FOOTWEAR UPPER HAVING A UNITARY KNIT STRUCTURE AND METHOD OF MANUFACTURING

Smart overview of the Invention

The patent application describes a footwear upper with a unitary knit structure designed to enhance functionality and sustainability. This knit structure consists of three integrally knitted layers: an outer face layer, an inner face layer, and an intermediate layer. These layers are engineered to provide varying breathability, elasticity, and cushioning across different zones of the shoe. The manufacturing process is streamlined to reduce waste and minimize post-processing steps, aligning with sustainable production goals.

Structural Composition

The knit structure is divided into first and second zones that alternate longitudinally across the footwear upper. The first zones feature a denser intermediate knit layer, offering greater elasticity and cushioning. In contrast, the second zones have less density or lack the intermediate layer entirely, enhancing breathability. This strategic zoning allows for targeted performance benefits like improved foot containment in the heel region and increased ventilation in the forefoot region.

Design Features

The footwear upper's design includes seamless integration of the knit layers, eliminating the need for sewn seams and reducing manufacturing complexity. The first zones are generally wider in the heel area for better support, while the second zones are broader in the forefoot for enhanced airflow. This configuration supports both stability and comfort, with boundaries between zones extending linearly across the shoe for optimal foot containment.

Material Selection

Materials used in the knit layers are carefully chosen to balance durability and recyclability. The outer face layer typically consists of monofilament yarns for abrasion resistance, while the inner face layer uses multi-filament yarns for comfort. The intermediate layer can contain either type of yarn, contributing to overall structural integrity. These materials are selected not only for performance but also to facilitate recycling processes.

Sustainability Considerations

The entire knit structure is designed to be recyclable, using thermoplastic yarns that can be melted down and reformed into new products. This approach minimizes environmental impact by allowing the footwear upper to be recycled efficiently. By focusing on single-class polymer materials, the design ensures that all components of the knit structure can be repurposed without additional processing complications.