Trimmed Knitted Footwear Upper for Variable Sizing
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Solution Overview
Problem
Conventional footwear manufacturing methods require multiple material elements and complex assembly processes, leading to inefficiencies in producing footwear that fits various foot sizes, particularly in terms of upper component sizing and adjustment.
Innovation Solution
A method involving a knitted component with a unitary knit construction and a tensile strand, where the knitted component can be trimmed to specific dimensions using predetermined trim lines to accommodate different foot sizes, and the tensile strand can be adjusted and manipulated to secure the fit, allowing for efficient production of footwear that fits various anatomical foot sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material elements and complex assembly processes are used to accommodate different foot sizes, then the fit and adjustability are improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The knitted upper is designed as a universal component that can be trimmed to multiple sizes, allowing a single base design to serve multiple foot sizes. The upper includes predetermined trim lines and tensile strands that enable size adjustment without requiring different upper designs for each size category.
Solution Approach 2:
The knitted upper is constructed with segmented tensile strands that can be individually adjusted and trimmed. This segmentation allows the upper to be customized for different foot sizes by trimming along predetermined lines while maintaining the structural integrity through the distributed tensile strand system.
2Reliability
If multiple material elements are used to form the upper, then the functional properties (stretch-resistance, wear-resistance, flexibility) are improved, but the manufacturing efficiency decreases
Solution Approach 1:
Multiple material functions are merged into a single knitted upper construction. The upper is formed from knit material that inherently provides stretch-resistance, wear-resistance, and flexibility without requiring separate material layers or components. Tensile strands are integrated into the knit structure to provide additional structural support.
Solution Approach 2:
The knitted upper combines knit material with integrated tensile strands to create a composite structure that achieves multiple functional properties simultaneously. The combination of knit material and tensile strands provides both the flexibility and durability of knit materials plus the structural strength and size-adjustment capability of tensile strands.
3Strength
If conventional uppers are formed from multiple material elements, then the durability and functional properties are improved, but the material waste and production complexity increase
Solution Approach 1:
The knitted upper is constructed with predetermined trim lines and integrated tensile strands before the trimming process. This preliminary arrangement of structural elements ensures that the upper maintains its strength and durability characteristics after trimming to the final size, eliminating the need for additional reinforcement materials that would increase waste.
Data Source
AI summary
An upper for an article of footwear associated with one of a first foot size and a second foot size. The upper includes a knitted component including a trim region that defines a trimmed outer edge of the knitted component. The trimmed outer edge is associated with a first dimension of the upper that corresponds to the first foot size, and the trim region includes a trim line that is spaced from the trimmed outer edge in an inboard direction on the knitted component. The trim line defines a second dimension of the upper that corresponds to the second foot size. The second foot size is smaller than the first foot size. The knitted component includes a knit element having a first layer and a second layer.