Needle Bed Racking for Complex Knitted Footwear Uppers

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Solution Overview

Problem

Existing knitting machines are limited in their ability to form complex knitted components with enhanced structures, particularly in forming upper components for footwear with precise alignment and connection of different portions.

Innovation Solution

A knitting machine with extreme racking capability, allowing for the simultaneous formation and alignment of first and second portions of a knitted component on separate needle beds, followed by the formation of connection courses to secure these portions together, thereby creating a knitted component with double-jersey knit structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional knitting machines are used to form knitted components, then the manufacturing process is simple, but the ability to form complex structures with precise alignment and integration is limited

Engineering Contradiction:

Improveability to form complex knitted structuresVSAvoidknitting machine capability

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The knitted component is divided into multiple portions (first portion, second portion, third portion) that are formed separately on different regions of the knitting machine. Each portion can be knitted with different structures (e.g., single-jersey, double-jersey) and then aligned and connected through connection courses, enabling complex structures to be built from simpler segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The needle beds are made movable relative to each other through racking mechanisms. This allows the first and second needle beds to be positioned at different locations during knitting, and then moved into alignment after knitting to connect the portions. The dynamic repositioning capability enables precise alignment of connection points without requiring complex static positioning systems.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple portions are knitted separately and then assembled, then manufacturing flexibility is improved, but post-knitting assembly processes are required

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly process requirement

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The knitting machine integrates multiple knitting regions and racking mechanisms into a single unified system. Multiple portions are knitted on the same machine simultaneously or sequentially, and the racking system enables their alignment and connection within the same manufacturing environment, eliminating the need for separate post-knitting assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection points and alignment features are prepared during the knitting process itself. Connection courses are knitted at predetermined locations, and the racking system pre-positions the needle beds to ensure proper alignment before final connection, so that no additional assembly steps are needed after knitting.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If needle beds are positioned far apart to form separate portions, then manufacturing flexibility is improved, but alignment precision for connection is reduced

Engineering Contradiction:

Improveportion separation capabilityVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The racking mechanisms enable the needle beds to be dynamically repositioned. After knitting portions at separated locations, the needle beds can be moved along controlled paths to precise alignment positions. The system maintains the ability to separate portions for flexibility while using active racking to achieve accurate alignment when needed for connection.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The knitting machine incorporates control systems that monitor and adjust the racking movements to ensure precise alignment. Position sensors and control algorithms enable the needle beds to be moved to exact predetermined positions for connection, maintaining alignment precision even when portions were knitted at widely separated locations.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP3894621B1Knitting method using needle bed racking

Publication Date: 2025.01.29 NIKE INNOVATE CV

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Figure 5A~5B

AI summary

A method may include knitting a first portion (152) of a knitted component on a first region (156) of a knitting machine, knitting a second portion (154) of the knitted component on a second region (158) of the knitting machine, moving the first portion (152) of the knitted component towards the second portion (154) of the knitted component by moving a first needle bed (102) of the knitting machine relative to a second needle bed (104) of the knitting machine, and knitting at least one course (142) with the knitting machine that connects the first portion (152) of the knitted component to the second portion (154) of the knitted component.