Three-Dimensional Knitted Shoe Upper with Shrink Yarn Support
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Solution Overview
Problem
Traditional shoe manufacturing methods face challenges in producing a knitted shoe upper with localized support and cushioning properties due to the complexity of sewing multiple materials together, leading to increased production costs and discomfort from seams.
Innovation Solution
A knitted shoe upper is produced as a single piece using a three-dimensional knitting process with activated shrink yarns to provide localized support and cushioning, allowing for seamless construction and improved fit, and incorporating fuse yarns for additional structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sheets of material with different properties are sewn together to provide localized support, then the level of support and cushioning is improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent combines multiple sheets of material with different elastic properties into a single integrated knitted upper. Different regions of the upper are knitted with varying yarn elasticities to provide localized support and cushioning, eliminating the need to sew multiple separate sheets together while maintaining the functional benefits of material differentiation.
Solution Approach 2:
The patent implements local quality by varying the elasticity of yarns used in different regions of the knitted upper. High-elasticity yarns are used in areas requiring flexibility and comfort, while low-elasticity yarns are used in areas requiring structural support, allowing each region to have optimized properties for its specific function.
2Reliability
If multiple sheets of material are sewn together to create different functional regions, then the level of support is improved, but wearing comfort deteriorates due to sewn seams
Solution Approach 1:
The patent merges multiple functional regions into a single seamlessly knitted upper. By knitting different regions with different yarn properties in one continuous process, the patent eliminates sewn seams that cause discomfort, blisters, and potential foot injuries while maintaining the localized support functions of each region.
3Adaptability or versatility
If the number of different yarns is increased to provide more functional regions, then the customization and support are improved, but the knitting time and production cost increase
Solution Approach 1:
The patent uses parameter changes by varying the elasticity parameter of yarns across different regions of the upper. Instead of using many different types of yarns, the patent achieves functional differentiation by controlling the elasticity parameter, allowing a limited number of yarn carriers to produce multiple functional regions with distinct properties.
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 method simplifies production, reduces waste, and enhances comfort by providing a seamless, customizable fit with improved support and stress transfer to the sole, suitable for sports shoes.
Implementation Method 1
the first yarn comprises a shrink yarn which shrinks when activated
Data Source
AI summary
A knitted upper for an article of footwear. The knitted upper is formed essentially as a single piece in a three-dimensional knitting process. The knitted upper includes at least one activated shrink yarn.