Multilayer Knitted Footwear Uppers With Localized Raised Structures
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Solution Overview
Problem
Conventional footwear uppers lack aesthetic and functional diversity, particularly in terms of visible raised structures that provide cushioning, rigidity, and desirable aesthetics while maintaining flexibility and durability.
Innovation Solution
A knitted component for footwear uppers is formed with at least one raised structure created by overlapping knit layers, where a third yarn is positioned between two knit layers, allowing the structure to be visible and varying in color and configuration, achieved through a knitting process and subsequent application of heat or steam to enhance loft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional single-layer knitting is used, then manufacturing simplicity is maintained, but aesthetic appeal and functional diversity are limited
Solution Approach 1:
The knitted component is divided into multiple knit layers (first knit layer, second knit layer, third knit layer) with different structures and functions. Each layer can be independently designed and knitted, then assembled together to create the final multi-layer structure with raised features, combining manufacturing simplicity with aesthetic and functional diversity
Solution Approach 2:
The patent implements a nested structure where the third knit layer is positioned between the first and second knit layers, with portions of the third layer extending beyond the outer layers to form raised features. This nested arrangement allows multiple functional and aesthetic layers to be integrated within a single knitted component structure
2Reliability
If raised structures are added for cushioning and rigidity, then functional performance is improved, but device complexity increases
Solution Approach 1:
The third knit layer is configured to extend beyond the first and second knit layers only at specific locations where raised features are desired. This localized extension approach provides cushioning and rigidity exactly where needed in the footwear application, while keeping other areas simple and integrated
Solution Approach 2:
The patent creates a composite knitted structure combining three different knit layers with distinct properties. The first layer provides base structure, the second layer provides additional support, and the third layer creates raised cushioning features, together forming a composite material system with enhanced overall performance
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 provides footwear uppers with enhanced cushioning, rigidity, durability, and aesthetic appeal, while maintaining flexibility, by forming visible raised structures that exhibit varying colors and configurations.
Implementation Method 1
subsequent application of heat or steam to enhance loft
Implementation Method 2
subsequent application of heat or steam to enhance loft
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A knitted component including a pod comprising a first knit layer, a second knit layer, a raised structure where the second knit layer extends away from the first knit layer, and a pocket that is formed between the first and second knit layers in the pod. A second area demarcating at least a portion of the pod, the second area having a height less than a height of the raised structure. At least one yarn positioned within the pocket between the first knit layer and the second knit layer of the pod, wherein the at least one yarn is secured to the first knit layer at a first location within the pocket and to the second knit layer at a second location within the pocket. The at least one yarn comprises a monofilament yarn and a high tenacity yarn.