Unitary Knitted Footwear Upper With Integrated Tongue

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Solution Overview

Problem

Conventional footwear uppers are complex, time-consuming to manufacture, and generate significant waste due to the use of multiple material elements that are cut and stitched together, making them difficult to recycle.

Innovation Solution

The footwear upper is constructed using a unitary knit component that integrates a knit element and a tongue, formed through a knitting process without significant additional manufacturing steps, reducing the number of material elements and simplifying the manufacturing process while enhancing recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple material elements are used and joined together, then the upper can achieve desired functionality and comfort, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

ImprovefunctionalityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the tongue and knit element into a single unitary knit component, eliminating the need for separate tongues and reducing the number of material elements. This integration simplifies the manufacturing process by reducing cutting and stitching operations while maintaining the functionality of both the tongue and knit structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The unitary knit component serves multiple functions simultaneously - it acts as both the tongue and the knit element, providing structural support, flexibility, and the tongue's protective function. This multi-functionality reduces the overall complexity by consolidating multiple components into one.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple material elements are cut and stitched together, then the upper achieves desired properties, but significant waste is generated

Engineering Contradiction:

Improvematerial propertiesVSAvoidwaste material

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

By combining the tongue and knit element into a single unitary component, the patent eliminates the waste associated with cutting separate pieces from larger material sheets. The integrated design allows for more efficient material utilization with minimal off-cut waste.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple material elements are joined together, then the upper achieves desired functionality, but the manufacturing time increases

Engineering Contradiction:

Improvefunctional propertiesVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The unitary knit component is formed in a single knitting process without requiring separate operations for creating the tongue and knit element, nor for joining them together. This eliminates the time required for cutting, positioning, and stitching multiple components.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If conventional cutting and stitching processes are used, then material elements can be joined, but the process is difficult to automate

Engineering Contradiction:

Improvejoining capabilityVSAvoidautomation difficulty

Core Design Contradiction:

Ease of manufactureVSExtent of automation

Solution Approach 1:

The patent replaces the mechanical cutting and stitching processes with a knitting process that forms the unitary component through yarn interlocking. This substitution enables better automation potential, as knitting can be more easily automated compared to multiple cutting and joining operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20260071359A1Article of footwear incorporating a knitted component with a tongue

Publication Date: 2026.03.12 NIKE INC

AI summary

The present disclosure provides an upper for an article of footwear. The upper may include a knit element defining a portion of at least one of an exterior surface of the upper and an opposite interior surface of the upper. An inlaid strand may extend through the knit element, and a tongue and the knit element may have a common yarn at least at a forward portion of the tongue, and the tongue may extend through a throat area of the upper.