Protected Float Knitted Footwear Component
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Solution Overview
Problem
Existing knitted components for footwear applications lack effective integration of multiple yarn types and structures to enhance both durability and comfort, while also providing adequate protection and visual appeal.
Innovation Solution
A knitted component with a multi-bed construction, featuring a first yarn type for the outer surface and a second yarn type with floats and stitches that extend across cavities formed in the first layer, providing enhanced strength, stretch resistance, and visual properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single yarn type is used in knitted components, then the manufacturing process is simple, but the durability and stretch resistance are insufficient
Solution Approach 1:
The patent employs composite materials by integrating multiple yarn types (first yarn type for outer surface, second yarn type with floats and stitches for internal structure) within the knitted component. This composite construction provides both durability through the second yarn type's reinforcing floats and stitches, and visual appeal through the first yarn type's outer surface, while maintaining stretch resistance through the multi-bed construction.
Solution Approach 2:
The knitted component is segmented into distinct functional layers: a first layer with outer surface yarns providing visual appearance, and a second layer with internal yarns providing structural reinforcement. This segmentation allows each yarn type to perform its specific function optimally while being integrated through the multi-bed knitting process.
2Reliability
If multiple yarn types are integrated to enhance durability and visual appeal, then the knitted component achieves improved performance, but the manufacturing process becomes more complex
Solution Approach 1:
The multi-bed construction serves multiple functions simultaneously: it creates the outer surface appearance, incorporates internal floats and stitches for reinforcement, and maintains stretch resistance all within a single knitting process. This multi-functionality achieves improved reliability without requiring separate manufacturing steps for different yarn types.
3Shape
If floats are exposed on the outer surface for visual appeal, then the visual properties are enhanced, but the floats become vulnerable to damage
Solution Approach 1:
The floats are nested within the multi-bed construction, where they are visible from the outer surface but protected by the surrounding knit structure. The floats are integrated into the second yarn type course that is spaced apart from the first yarn type outer surface, allowing visual appeal while the knit stitches provide protective coverage.
Data Source
Figure 1
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Figure 4~5
AI summary
A knitted component (10, 38) may include a course of a first yarn type (26) and a course (48, 62, 66) of a second yarn type (58), a first surface (18) at least partially formed by the course of the first yarn type (26), and a cavity (30, 42) formed within the knitted component (10, 38) that is recessed relative to the first surface (18), wherein the cavity (30, 42) has a sloped surface (46). A first float (44, 78) formed by the course (44, 62, 66) of the second yarn type (58) extends across the cavity (30, 42) and is exposed.