Sock-like Footwear Upper with Integrated Knitted Sub-structures
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Solution Overview
Problem
The manufacturing process of footwear is labor-intensive due to the need for numerous components and materials, which complicates the construction of a comfortable and secure upper that fits well on the foot.
Innovation Solution
A sock-like upper design featuring two knitted layers with integrated sub-structural components, such as a heel counter and toe box, where the second layer is pulled over the first to create a seamless, three-dimensional structure, simplifying the manufacturing process and enhancing comfort and fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multi-component upper construction is used, then structural support and comfort can be achieved, but manufacturing complexity and labor intensity increase significantly
Solution Approach 1:
The patent merges multiple separate upper components into a single integrated knitted structure. The upper is constructed as one piece with embedded sub-structural components (heel counter, toe box, tongue) rather than assembling multiple separate parts, thereby reducing manufacturing steps and complexity while maintaining structural functionality
Solution Approach 2:
The single knitted upper structure performs multiple functions simultaneously: it provides structural support, comfort, breathability, and secure fit. The integrated design allows one component to replace what traditionally required multiple specialized parts, simplifying the overall construction while maintaining all necessary footwear functions
2Productivity
If multiple separate parts are stitched or cemented together, then structural integrity can be achieved, but manufacturing time and labor requirements increase
Solution Approach 1:
The sub-structural components (heel counter, toe box, tongue) are pre-formed and then integrated into the knitted upper structure during the knitting process itself, rather than requiring separate assembly steps afterward. This preliminary preparation and integration eliminates time-consuming post-manufacturing assembly operations
Solution Approach 2:
The knitting process itself creates the final upper structure with embedded support components without requiring external stitching or cementing operations. The structure builds itself through the knitting process, eliminating the need for additional labor-intensive assembly steps and reducing overall manufacturing time
3Adaptability or versatility
If traditional upper construction with multiple materials is used, then functional requirements can be met, but material selection complexity and processing requirements increase
Solution Approach 1:
The upper is constructed from a single material type (knitted fabric) throughout, eliminating the need to work with multiple different materials. This homogeneous construction simplifies material selection and processing while still achieving functional requirements through the three-dimensional knitted structure and embedded components rather than material diversity
Data Source
AI summary
Articles of footwear with a sock-like upper and methods for constructing thereof are provided. In one embodiment, an upper comprises a first layer including a first interior and a first exterior, a second layer including a second interior and a second exterior, where the first layer and the second layer comprise a same material and are physically coupled at one end of each layer, and a plurality of sub-structural components positioned between the first exterior and the second interior. In this way, manufacturing articles of footwear with a sock-like upper may be simplified, while the comfort and fit of the articles of footwear may be improved.