Abstract: An automated unspooling mechanism capable of dispensing of knitting material strands in a dynamically-controlled tension on a knitting machine. An unspooling device is configured to sense the tension of a strand fed to the knitting machine, and responsively adjust the strand deployment speed to avoid too little or too much strand dispensing without interrupting the knitting process. The unspooling device includes a variable motor drive that can rotate the strand package in various speeds, and a spring arm trigger that can sense the current tension of the dispensed material. The spring arm trigger can vary its arm position based on the sensed tension. The arm position is then processed and converted to a signal to vary the motor speed. Therefore, the deployment speed of the strands can be dynamically controlled based on a sensed tension of feeding the strand.

Abstract: Systems and methods for manufacturing knitted shoe uppers. An article of fully finished three-dimensionally weft knitted footwear is manufactured through a knitting process which can be performed by an automated V-bed flat knitting machine. During the knitting process, a plurality of knitted members are knitted into shape sequentially and connected to one another through knitted live hinges, each member being a ply, a layer, a layer portion or an appendage. The knitting machine manipulates the knitted members into their destined places as in the final product without cutting and sewing, thereby forming a seamless unitary textile construction. The process creates a seamless, full gauge, dimensionally stable footwear upper, as a unitary textile construction with an integrated anatomically appropriate heel. The entire upper, including the closure element of the upper, may be completed exclusively by the knitting machine, ready for the following shoe making process.

Abstract: Systems and methods for manufacturing knitted shoe uppers. An article of fully finished three-dimensionally weft knitted footwear is manufactured through a knitting process which can be performed by an automated V-bed flat knitting machine. The knitting process includes manipulating one or more double-knit stitch types and joining the stitches exclusively in the knitting process to create a seamless upper to fit a foot. A resulting upper advantageously has no sewn seams and requires no manual post process to cut or sew the upper to create the dimensional shape. The process creates a seamless, full gauge, dimensionally stable footwear upper, as a unitary textile construction with an integrated anatomically appropriate heel. The entire upper, including the closure element of the upper, may be completed exclusively by the knitting machine, ready for the following shoe making process.

Abstract: System and method of manufacturing a unitary construction of a weft knit article with one or more warp insert in an integrated knitting process by using a weft knit machine. The unitary construction comprises one or more yarn materials which are incorporated into one or more weft and warp stitch structures. The knitting machine is equipped with a warp feeder assembly, including a weft knit warp feeder, a warp knitting guide needle block operable to hold a plurality of warp strands, a strand guide bar configured to guide the plurality of warp strands to the weft knit warp feeder, and a cam box. The cam box includes at least a weft stitch cam, a weft guard cam, a warp stitch cam, and a warp guard cam.

Abstract: Systems and methods for manufacturing knitted shoe uppers. An article of fully finished three-dimensionally weft knitted footwear is manufactured through a knitting process which can be performed by an automated V-bed flat knitting machine. During the knitting process, a plurality of knitted members are knitted into shape sequentially and connected to one another through knitted live hinges, each member being a ply, a layer, a layer portion or an appendage. The knitting machine manipulates the knitted members into their destined places as in the final product without cutting and sewing, thereby forming a seamless unitary textile construction. The process creates a seamless, full gauge, dimensionally stable footwear upper, as a unitary textile construction with an integrated anatomically appropriate heel. The entire upper, including the closure element of the upper, may be completed exclusively by the knitting machine, ready for the following shoe making process.

Abstract: Systems and methods for manufacturing knitted shoe uppers. An article of fully finished three-dimensionally weft knitted footwear is manufactured through a knitting process which can be performed by an automated V-bed flat knitting machine. The knitting process includes manipulating one or more double-knit stitch types and joining the stitches exclusively in the knitting process to create a seamless upper to fit a foot. A resulting upper advantageously has no sewn seams and requires no manual post process to cut or sew the upper to create the dimensional shape. The process creates a seamless, full gauge, dimensionally stable footwear upper, as a unitary textile construction with an integrated anatomically appropriate heel. The entire upper, including the closure element of the upper, may be completed exclusively by the knitting machine, ready for the following shoe making process.

Abstract: An article includes a knitted component of unitary knit construction. The knitted component has a first edge and a second edge. The knitted component has a length that is measured between the first edge and the second edge. The length is substantially fixed. The knitted component also includes a base structure and an adjustment member that is integrally knit to the base structure. The adjustment member includes a bunched region that is configured to slide along the base structure between a first position on the knitted component and a second position on the knitted component.