Multi-Layer Knitted Footwear Components with Interlooped Zones
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Solution Overview
Problem
Conventional knitted components for footwear lack sufficient strength and durability, particularly in overlapping areas, which can lead to reduced performance and increased manufacturing time and costs due to the need for post-knitting processes.
Innovation Solution
A knitted component with a multi-bed knit construction is created by interlooping yarns from two layers during the knitting process, forming a freely separable area with a binding edge that enhances strength and durability, allowing for a single-piece knitting process without additional post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional single-layer knitting is used, then manufacturing simplicity is maintained, but strength and durability are insufficient
Solution Approach 1:
The patent combines multiple knitting layers (first layer and second layer) into a single integrated knitted component through interlayer knit stitches. The first and second layers are knitted simultaneously on different needle beds, with yarns from both layers interlooping at designated interfaces to create a unified structure that enhances strength and durability while maintaining manufacturing efficiency.
Solution Approach 2:
The patent transitions from conventional single-layer two-dimensional knitting to multi-layer three-dimensional knitting. By adding the vertical dimension with multiple layers (first layer and second layer) that overlap and interconnect through interlayer knit stitches, the structure achieves enhanced mechanical properties while maintaining flexibility.
2Duration of action of stationary object
If multi-layer overlapping construction is added to improve strength, then durability increases, but manufacturing time and cost increase due to post-knitting processes
Solution Approach 1:
The patent performs the layer integration action during the knitting process itself rather than as a post-processing step. Interlayer knit stitches are formed simultaneously with the knitting of the first and second layers, creating the integrated multi-layer structure before the component leaves the knitting machine. This eliminates the need for subsequent joining operations and reduces manufacturing time.
Solution Approach 2:
The patent maintains continuous knitting action across multiple layers without interruption for post-processing. The first and second layers are knitted continuously with interlayer knit stitches formed in sequence during the same knitting operation, ensuring uninterrupted production flow and eliminating downtime associated with separate joining operations.
3Reliability
If interlayer knit stitches are formed to join layers, then strength and durability improve, but device complexity increases
Solution Approach 1:
The patent applies interlayer knit stitches only at specific locations where the first and second layers interface, rather than throughout the entire component. This localized approach to joining creates sufficient structural integrity at critical points while maintaining simplicity in regions where layers remain freely separable, thus balancing reliability with manufacturing complexity.
Data Source
AI summary
In one aspect of the disclosure, a knitted component for use in an article of footwear may include a first knitted layer and a second knitted layer at least partially overlapping the first knitted layer. The knitted component may also include an interlooped area comprising the first knitted layer interlooped with the second knitted layer and a knitted loop structure that is adjacent the interlooped area and that comprises the first knitted layer freely separable from the second knitted layer to comprise a passageway. The first knitted layer has a first edge comprising a first opening of the passageway and a second edge comprising a second opening of the passageway. Each of the first edge and the second edge extend in a course-wise direction and the passageway extends between the first opening and the second opening in a wale-wise direction.