Knitted Footwear Upper With Heat-Formed Raised Cushioning Structure

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional footwear uppers lack sufficient cushioning, rigidity, and durability while maintaining flexibility, and existing textile manufacturing methods do not efficiently create structures that balance these properties.

Innovation Solution

A knitted component with raised structures, formed using a weft-knitting process, incorporates different yarns with varying elasticity and shrinkage rates, and is subjected to a heat stimulus to create a seamless upper with defined ottoman-like structures that provide cushioning and rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional weaving or interlooping methods are used to form textile uppers, then the upper can be manufactured with basic flexibility, but the upper lacks sufficient cushioning, rigidity, and durability

Engineering Contradiction:

Improvedurability and rigidityVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The knitted fabric is segmented into multiple layers with different yarn compositions and properties. Each layer contributes specific characteristics (e.g., cushioning, rigidity, durability) and when combined, the layers work together to achieve superior overall performance that cannot be obtained with conventional single-layer textiles

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite yarns containing multiple types of fibers (natural, synthetic, elastic) within single yarns, and combines different yarn types across multiple layers. This composite approach enables the upper to simultaneously achieve cushioning, rigidity, and durability while maintaining flexibility

Inventive Principle:

Principle #40Composite materials

2Strength

If multiple post-manufacturing steps are added to create cushioning and rigidity structures, then the upper can achieve desired structural properties, but the manufacturing process becomes more complex and time-consuming

Engineering Contradiction:

Improvecushioning and rigidityVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The cushioning and rigidity structures are built into the fabric during the knitting process itself, rather than being added afterward. The multi-layer construction with varying yarn properties is created directly on the knitting machine, eliminating the need for subsequent structural modification steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention merges the structural formation process with the fabric manufacturing process. The knitting machine simultaneously creates the multi-layer fabric structure and the cushioning/rigidity features in a single integrated operation, rather than requiring separate sequential steps

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If conventional textile structures are used, then the manufacturing process is simpler, but the upper lacks sufficient cushioning while maintaining flexibility

Engineering Contradiction:

ImprovecushioningVSAvoidupper weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Different regions of the upper are constructed with different layer configurations and yarn compositions tailored to local requirements. High-cushioning areas use specific layer combinations while other areas prioritize flexibility or durability, optimizing performance without uniformly increasing weight across the entire upper

Inventive Principle:

Principle #3Local 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 achieves a footwear upper with enhanced cushioning, rigidity, and durability by forming ottoman-like structures that maintain flexibility and aesthetic appeal, using a knitting process that minimizes post-manufacturing steps.

Implementation Method 1

incorporates different yarns with varying elasticity and shrinkage rates, and is subjected to a heat stimulus to create a seamless upper with defined ottoman-like structures

Methodology Applied

Scientific EffectDifferential shrinkage: Thermal Contraction

Data Source

PatentUS20260028755A1Knitted article with raised structure and methods of manufacture

Publication Date: 2026.01.29 NIKE INC

AI summary

A knitted article having a first layer and a second layer is described. The first layer is formed from a first yarn having a first shrinkage rate and the second layer is formed by a second yarn having a second shrinkage rate. The shrinkage rate of the first yarn is greater than the shrinkage rate of the second yarn when subjected to heat. Upon heat exposure, the second layer forms a raised structure. The raised structures have a length that is generally perpendicular to the lateral-to-medial course-wise direction of the knitted article.