Footwear Upper With Ribbed Cuff and Asymmetric Knit Shape
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Solution Overview
Problem
Conventional footwear uppers lack a combination of flexibility, support, and aesthetic appeal, particularly in athletic footwear, while also requiring complex post-knitting processes to achieve desired shapes and structures.
Innovation Solution
The upper is formed using a multi-layer knit element with a ribbed knit structure for the cuff, incorporating elastic yarns and hidden yarns that reveal upon stretching, and a second knit structure with asymmetrical material distribution to create a curved shape, allowing for a dynamic visual effect and enhanced support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional upper structure is used, then manufacturing simplicity is maintained, but flexibility and support are insufficient
Solution Approach 1:
The upper incorporates a knit element with multiple knit structures (first knit structure in the collar area providing flexibility, second knit structure in the instep area providing support) combined with inlaid strands of different materials (elastic strand, non-elastic strand) to achieve both flexibility and support within a single integrated structure
Solution Approach 2:
The knit element is divided into different functional regions with distinct knit structures - the collar area uses a first knit structure for flexibility while the instep area uses a second knit structure for support, allowing each region to perform its specific function optimally
2Manufacturing precision
If complex post-knitting processes are applied to achieve desired shapes, then manufacturing precision is improved, but manufacturing complexity and time increase
Solution Approach 1:
The desired curved shape and structural features are built directly into the knit element during the knitting process itself through asymmetric material distribution and specific knit structure formation, eliminating the need for complex post-knitting shaping operations
Solution Approach 2:
The knitting process integrates multiple functions - forming the basic upper structure, creating the curved shape, incorporating different knit structures for different regions, and embedding inlaid strands - all in a single continuous process rather than separate sequential operations
3Ease of manufacture
If uniform material distribution is used in the knit element, then manufacturing simplicity is maintained, but aesthetic appeal and visual interest are reduced
Solution Approach 1:
The knit element employs asymmetric material distribution where the first side has different material composition and knit structure than the second side, creating a curved shape and visual interest while the knitting machine maintains uniform manufacturing processes through programmed needle selection
Solution Approach 2:
The knit element is designed with intentional asymmetry where one side contains more material and forms a convex curve while the other side has less material, creating an aesthetically pleasing irregular shape that deviates from conventional symmetric footwear uppers
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 a comfortable, secure fit with adjustable support and breathability, while reducing the need for post-knitting processes, and offering a visually appealing design through hidden and revealed yarns.
Implementation Method 1
The ribbed knit structure may include a yarn formed of an elastic material
Implementation Method 2
the first side may be formed of at least 30% more material than the second side such that the first area is configured to curve convexly away from the first side
Data Source
Figure 1
Figure 2
Figure 3A~3D
AI summary
In one aspect, an upper for an article of footwear may include a knit element, a collar area configured to form an ankle opening, and a cuff in the collar area. The cuff may be at least partially formed by the knit element and may include a ribbed knit structure of the knit element. In another aspect, an upper for an article of footwear may include a knit element with a first area, the first area including a first side and a second side opposite the first side. The first side may be formed of at least 30% more material than the second side such that the first area is configured to curve convexly away from the first side.