Knitted Footwear Upper Structure for Low Weight and Breathability
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Solution Overview
Problem
Conventional footwear uppers are often heavy, lack breathability, and require significant post-knitting processes, compromising their aesthetic and functional properties.
Innovation Solution
A knitted footwear upper formed from alternating courses of monofilament and multifilament yarns, using a half-gauge or lesser gauge knit, with a thermoplastic skin layer for heat bonding, allowing for a lightweight, breathable, and durable structure with integrated aesthetic features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional textile uppers are used, then structural strength is maintained, but weight increases and breathability decreases
Solution Approach 1:
The patent uses composite construction by combining a knitted textile component with a foam component. The knitted textile provides breathability and lightweight properties, while the foam component (such as EVA foam) provides structural strength, cushioning, and support. This composite approach allows the upper to achieve both low weight and high strength simultaneously, resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The patent applies different materials and structural properties to different regions of the upper. The knitted textile is used in areas requiring breathability and flexibility, while the foam component is strategically placed in areas requiring structural support and cushioning. This localized differentiation allows each region to optimize its properties, achieving overall strength without compromising weight reduction.
2Reliability
If conventional uppers are used, then durability is maintained, but breathability is reduced
Solution Approach 1:
The composite structure combines a knitted textile with foam material, where the knitted textile provides breathability through its open weave structure while the foam provides durability and cushioning. The foam component can be selected to have appropriate density and composition (such as EVA foam) to ensure long-term durability while maintaining the breathability characteristics of the textile layer.
Solution Approach 2:
The knitted textile component inherently provides a porous, breathable structure that allows air circulation. The foam component is also typically porous in nature, providing both breathability and structural integrity. This use of porous materials in both layers enables the upper to maintain high breathability while achieving the durability needed for long-term use.
3Shape
If post-knitting processes are applied, then aesthetic features are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates aesthetic features directly into the knitting process itself, rather than adding them as separate post-knitting steps. The knitted textile is formed with the desired patterns, textures, and structural variations during the knitting process, eliminating or reducing the need for subsequent processing steps. This preliminary integration of aesthetic features simplifies the overall manufacturing process while maintaining design quality.
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 solution provides a lightweight, breathable, and durable footwear upper with enhanced strength and containment, while minimizing post-knitting processes and enabling integrated visual elements.
Implementation Method 1
The upper may include a thermoplastic skin layer for heat bonding
Data Source
AI summary
A lightweight, breathable and high-strength upper formed from a half-gauge knit or lesser gauge knit, at least in part from alternating courses of a first monofilament and a second multifilament yarn, is described. The upper may include a skin layer. Methods of manufacture of an article of footwear including the lightweight upper are also described.