Knitted Footwear Upper with Expandable Yarns

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional footwear uppers lack sufficient elasticity, breathability, and cushioning, particularly in areas like the throat and heel, which can lead to discomfort and pressure points due to the lack of advanced materials and construction techniques.

Innovation Solution

The use of a knitted component with expandable yarns, where certain yarns are inlaid and others are exposed to provide enhanced elasticity, breathability, and cushioning, incorporating thermoplastic polymer materials that transition with temperature, and a unique knitting process to create a seamless, lightweight upper with varied properties across different areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional materials and construction techniques are used for footwear uppers, then manufacturing simplicity is maintained, but elasticity, breathability, and cushioning are insufficient

Engineering Contradiction:

ImproveelasticityVSAvoidconstruction complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent changes the physical and chemical parameters of the yarn by using expandable yarns that can change their diameter and properties in response to environmental conditions (temperature, moisture). This allows the upper material to dynamically adjust its elasticity, breathability, and cushioning properties without fundamentally changing the construction process.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials by combining conventional yarns with expandable yarns in the knitted upper. This creates a multi-functional material system where the expandable yarns provide enhanced elasticity and adaptive cushioning while the conventional yarns maintain structural integrity, resolving the contradiction between improved performance and construction complexity.

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If conventional yarns are used in the upper, then manufacturing simplicity is maintained, but breathability and cushioning are insufficient

Engineering Contradiction:

Improvepressure pointsVSAvoidmanufacturing simplicity

Core Design Contradiction:

Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The patent applies local quality by strategically placing expandable yarns in specific regions of the upper where pressure points are most likely to occur (such as the throat area and heel). This allows the material to provide enhanced cushioning and breathability locally without requiring all of the upper to be constructed with complex materials, thus maintaining manufacturing simplicity while reducing pressure points.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the upper lacks adaptive materials, then construction simplicity is maintained, but comfort and support are insufficient

Engineering Contradiction:

Improveadaptive supportVSAvoidmaterial complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent introduces dynamics into the upper material through expandable yarns that can dynamically adjust their properties in response to environmental conditions. The yarns expand or contract based on temperature and moisture changes, providing adaptive support and comfort without requiring complex mechanical or electronic systems, thus maintaining relative construction simplicity while achieving adaptability.

Inventive Principle:

Principle #15Dynamics

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 knitted component with expandable yarns offers improved elasticity, breathability, and cushioning, reducing pressure points and enhancing comfort by allowing the yarns to expand and provide additional support where needed, while maintaining durability and aesthetic appeal.

Implementation Method 1

incorporating thermoplastic polymer materials that transition with temperature

Methodology Applied

Scientific EffectThermoplastic phase transition: Phase Change

Implementation Method 2

expandable yarns, where certain yarns are inlaid and others are exposed to provide enhanced elasticity... allowing the yarns to expand and provide additional support where needed

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20220240624A1Knitted component with at least one expandable yarn

Publication Date: 2022.08.04 NIKE INC

AI summary

An upper may include a knitted component that at least partially forms a throat area of the upper. A first expandable yarn may be at least partially inlaid within a first course of the knitted component, the first expandable yarn having an inlaid portion that is between a first surface and a second surface of the knitted component, the first surface and the second surface including knitted loops of at least one course including a second yarn. The first expandable yarn may include an exposed portion that is exposed on the first surface of the knitted component. The inlaid portion of the first expandable yarn may have a first diameter, where the exposed portion of the first expandable yarn has a second diameter, and where the second diameter is larger than the first diameter.