Knitted Footwear Sole With Integrated Cleats and Fewer Joints

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Solution Overview

Problem

Conventional articles of footwear require multiple components with different properties and characteristics, leading to assembly challenges, premature failure, and increased waste due to complex construction, which affects manufacturing efficiency and recyclability.

Innovation Solution

A sole system for footwear incorporating a knitted component of unitary knit construction, including a knitted outsole and upper, formed through vacuum forming around an insert member with protuberances to create cleat members, reducing the need for separate components and joints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple components with different properties are used in footwear construction, then the desired functional properties and characteristics can be achieved, but assembly complexity increases and premature failure occurs at joints

Engineering Contradiction:

Improvefunctional propertiesVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the upper and outsole into a single knitted component with unitary construction, eliminating the need for separate components and joints. This integration maintains different functional properties (upper coverage, outsole traction) while reducing assembly complexity to a single piece manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The knitted component serves multiple functions simultaneously: it provides upper coverage, outsole traction, and structural support all in one element. The vacuum-formed knit structure integrates the functionality of separate components into a universal multi-functional piece.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple components are assembled together, then functional requirements can be met, but assembly errors increase and manufacturing efficiency decreases

Engineering Contradiction:

Improvefunctional requirementsVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

By combining multiple components into a single knitted component, the patent reduces the number of assembly steps and eliminates assembly errors, thereby improving manufacturing efficiency and productivity while still meeting functional requirements through integrated design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The knitted component is pre-formed with vacuum forming around an insert member that defines the final shape and features, including cleat members, before assembly. This preliminary action of forming all features in one piece eliminates subsequent assembly operations.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple separate components are used, then functional properties can be achieved, but material waste increases and recyclability decreases

Engineering Contradiction:

Improvefunctional propertiesVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent merges multiple components into a single knitted component, reducing the total amount of material used and eliminating waste from multiple separate material elements. This integration improves recyclability by reducing the complexity of material separation and processing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The unitary knit construction minimizes material waste during manufacturing, and the simplified structure facilitates material recovery and recycling by reducing the number of different materials that need to be separated and processed.

Inventive Principle:

Principle #34Discarding and recovering

4Ease of manufacture

If joints between components are used, then assembly is necessary to create footwear, but durability decreases due to wear at joints

Engineering Contradiction:

Improveassembly necessityVSAvoiddurability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent eliminates joints by merging the upper and outsole into a single knitted component, thereby improving durability by removing the weak points where wear occurs at joints, while still maintaining the necessary structural functionality.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach simplifies assembly, reduces assembly errors, enhances durability by eliminating joints, and improves recyclability by minimizing material elements while providing desired properties and traction.

Implementation Method 1

vacuum forming the knitted component using an insert member to form the knit sole system

Methodology Applied

Scientific EffectVacuum forming: Vacuum

Data Source

PatentUS20260101968A1Sole system for an article of footwear incorporating a knitted component

Publication Date: 2026.04.16 NIKE INC

AI summary

A sole system for an article of footwear may include one or more of the following: a knitted component including an underfoot portion having a plurality of knitted cleat members; and an outsole cover assembly having a plurality of recesses corresponding to the plurality of knitted cleat members of the knitted component. The outsole cover assembly may substantially cover the underfoot portion of the knitted component.