Knitted Footwear Upper With Integrated Tensioning Strand
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Solution Overview
Problem
The existing methods for manufacturing footwear, particularly athletic footwear, face challenges in efficiently shaping the upper material around a last to securely attach the sole structure, often requiring a strobel material and complex stitching or adhesive processes.
Innovation Solution
A method involving a lasting element with a pair of strips and a strand forming a w-shaped configuration is used to tighten the upper around a last, allowing for secure attachment of the sole structure without the need for a strobel sock, utilizing a unitary knit construction and various materials like textiles and polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a strobel material is used to tighten the upper around the last, then the upper can be secured to the last for lasting, but the manufacturing process becomes more complex and requires additional materials
Solution Approach 1:
The patent removes the strobel material from the footwear construction by integrating the tightening function directly into the upper material itself through a knit structure with tensioning elements, eliminating the need for separate strobel components
Solution Approach 2:
The upper and the tightening mechanism are merged into a single integrated knit structure where the tensioning elements are built into the upper material, combining functions that were previously separate components
2Reliability
If traditional stitching or adhesive processes are used to attach the sole structure, then the sole can be secured to the upper, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent replaces traditional mechanical attachment methods (stitching, adhesives) with a mechanical tensioning system built into the knit upper that secures the sole through integrated tensioning elements, eliminating complex external attachment processes
Solution Approach 2:
The upper structure provides its own attachment mechanism through built-in tensioning elements that secure the sole without requiring separate stitching or adhesive application processes
3Ease of manufacture
If a unitary knit construction is used for the upper, then manufacturing can be simplified and customized, but the upper requires an integrated tightening mechanism to secure around the last
Solution Approach 1:
The knit upper is divided into functional zones with tensioning elements strategically positioned to provide tightening at specific locations, allowing the upper to be constructed as a single knit piece while incorporating distributed tightening functions
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
This approach simplifies the manufacturing process, enhances the fit and durability of the footwear by ensuring a snug and secure attachment of the sole to the upper, while allowing for customizable properties through yarn selection and tensioning of the strand.
Implementation Method 1
The strand is tensioned, and a sole structure of the article of footwear is joined to the upper
Data Source
AI summary
The present disclosure provides a knitted component, the knitted component with a knit element that forms at least a portion of an upper for an article of footwear and defines an interior void for receiving a foot. A lower perimeter edge of the knit element may extend between a lateral side and a medial side of the upper. At least one strand of the knitted component may extend through the lower perimeter edge on opposite sides of the knitted component so as to extend between the lateral side and the medial side of the upper. The knitted component may be formed on a knitting machine, and the at least one strand may be configured to be tensioned to tighten the upper around a last.