Knitted Footwear Upper With Floated Portions for Stress Distribution

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Solution Overview

Problem

Conventional footwear uppers require multiple material elements, leading to increased manufacturing time, waste, and discomfort due to uneven stress distribution and stitch junctions, which complicates recycling and reduces efficiency.

Innovation Solution

A knitted component with a first course and a second course, featuring a floated portion and tuck stitches, is used to form a stretch-resistant area in the upper, minimizing material elements and enhancing comfort and recyclability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple material elements are used in the upper, then different properties (stretch-resistance, wear resistance, flexibility) can be imparted to different areas, but manufacturing time and expense increase

Engineering Contradiction:

Improveproperty differentiationVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent merges multiple material elements into a single knitted component by using multiple yarns with different properties (e.g., stretch-resistant yarn, wear-resistant yarn) that are knitted together in the same structure. This allows different areas of the upper to exhibit different properties without requiring separate material pieces to be stitched together, thereby reducing manufacturing time and complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The knitted component serves multiple functions simultaneously by incorporating yarns with different characteristics into the same structure. A single knitted component can provide stretch-resistance, wear resistance, flexibility, and ventilation all at once, eliminating the need for multiple specialized material elements and their associated assembly processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple material elements are used in the upper, then different properties can be imparted to different areas, but waste material accumulates to a greater degree

Engineering Contradiction:

Improveproperty differentiationVSAvoidwaste material

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

By combining multiple yarn types into a single knitted component, the patent eliminates the cutting and trimming operations required when working with multiple separate material pieces. Each yarn runs continuously through the knitting process, minimizing off-cut waste that would otherwise be generated by cutting multiple material elements to shape.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple material elements are stitched together, then different properties can be imparted to different areas, but stitch junctions transfer stress at an uneven rate causing failure or discomfort

Engineering Contradiction:

Improveproperty differentiationVSAvoidstress distribution

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent eliminates stitch junctions by knitting multiple yarns together in a continuous interlocking structure. The knitted construction creates uniform stress distribution across the entire upper, as the interlooping nature of knitting allows stress to be distributed evenly through the fabric structure rather than concentrating at stitch points where multiple materials are joined.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If multiple material elements are used in the upper, then different properties can be imparted to different areas, but the upper becomes more difficult to recycle

Engineering Contradiction:

Improveproperty differentiationVSAvoidrecyclability

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By knitting multiple yarns together in a single integrated component, the patent creates a more recyclable structure compared to multiple separate material pieces. The continuous yarn construction allows for easier separation and processing during recycling, and the uniform structure enables more straightforward material recovery compared to assembled multi-material components with adhesives and stitching.

Inventive Principle:

Principle #5Merging (Combining)

5Adaptability or versatility

If additional material and stitch joints are used, then different properties can be imparted to different areas, but discomfort occurs when worn

Engineering Contradiction:

Improveproperty differentiationVSAvoidcomfort

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent creates a seamless, comfortable upper by knitting multiple yarns together in a continuous fabric structure. This eliminates the hard stitch junctions and material edges that cause discomfort in traditionally constructed uppers. The knitted structure conforms smoothly to the foot, providing comfort while still delivering property differentiation through the multi-yarn construction.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4272593B1Article of footwear incorporating a knitted component having floated portions

Publication Date: 2025.12.17 NIKE INNOVATE CV

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AI summary

An article of footwear includes an upper incorporating a knitted component formed of unitary knit construction. The knitted component includes portions having extended floated portions to distribute forces acting on the knitted component and resist stretching of the knitted component when the article of footwear is worn during a sport or athletic activity.