Knitted Footwear Upper with Thermoformed Abrasion Barrier
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Solution Overview
Problem
Knitted uppers in footwear experience high rates of abrasion, leading to tearing, holes, and a decrease in the useable life of the footwear, especially in activities like skateboarding.
Innovation Solution
The implementation of a knitted upper with a first knit zone featuring a thermoformed layer created by inlaying thermoplastic yarns between two knit layers, which acts as a barrier against abrasion forces, and additional knit zones with exposed inlaid yarns for enhanced durability and tactile feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials are layered on top of each other to withstand abrasion, then durability is improved, but weight increases
Solution Approach 1:
The patent uses composite materials by integrating thermoplastic yarns within the knitted upper structure. The thermoplastic yarns form a reinforced network that resists abrasion while maintaining a single-material construction, avoiding the weight penalty of multiple layered materials.
Solution Approach 2:
The thermoplastic yarns are nested within the knitted fabric structure, with the yarns positioned between and within the knit loops. This nested arrangement provides internal reinforcement without adding external layers, thereby improving durability while minimizing weight increase.
2Reliability
If multiple materials are layered on top of each other to withstand abrasion, then durability is improved, but manufacturing time increases
Solution Approach 1:
The patent merges the reinforcement function with the structural fabric by integrating thermoplastic yarns directly into the knitted upper during the same manufacturing process. This eliminates the need for separate steps to add protective layers, thereby reducing manufacturing time while maintaining durability.
Solution Approach 2:
The thermoplastic yarns serve multiple functions simultaneously: they provide structural reinforcement, abrasion resistance, and maintain the knit fabric's flexibility. This multi-functionality eliminates the need for separate protective layers, streamlining the manufacturing process and reducing production time.
3Reliability
If multiple materials are layered on top of each other to withstand abrasion, then durability is improved, but manufacturing expense increases
Solution Approach 1:
The patent employs composite materials through the integration of thermoplastic yarns within the knitted upper. This approach provides durability enhancement without requiring multiple material layers, thereby reducing material costs and simplifying the manufacturing process to lower production expenses.
Solution Approach 2:
The patent utilizes parameter changes by melting and repositioning thermoplastic yarns during the manufacturing process. The thermoplastic yarns are heated to a molten state and then cooled to form a reinforced network, enabling a single-step process that reduces manufacturing complexity and expense while achieving enhanced durability.
4Ease of operation
If yarns are used in knitted uppers, then flexibility and comfort are improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent creates a composite structure where thermoplastic yarns are integrated within the knitted fabric. The thermoplastic component provides abrasion resistance while the knitted structure maintains flexibility and comfort, achieving a balance between these opposing requirements through material composition rather than structural layering.
Solution Approach 2:
The patent applies local quality by positioning thermoplastic yarns specifically in high-abrasion areas of the knitted upper. The thermoplastic reinforcement is concentrated where abrasion occurs, while the rest of the knitted fabric maintains its flexible, comfortable characteristics, thereby improving abrasion resistance without compromising overall flexibility.
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 significantly enhances the durability of the knitted upper by reducing abrasion and extending the life of the footwear, while also providing improved tactile feedback through the exposed inlaid yarns.
Implementation Method 1
applying one or more of heat and pressure such that the thermoplastic material of the one or more inlaid yarns rises to a temperature at or above the melting point of the thermoplastic material
Implementation Method 2
applying one or more of heat and pressure such that the thermoplastic material of the one or more inlaid yarns rises to a temperature at or above the melting point of the thermoplastic material
Data Source
AI summary
Aspects herein are directed to, among other things, a knitted upper for an article of footwear. The knitted upper includes different knit zones including a first knit zone which may be located in a toe and forefoot region of the article of footwear. The first knit zone includes a first knit layer forming an outer-facing surface of the knitted upper, a second knit layer forming an inner-facing surface of the knitted upper, and a third thermoformed layer substantially contained between the first knit layer and the second knit layer. The third thermoformed layer acts as a barrier, reducing the likelihood of abrasion forces that may occur from contact between the knitted upper and a ground or other surface from contacting yarns that form the second knit layer, thereby increasing the structural integrity of the knitted upper.