite material system where different yarns work together to provide varied functionality - elasticity, support, breathability, and comfort - within one integrated upper.
4Strength
If melt and elastic yarns are used for reinforcement and stability, then the support and stability of the shoe upper can be maintained, but the production process becomes more complex
Solution Approach 1:
Melt and elastic yarns are strategically placed in specific regions where reinforcement is needed. The knitting machine controls yarn selection to place these specialized yarns only in critical areas rather than throughout the entire upper, maintaining strength where needed while simplifying the overall production process.
Data Source
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AI summary
The invention concerns a shoe upper (40) comprising a tubular knitted element (10), wherein the tubular knitted element (10) comprises an integrally-formed aperture (11); wherein the aperture (11) is formed by casting-off or binding-off at least one stitch, and wherein the aperture (11) comprises at least a first width (wi).