Knitted Footwear Upper With Radial Containment and Inlaid Strands

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Solution Overview

Problem

Conventional knitted footwear uppers lack sufficient structure and containment, leading to foot displacement during movement, and additional components added post-knitting increase weight, production time, and reduce recyclability.

Innovation Solution

Knitted components with radially-extending knit courses and inlaid strands, formed through a continuous knitting process, provide multi-directional containment and stability, using high-tenacity yarns and engineering filaments for reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional components are added to a knitted upper through post-knitting processes to keep the foot contained, then foot containment and stability are improved, but weight increases, production time increases, and recyclability is reduced

Engineering Contradiction:

Improvefoot containmentVSAvoidupper weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent combines the containment function with the knitted upper itself by integrating radially-extending knit courses directly into the knitting process. This merging eliminates the need for separate post-knitting containment components, thereby maintaining foot containment while reducing weight and improving recyclability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The containment structure is built into the knitted upper during the initial knitting process rather than being added later. The radially-extending knit courses are formed as part of the base knit structure, providing preliminary containment action that prevents foot displacement before the footwear is even assembled.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If additional components are added to a knitted upper through post-knitting processes to keep the foot contained, then foot containment and stability are improved, but production time increases

Engineering Contradiction:

Improvefoot containmentVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the containment structure creation with the base knit production process. The radially-extending knit courses are formed during the same knitting operation that creates the upper, eliminating separate production steps and reducing overall production time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The knitting process continues uninterrupted to form both the base knit structure and the radially-extending containment courses in a single continuous operation. This continuity eliminates downtime between operations and streamlines production.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If additional components are added to a knitted upper through post-knitting processes to keep the foot contained, then foot containment and stability are improved, but recyclability is reduced

Engineering Contradiction:

Improvefoot containmentVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent merges the containment function into the knitted upper material itself through radially-extending knit courses. This integration means the containment structure becomes an inherent part of the recyclable knitted component rather than a separate non-recyclable addition.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The containment structure is made from the same knitted material as the rest of the upper, creating a homogeneous structure that can be recycled together as a single material type. This homogeneity simplifies recycling processes compared to mixed-material constructions.

Inventive Principle:

Principle #33Homogeneity

4Weight of moving object

If conventional knitted uppers are used without additional components, then weight is reduced and production time is shortened, but foot containment and stability are insufficient

Engineering Contradiction:

Improveupper weightVSAvoidfoot containment

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent applies radially-extending knit courses specifically in regions where containment is needed, such as the midfoot and heel areas. This localized application provides containment only where necessary, maintaining lightweight construction while improving foot stability in critical zones.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates a composite knit structure combining standard knit courses with radially-extending containment courses. This composite construction integrates different functional elements (support and containment) within a single lightweight knitted component.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20260020634A1Articles of footwear with knitted components and methods of manufacturing the same

Publication Date: 2026.01.22 NIKE INC

AI summary

A knitted component having an outer perimeter and a common portion, which may be a centrally-located region, such as a throat region and/or a collar region. A plurality of courses of the knitted component extend between the between the outer perimeter and the common portion such that the courses may be radially-extending outwards from the common portion. One or more continuous strand may be inlaid within the knit courses to form a plurality of strand segments that extend within respective ones of the plurality of courses of the knitted component between the outer perimeter and the common portion of the knitted component.