Shoe with knitted outer sole
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Solution Overview
Problem
The manufacturing of sports shoes faces challenges such as waste production, difficulty in connecting outer soles and midsoles made from different materials, and the time-consuming process of forming functional areas, which increases costs and weight.
Innovation Solution
The use of knitwear for both the outer sole and midsole, which can be easily manufactured on knitting machines without cutting, and connected to the upper using sewing or thermoplastic yarns that fuse under pressure, allowing for simpler and cost-effective production with reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If outer soles and midsoles are made from different materials (e.g., rubber and polyurethane), then functional properties are improved, but connection difficulty increases and manufacturing complexity worsens
Solution Approach 1:
The patent merges the outer sole and midsole into a single integrated knitwear component manufactured in one piece on a knitting machine. This eliminates the need for separate manufacturing and connection processes, reducing manufacturing complexity while maintaining functional properties through material selection in different zones of the knitwear structure.
Solution Approach 2:
The patent applies local quality by using different yarns and knitting patterns in different areas of the sole to provide zone-specific functional properties. The knitwear can incorporate varying material compositions, densities, and structures in different regions to optimize performance while maintaining a unified manufacturing process.
2Manufacturing precision
If traditional cutting processes are used for manufacturing outer soles and midsoles, then shape precision is improved, but waste production increases
Solution Approach 1:
The patent extracts the cutting operation entirely from the manufacturing process by knitting the outer sole and midsole directly into the desired final shape on the knitting machine. This eliminates material waste associated with cutting while maintaining precise shape control through the knitting process itself, which can produce complex geometries without post-processing removal of material.
3Adaptability or versatility
If functional areas are formed during the manufacturing process, then product functionality is improved, but production time and costs increase
Solution Approach 1:
The patent applies preliminary action by incorporating all functional features, zones, and structural elements directly into the knitwear during the primary knitting process. Functional areas such as cushioning zones, traction patterns, and structural reinforcements are built-in from the start rather than added later, eliminating secondary processing steps and reducing production time while maintaining full functionality.
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
This approach results in a lightweight, cost-effective, and quickly manufactured shoe with minimal waste, where functional areas can be easily formed during production, enhancing durability and traction while reducing production time and costs.
Implementation Method 1
thermoplastic yarns that fuse under pressure
Implementation Method 2
thermoplastic yarns that fuse under pressure
Data Source
AI summary
Described are shoes, particularly a sports shoe, having an upper and at least one of an outer sole and a midsole connected to the upper. As examples, the outer sole is knitted in a unitary fashion with the upper. As further examples, an insert is positioned within the one-piece knitwear, wherein the insert comprises a profile that increases traction of the outer sole.