Layered Knitted Upper Structure for Zoned Elasticity and Support
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Solution Overview
Problem
Conventional footwear uppers lack a structured design that balances elasticity, durability, and support, leading to suboptimal fit and performance during various activities.
Innovation Solution
A knitted upper design featuring a base layer and a second layer with varying regions of elasticity and structure, formed using a multi-bed knitting machine to integrate zones with distinct elastic properties, providing enhanced support and durability where needed while maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional single-layer upper design is used, then the structure is simple and easy to manufacture, but the balance between elasticity, durability, and support is insufficient
Solution Approach 1:
The upper is divided into multiple functional layers: a base layer providing elasticity and a second layer providing durability and support. Each layer is segmented into different regions with varying knit densities and elastic properties to achieve zone-specific performance characteristics.
Solution Approach 2:
The upper combines different material properties through layering - the base layer uses highly elastic knit construction while the second layer uses more durable, less elastic knit construction. This composite structure allows each material to contribute its strengths to the overall performance.
2Ease of operation
If a knitted structure with high elasticity is used, then comfort and flexibility are improved, but durability and structural support are reduced
Solution Approach 1:
The knitted structure is segmented into distinct functional zones with different elastic properties. The base layer provides high elasticity for comfort, while the second layer with its different knit density provides durability and support in specific regions.
Solution Approach 2:
Different regions of the upper have different knit densities and elastic properties tailored to their specific functional requirements. High elasticity is concentrated where flexibility is needed, while higher durability is provided where structural support is required.
3Reliability
If a multi-layered structure with varying elasticity zones is implemented, then fit and performance are enhanced, but manufacturing complexity increases
Solution Approach 1:
Multiple layers with different elastic properties are combined through integrated knitting processes where the base layer and second layer are knitted in sequence on the same or different needle beds, creating a unified structure with zone-specific properties.
Solution Approach 2:
The knitting process parameters such as needle bed configuration, yarn tension, and knit density are varied across different zones and layers to achieve the desired elastic properties. The base layer uses different knitting parameters than the second layer to create the intended performance characteristics.
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 layered structure achieves a balanced fit and performance by allowing specific zones to elongate differently under tension, enhancing comfort and structural integrity.
Implementation Method 1
The first zone may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone may have a second degree of elasticity such that it has a second elongation when subjected to the tensile load.
Data Source
AI summary
One general aspect of the present disclosure includes an article having a first zone, the first including a first region of a knitted base layer and a knitted second layer, where the second layer is disposed primarily on one side of the base layer. The article may further include a second zone that may include a second region of the base layer, where the second region of the base layer and the first region of the base layer have a common yarn, and where the second region of the base layer and the second layer have a common yarn. The first zone may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone may have a second degree of elasticity such that it has a second elongation when subjected to the tensile load.