Knitted Footwear Upper With Dual-Layer Structure and Hidden Functions

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional footwear uppers lack integration of functional and aesthetic features due to separate manufacturing processes for inner and outer surfaces, limiting flexibility and comfort.

Innovation Solution

A single knitting process forms a first and second knitted portion for the outer and inner surfaces of the upper, connected by a knitted connection structure, allowing for enhanced elasticity, breathability, and hidden functional elements like pockets and sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate manufacturing processes are used for inner and outer surfaces of footwear uppers, then manufacturing flexibility is maintained, but integration of functional and aesthetic features is limited

Engineering Contradiction:

Improveintegration of functional and aesthetic featuresVSAvoidseparate manufacturing processes

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the manufacturing of inner and outer surfaces into a single knitted structure formed by one or more continuous yarns. This merging of previously separate manufacturing processes allows functional elements (sensors, pockets) to be integrated with aesthetic outer surfaces, resolving the contradiction between versatility and process complexity

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If a single knitting process forms both inner and outer surfaces, then integration of features is enhanced, but manufacturing precision requirements increase

Engineering Contradiction:

Improveseamless integration of featuresVSAvoidknitting process precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent employs local quality by varying yarn properties (thickness, material composition, elasticity) at different locations within the single knitted structure. This allows different regions to serve different functions (aesthetic outer surface, functional inner surface, hidden pockets) while maintaining overall structural integrity, thereby managing precision requirements through localized differentiation

Inventive Principle:

Principle #3Local quality

3Ease of operation

If conventional separate manufacturing is used, then production simplicity is maintained, but flexibility and comfort of the upper are limited

Engineering Contradiction:

Improveflexibility and comfortVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent incorporates dynamic properties by using elastic and stretchable yarns in the knitted structure, allowing the upper to adapt dynamically to foot movement and deformation. This dynamic flexibility is achieved through the inherent properties of the continuous yarn construction, maintaining manufacturing simplicity while enhancing comfort and flexibility

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20260000149A1Upper for an article of footwear with first and second knitted portions

Publication Date: 2026.01.01 NIKE INC

AI summary

An upper may include a first knitted portion configured to form an outer surface of the upper, a second knitted portion configured to form an inner surface of the upper, where the second knitted portion is at least partially coextensive with the first knitted portion, an interstitial space between the first knitted portion and the second knitted portion, and a knitted connection structure connecting the first knitted portion to the second knitted portion. The knitted connection structure may extend at least partially along at least one of a tongue and a collar of the upper, and the second knitted portion may include at least one double jersey knit structure that is coextensive with the first knitted portion.