Knitted Footwear Component with Zonal Stretch Limiter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional footwear manufacturing processes are inefficient and wasteful due to the use of multiple material elements, leading to increased waste and reduced recyclability, as well as complexity in cutting and joining processes.
Innovation Solution
A knitted component with a unitary knit construction and integrated tensile strands that provide stretchability and adjustability, allowing for controlled stretching and reduced material usage, thereby simplifying the manufacturing process and enhancing recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material elements are used in the upper to impart different properties to different areas, then functional performance is improved, but manufacturing complexity and waste increase
Solution Approach 1:
The patent combines multiple material elements into a single knitted component formed from a single yarn that contains multiple functional sections. Each section of the yarn provides different properties (elasticity, wear-resistance, air-permeability, compressibility, comfort, moisture-wicking) without requiring separate material elements to be cut and joined, thus reducing manufacturing complexity while maintaining functional performance
Solution Approach 2:
The single yarn used in the knitted component is designed to perform multiple functions simultaneously. The yarn contains different sections with different properties that can be distributed to different areas of the upper, allowing one material element to replace multiple specialized material elements while maintaining adaptability and versatility
2Adaptability or versatility
If multiple material elements are used in the upper to impart different properties to different areas, then functional performance is improved, but waste material accumulates
Solution Approach 1:
The patent combines multiple material elements into a single knitted component formed from a single yarn that contains multiple functional sections. Each section of the yarn provides different properties (elasticity, wear-resistance, air-permeability, compressibility, comfort, moisture-wicking) without requiring separate material elements to be cut and joined, thus reducing manufacturing complexity while maintaining functional performance
Solution Approach 2:
By using a single continuous yarn instead of multiple separate material elements that require cutting, the patent eliminates cutting waste. The yarn is knitted continuously without the need to discard off-cuts from multiple material pieces, thereby reducing substance loss during manufacturing
3Adaptability or versatility
If multiple material elements are joined together to form the upper, then different properties are imparted to different areas, but manufacturing time and expense increase
Solution Approach 1:
The patent combines multiple material elements into a single knitted component formed from a single yarn that contains multiple functional sections. Each section of the yarn provides different properties (elasticity, wear-resistance, air-permeability, compressibility, comfort, moisture-wicking) without requiring separate material elements to be cut and joined, thus reducing manufacturing complexity while maintaining functional performance
Solution Approach 2:
The yarn is pre-engineered with multiple functional sections before knitting begins. This preliminary preparation of the yarn with integrated multi-functionality eliminates the need for subsequent joining operations, reducing manufacturing time and expense while maintaining the ability to impart different properties to different areas of the upper
4Adaptability or versatility
If more material elements are incorporated into the upper to enhance functionality, then performance is improved, but recyclability decreases
Solution Approach 1:
The patent combines multiple material elements into a single knitted component formed from a single yarn that contains multiple functional sections. Each section of the yarn provides different properties (elasticity, wear-resistance, air-permeability, compressibility, comfort, moisture-wicking) without requiring separate material elements to be cut and joined, thus reducing manufacturing complexity while maintaining functional performance
Solution Approach 2:
The patent uses a single yarn throughout the knitted component, creating a more homogeneous structure compared to multiple different material elements. This homogeneity makes the upper easier to recycle as it consists of fewer different material types, while the yarn itself is engineered with varying sections that provide different functional properties
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 reduces waste, increases manufacturing efficiency, and improves the comfort and fit of footwear by using a fewer number of material elements, while allowing for customizable stretchability and support across different regions of the foot.
Implementation Method 1
a stretch limiter element (180) of the tensile strand (150). The stretch limiter element (180) limits stretching of the knit element (131)
Data Source
Figure 1~4
Figure 5
Figure 6
AI summary
An article includes a knitted component. The knitted component includes a knit element that is configured to stretch between a neutral position and a stretched position. The knitted component also includes a tensile strand. The tensile strand is at least partially inlaid within the knit element. The tensile strand includes a portion that is arranged as a stretch limiter element that is configured to move between a slack position and a taut position as the knit element moves between the neutral position and the stretched position. The stretch limiter element is in the slack position when the knit element is in the neutral position, and the stretch limiter element is in the taut position when the knit element is in the stretched position to prevent stretch of the knit element beyond the stretched position.