Knitted Footwear Upper With Zoned Density for Containment and Breathability

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Solution Overview

Problem

Existing footwear uppers made from knitted textiles face challenges in maintaining foot containment and breathability while minimizing weight and production time, and adding post-knitting components can negatively impact performance and recyclability.

Innovation Solution

A knitted component for footwear uppers with integrally knit zones of varying densities, combined with a thermoplastic film layer, provides enhanced containment in high-impact areas and increased breathability in other regions, using high-tenacity and low-melting yarns to ensure a strong bond with the sole structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If components (synthetic leather textiles, laminate film layers) are added through post-knitting processes to keep the foot contained, then foot containment is improved, but weight increases

Engineering Contradiction:

Improvefoot containmentVSAvoidweight of upper

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The knitted upper is divided into multiple knit zones with different knit densities to provide containment only where needed. The processor creates zones of higher knit density in specific regions (toe, heel, midfoot) while maintaining lower density in other areas, eliminating the need for additional containment components and reducing overall weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the knitted upper are assigned different knit densities based on functional requirements. High-containment areas receive higher knit density while breathability areas maintain lower density, optimizing performance locally without adding weight through uniform reinforcement or additional components.

Inventive Principle:

Principle #3Local quality

2Reliability

If components are added through post-knitting processes to increase durability, then durability is improved, but production time increases

Engineering Contradiction:

Improvedurability of upperVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines multiple functions (containment, durability, breathability) into a single integrated knitting process. The processor creates zones of varying knit densities in one operation, eliminating the need for separate post-knitting steps to add reinforcement components, thereby reducing production time while maintaining durability.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If components are added through post-knitting processes, then foot containment is improved, but recyclability is reduced

Engineering Contradiction:

Improvefoot containmentVSAvoidrecyclability of upper

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The entire upper is constructed from homogeneous knitted material with varying densities, rather than combining different material types (synthetic leather, laminate films, knit fabric). This single-material construction maintains recyclability while achieving containment through structural variation rather than material diversity.

Inventive Principle:

Principle #33Homogeneity

4Reliability

If knit density is increased in certain zones to provide containment, then foot containment is improved, but breathability is reduced

Engineering Contradiction:

Improvefoot containmentVSAvoidbreathability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The knitted upper features spatially varying knit densities optimized for local functions. High-density zones provide containment where foot movement occurs (toe, heel, midfoot), while low-density zones maintain breathability in areas requiring air flow, achieving both containment and breathability simultaneously through local optimization.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The upper is segmented into multiple knit zones with different densities. This segmentation allows the high-density containment zones to be isolated to specific regions while low-density breathable zones occupy other areas, preventing the breathability reduction that would occur with uniform high-density construction.

Inventive Principle:

Principle #1Segmentation

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 enhances foot containment and breathability, reduces weight, and improves production efficiency by integrating different knit densities and a thermoplastic film layer, resulting in a durable and recyclable upper.

Implementation Method 1

a thermoplastic film layer, wherein the sole structure is bonded to the knitted component and the thermoplastic film layer

Methodology Applied

Scientific EffectThermoplastic melting: Melting

Data Source

PatentUS20260020639A1Article of footwear with a knitted component

Publication Date: 2026.01.22 NIKE INC

AI summary

Aspects herein are directed to, among other things, a knitted component for an article of footwear and a method of manufacturing a knitted component having a first knit zone in a heel region having a lower knit density than a second knit zone in the midfoot and/or forefoot regions. The first and second knit zones may be integrally knit and adjacent one another along a seamless boundary. In some examples, the boundary between the first and second knit zones is more rearward on the medial side of the upper than on the lateral side. The knitted component may also extend underfoot and combine with a thermoplastic film layer to form a composite structure to which a sole structure is secured.