Knitted Footwear Upper Structure for Breathable Elastic Support
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Solution Overview
Problem
Conventional footwear uppers lack advanced materials and structures that provide a combination of elasticity, breathability, and support, particularly in athletic footwear, which can lead to discomfort and reduced performance during physical activities.
Innovation Solution
A knitted component with a forefoot portion and a heel portion, featuring multiple layers and extensions, is integrated into the upper structure, utilizing a double jersey knit structure and thermoplastic polymer materials to enhance elasticity, breathability, and support, with customizable properties and visual designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional materials and structures are used in footwear uppers, then manufacturing simplicity is maintained, but elasticity, breathability, and support are insufficient
Solution Approach 1:
The upper incorporates multiple materials including thermoplastic polymer materials, knit fabrics, and foam materials in a composite structure. This allows the upper to simultaneously achieve elasticity from the knit fabric, support from the thermoplastic polymer, and cushioning from the foam, resolving the contradiction between material performance and structural simplicity
Solution Approach 2:
The upper is divided into multiple functional zones including a forefoot portion, a heel portion, and a midfoot portion, each with different material compositions and structural characteristics. This segmentation allows each zone to be optimized for its specific function while maintaining overall structural integrity
2Adaptability or versatility
If conventional single-layer upper structures are used, then ease of manufacture is maintained, but breathability and comfort are reduced
Solution Approach 1:
The upper uses a multi-layer composite structure with each layer serving a specific function: the knit fabric layer provides breathability and flexibility, the thermoplastic polymer layer provides structural support, and the foam layer provides cushioning. This composite approach achieves superior breathability and comfort while managing the increased structural complexity
Solution Approach 2:
Different regions of the upper have different material compositions and layer configurations optimized for local requirements. The forefoot area has higher flexibility for toe movement, while the heel area has enhanced support structures, achieving localized optimization of breathability and comfort
3Reliability
If advanced knitted components with multiple layers are integrated, then fit and support are enhanced, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct steps: forming the knit fabric component, attaching the thermoplastic polymer overlays, and adding the foam cushioning elements. This segmentation of the manufacturing process makes the complex multi-layer construction more manageable and scalable
Solution Approach 2:
Multiple components are merged into a single integrated upper assembly through bonding and stitching processes. The knit fabric, thermoplastic polymer overlays, and foam elements are combined to form a unified structure that provides enhanced support while being manufactured as an integrated unit
4Strength
If thermoplastic polymer materials are used to enhance support, then structural integrity is improved, but weight increases
Solution Approach 1:
The thermoplastic polymer materials are applied locally only in regions requiring enhanced structural integrity such as the heel counter and midfoot support areas, rather than throughout the entire upper. This localized application provides necessary structural support while minimizing the overall weight increase
Solution Approach 2:
The upper uses a composite structure where lightweight knit fabric serves as the base material and thermoplastic polymer overlays are applied strategically to provide structural support only where needed. This composite approach achieves structural integrity while maintaining lightweight characteristics
Data Source
AI summary
In one aspect, the present disclosure provides a knitted component. The knitted component may have a forefoot portion with a top layer and a bottom layer, where a void is formed between the top layer and the bottom layer, and where the top layer is secured to the bottom layer via at least one common knit structure. A heel area may extend from the bottom layer of the forefoot portion in a longitudinal direction and may be secured to the bottom layer of the forefoot portion via at least one common knit structure. At least one extension may extend from the heel area in a second direction, the second direction being different than the longitudinal direction.