Unitary Knit Footwear Upper With Gores for Even Stress Distribution

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Solution Overview

Problem

Conventional footwear uppers are complex, requiring multiple material elements that increase manufacturing time, cost, waste, and discomfort due to uneven stress distribution and stitch junctions, while being difficult to recycle.

Innovation Solution

A knitted footwear upper formed through a unitary knit construction with strategically aligned knitting directions and gores to distribute forces and reduce material complexity, using varied yarns for specific properties and seamless integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple material elements are used in the upper to provide different properties (stretch-resistance, wear resistance, flexibility, air-permeability), then the performance and functionality of the upper is improved, but the manufacturing complexity, time, and cost increase

Engineering Contradiction:

Improvefunctional properties of upperVSAvoidnumber of material elements

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple material elements into a single integrated knitted upper. The knitted construction allows different zones of the upper to have different properties (stretch-resistance, wear resistance, flexibility, air-permeability) without requiring separate material pieces to be stitched together. This reduces manufacturing complexity while maintaining functional versatility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The knitted upper implements local quality by varying the knit structure in different regions to provide specific properties where needed. For example, certain areas can have tighter knits for durability while other areas have looser knits for breathability or stretch, all within a single continuous material.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If multiple material elements are joined together with stitching or adhesive bonding, then different properties can be imparted to different areas, but waste material accumulates and manufacturing expense increases

Engineering Contradiction:

Improvearea-specific propertiesVSAvoidwaste material from cutting and stitching

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

By combining all material elements into one knitted piece, the patent eliminates the cutting and stitching processes that generate waste. The entire upper is constructed from a single continuous knitted fabric, minimizing material loss and eliminating adhesive or thread waste.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple material elements are joined together, then multiple properties can be achieved, but the upper becomes more difficult to recycle

Engineering Contradiction:

Improvemulti-property upperVSAvoidrecyclability

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple functional properties into a single homogeneous knitted material structure, making the entire upper recyclable as one material type. Unlike multi-material constructions that require separation before recycling, the knitted upper can be processed uniformly, improving ease of recycling while maintaining multi-property functionality.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If multiple pieces are stitched together, then structural integrity can be achieved, but stitch junctions transfer stress unevenly causing failure or discomfort

Engineering Contradiction:

Improvestructural integrityVSAvoiduniform stress distribution

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent merges multiple pieces into a single continuous knitted structure, eliminating stitch junctions that create stress concentration points. The uniform knit structure distributes stress evenly across the entire upper, improving reliability and preventing failure at junction points while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

5Strength

If additional material and stitch joints are added, then support and structure are enhanced, but comfort is reduced due to discomfort when worn

Engineering Contradiction:

ImprovesupportVSAvoidcomfort

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent merges support structures into the knitted fabric itself rather than adding separate rigid elements. The knitted construction provides necessary support through its inherent elasticity and structure while maintaining comfort by avoiding hard stitch joints and additional material layers that would cause discomfort.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3175026B1Article of footwear incorporating an upper with a gore in the knit structure

Publication Date: 2025.09.24 NIKE INNOVATE CV

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AI summary

An article of footwear includes an upper incorporating a knitted component formed of unitary knit construction. The knitted component includes portions having courses aligned along different knitting directions, including a first knitting direction and a second knitting direction. The knitting direction of the courses transitions gradually from the first direction to the second direction. The knitting direction of the courses of the knitted component is configured to be aligned so as to distribute forces acting on the knitted component when the article of footwear is worn during a sport or athletic activity.