Knitted Textile Emblem With Spacing for Footwear Comfort
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Solution Overview
Problem
Existing textile manufacturing processes require separate machines for knitting and embroidery, leading to inefficiencies and increased waste, and embroidered elements often compromise comfort and durability in footwear applications.
Innovation Solution
A textile component is formed as a single-piece knitted structure with integrated embroidery and cushioning, using a single knitting process that incorporates a spacing element between layers to separate the embroidery from the wearer's foot, enhancing comfort and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate machines are used for knitting and embroidery, then embroidery quality can be maintained, but manufacturing efficiency decreases and waste increases
Solution Approach 1:
The patent combines the knitting and embroidery processes into a single integrated machine operation. The embroidery machine is configured to both knit the base textile layer and embroider the emblem in one continuous process, eliminating the need for separate knitting and embroidery machines. This merging of processes directly addresses the technical contradiction by improving manufacturing efficiency while maintaining embroidery quality through the unified machine system.
Solution Approach 2:
The embroidery machine is designed with multi-functionality, serving both as a knitting machine for creating the base textile layer and as an embroidery machine for adding the emblem. This universal device performs multiple functions that previously required separate specialized machines, thereby reducing overall manufacturing complexity and improving efficiency without compromising the quality of either the knitted base layer or the embroidered emblem.
2Shape
If embroidery is added to textile components, then aesthetic appearance improves, but comfort and durability in footwear applications deteriorate
Solution Approach 1:
The patent segments the textile component into distinct functional layers: a knitted base layer providing structure and comfort, and an embroidered emblem layer providing aesthetic appearance. The spacing element further divides the structure by creating separation between the embroidery and the wearer's foot. This segmentation allows each layer to optimize its specific function while maintaining overall component integrity, resolving the contradiction between appearance and comfort.
Solution Approach 2:
The spacing element acts as an intermediary component between the embroidered emblem and the wearer's foot. This intermediate layer separates the aesthetic embroidery from direct contact with the foot, preserving comfort and durability while still allowing the emblem to be visible and aesthetically pleasing. The spacing element mediates between the conflicting requirements of aesthetic appearance and comfort/durability.
3Adaptability or versatility
If embroidery is placed in high-stress areas, then design flexibility improves, but wear resistance decreases
Solution Approach 1:
The patent introduces a new spatial dimension by incorporating a spacing element that creates vertical separation between the embroidery and the high-stress contact area. This dimensional change allows the embroidery to be positioned in high-stress areas for design flexibility while the spacing element provides protective separation that maintains wear resistance. The spacing element adds a vertical dimension that resolves the contradiction between design flexibility and wear resistance.
Data Source
AI summary
A textile component may include a knitted component with a first knit layer, a second knit layer, and a pocket, where the pocket is located between the first knit layer and the second knit layer. A spacing element may be included, where the spacing element is located within the pocket. An embroidered element on an exterior surface of the first knit layer may be included, where the embroidered element extends through the first knit layer but does not extend through the second knit layer. The textile may also include a cushioning area that is elevated relative to a base portion of the knitted component. An emblem formed by the embroidered element is located within the cushioning area.