Seamless Knitted Footwear Upper With Integrated Underfoot Structure

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Solution Overview

Problem

Conventional footwear uppers often require complex post-knitting processes and multiple components, which can compromise durability, aesthetics, and comfort.

Innovation Solution

A seamless knitted component for footwear uppers is created using a single pass of a knitting machine, integrating a first and second side with an underfoot portion, featuring a toe portion with a cavity and a cup-shaped heel portion, and secured with a fastening element, allowing for a single-piece, elastic, and aesthetically appealing design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional footwear uppers are constructed using multiple components and complex post-knitting processes, then structural integrity can be maintained, but manufacturing complexity and production time increase

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (upper body, toe cap, heel counter, tongue, and panels) into a single integrated knitted component. This is achieved by forming all elements in one continuous knitting process without cutting or assembling separate pieces, thereby simplifying manufacturing while maintaining structural integrity through the unified knitted construction

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If seams are visible on the footwear upper, then construction simplicity is maintained, but aesthetic appeal and protection are compromised

Engineering Contradiction:

Improveconstruction simplicityVSAvoidaesthetic degradation and seam exposure

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

By knitting the entire upper as one continuous piece without cutting or joining separate components, the invention eliminates visible seams on the exterior surfaces. The seamless construction achieves both aesthetic appeal and durability while maintaining construction simplicity through the single-piece knitting process

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If a single pass knitting process is used to create the footwear upper, then productivity is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveproduction speedVSAvoidknitting pattern accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The knitting machine is pre-programmed with the complete pattern sequence before production begins. This preliminary programming allows the complex multi-element upper (with toe cap, heel counter, tongue, and panels) to be knitted automatically in one continuous pass without manual intervention, maintaining high precision while maximizing productivity

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250386900A1Knitted upper with two sides and an underfoot portion

Publication Date: 2025.12.25 NIKE INC

AI summary

The present disclosure provides a knitted component for an article of footwear. The knitted component may include a first side and a second side, where the first side and the second side form an overfoot portion. An underfoot portion may be located between the first side and the second side, where at least a portion of the first side and at least a portion of the second side of the knitted component are located on one of a medial side and a lateral side of the overfoot portion, and where a knitted course extends from the first side, through the underfoot portion, and to the second side.