DE102023135606A1 - Knitted upper material for a sports shoe - Google Patents

Abstract

The present invention relates to a knitted upper material (1) for a shoe, comprising: a knitted inner collar (2) defining a circumferential first free edge (3) of the upper material (1) and adapted to completely surround a portion of a leg of a wearer of the shoe; at least one knitted outer collar (4) at least partially surrounding the inner collar (2) and defining a second free edge (5) of the upper material (1), wherein the inner collar (2) and the outer collar (4) are a one-piece knitted construction.

Description

1. Technical area

The present invention relates to a knitted upper material for a sports shoe, a shoe with such a knitted upper material and a method for producing such a knitted upper material.

2. State of the art

A footwear article typically comprises two main elements: an upper and a sole element. Knitting is widely used to manufacture shoe uppers, especially for athletic shoes. Knitted uppers offer high levels of comfort, flexibility, and breathability. A particular design focus of shoe uppers for athletic shoes in general is the collar portion of the upper. Since the collar portion is usually located at or near the Achilles tendon, which is quite sensitive to pressure, the collar of a shoe upper, especially for an athletic shoe, must be carefully designed. On the other hand, the collar portion complements the fit of the shoe and must provide some support for the ankle portion to prevent the foot from slipping inside the shoe. Finally, the collar portion must provide sufficient grip for the fingers to assist stepping into the shoe.

Thus, known knitted upper materials leave room for improvement, especially regarding the design of the collar section, to meet the above-mentioned needs.

3. Summary of the invention

The above objects are at least partially achieved by the subject matter of the independent claims. Preferred embodiments are subject matter of the dependent claims, and other suitable aspects of the present invention are described by the overall disclosure of the present application.

In one aspect, these objects are achieved by a knitted upper for a shoe, comprising: a knitted inner collar defining a circumferential first free edge of the upper and configured to completely surround a portion of a leg of a wearer of the shoe; at least one knitted outer collar at least partially surrounding the inner collar and defining a second free edge of the upper, wherein the inner collar and the outer collar are a one-piece knitted construction.

The knitted upper according to the invention comprises a knitted inner collar and a knitted outer collar. "Inner" and "outer" are to be understood with reference to the position of the collars relative to a foot or leg of a wearer who would wear a shoe comprising the knitted upper in the usual manner. Thus, the inner collar would be located near a leg portion, e.g., an ankle, a lower leg, or even a knee, while the outer collar would be located more distal to that portion of the leg. Depending on the tension and/or diameter and/or height and/or vertical extent of the inner collar, it could at least partially contact the foot, leg, or sock of a wearer.

According to the invention, both collars are knitted, which typically means that they are knitted on a conventional knitting machine, like the rest of the knitted upper. The inner collar defines a circumferential free edge of the upper. "Circumferential" is again to be understood with reference to a wearer's foot or leg and means that the edge defined by the inner collar completely surrounds the foot or leg. The edge is further "free" in the sense that it is not directly connected to other sections of the upper. For example, it would be possible to grasp the free edge and hold it between two fingers.

The outer collar also defines a free edge in the sense explained with respect to the inner collar. Thus, the free edge of the inner collar is not directly connected to sections of the outer collar, and the free edge of the outer collar is not directly connected to sections of the inner collar.

The inner collar and outer collar are a one-piece knitted construction, meaning they are not knitted in separate processes and then joined by, for example, gluing, welding, or sewing. Instead, both the inner collar and the outer collar are obtained in a single knitting operation. This is easily visible by the absence of any additional connecting means such as glue, fused material, or sewing threads. Rather, some loops forming the outer collar are knitted together with some loops forming the inner collar. An exemplary technique for this is explained in more detail below.

A knitted upper according to the invention with an inner collar and an outer collar provides additional grip to assist stepping into a shoe. To this end, a wearer can grasp the inner collar with their fingers and pull the heel portion of the shoe, which comprises the upper, to place the shoe over the foot. Thus, the inner collar acts as a type of handle. In general, the inner collar can be designed to serve various functions. For example, the inner collar could be designed to fit securely around an ankle or upper portion of a wearer to provide support. Additionally, the inner collar can be provided with additional cushioning or padding to protect the sensitive Achilles tendon and/or ankle (ankle bone). Furthermore, the height of the inner collar can be selected independently of the position of the outer collar. Thus, the inner collar could end much higher on a wearer's foot or leg than the outer collar. Thus, the inner collar could provide a better fit of the shoe, while the outer collar, as described above, could act as a handle or additional grip, which would not be possible with just a single collar. A higher inner collar would also reduce pressure, as it would have a much larger contact area compared to a lower collar. Similarly, the inner collar could be designed to be much thicker than the outer collar to reduce pressure and provide a means to grip and pull the shoe. In general, the function of the inner collar can be designed independently of the function of the outer collar. However, since the collars can be manufactured together with the rest of the upper in a single knitting process, no additional parts are required to achieve such decoupled functions, saving knitting time and manufacturing costs. The outer collar can act as an additional stabilizing element and can also ensure that the entire collar unit does not slip. The outer collar also increases compression on the foot, ensuring it is more consistent throughout the wear period.

The inner collar and outer collar can be knitted in a single knitting operation. As mentioned above, this allows for two different functionalities of the collar portion of the upper without additional parts, saving manufacturing time and costs.

The outer collar may be shaped like a tab or a sipe. This allows the outer collar to be used as a handle to grasp a shoe, encompassing the upper, or to pull the shoe over a foot when stepping into the shoe.

The inner collar and outer collar can overlap in a heel area of the upper. Thus, the outer collar can provide an additional function in the heel area. For example, the inner collar can be sufficiently thick and high to protect the Achilles tendon and/or ankle. Additionally, it could act as a grip in the heel area. The outer collar can act as an additional stabilizing element.

The inner collar may comprise a first yarn, and the outer collar may comprise a second yarn, wherein the first yarn may be different from the second yarn. In this way, different functions can be provided to the inner and outer collars by appropriately selecting the yarns.

The first yarn may be more moisture-permeable than the second yarn. Thus, the inner collar can wick moisture away from a foot, while the outer collar can provide a different function.

The second yarn may be more abrasion-resistant than the first. This allows the outer collar to protect the inner collar, which in turn may comprise a more delicate yarn providing a different function, such as moisture permeability, as explained above.

The inner collar may be disposed proximal to a foot of a wearer wearing a shoe comprising the knitted upper, and the outer collar may be disposed distal to the foot. Thus, as explained above, the inner collar may provide functions such as cushioning, padding, and protection, whereas the outer collar, which is more distal to the foot, may provide functions such as additional grip.

The inner collar and/or the outer collar may comprise an elastic yarn. This facilitates the insertion of a foot into the shoe, which encompasses the upper material, as both collars can stretch sufficiently.

At least one of the first collar and the second collar may have been obtained by partial knitting. Partial knitting is a technique that allows only a specific needle section of a row of needles to be used for stitch formation. Thus, no knitting takes place across the entire row of needles. Wise knitting allows you to get collars with almost any shape instead of just uniform circumference collars.

The yarn tension in the inner collar can be different from the yarn tension in the outer collar. This allows the inner collar to be shaped differently than the outer collar, as the yarn tension influences the shape of the knitted structure. Furthermore, the yarn tension determines the stretchability of a knitted structure to a certain extent, so the inner collar and outer collar can be provided with different stretchability.

The knit structure of the inner collar may differ from the knit structure of the outer collar. This may result in different functions provided by the inner collar and the outer collar. For example, the knit structure of the outer collar may be coarser than the knit structure of the inner collar. This makes the outer collar easier to grip, for example, to pull on a shoe, whereas the inner collar provides a more comfortable feel.

A coarser outer collar would provide better thermal insulation and allow for greater forces to be absorbed, for example when tightening the shoe.

The shape of the inner collar may differ from the shape of the outer collar. This allows the collars to be provided with specific functions. For example, the outer collar may be shaped like a tab to facilitate gripping of a shoe, encompassing the shoe upper.

The outer collar may define a circumferential second free edge of the upper configured to surround a portion of a leg of a wearer of the shoe. Thus, the outer collar may surround the foot in the same way as the inner collar. The outer collar may protect the underlying inner collar. In another example, the outer collar acts as a circumferential tab for grasping and/or pulling a shoe that includes the upper.

The inner collar and outer collar can each be formed by a single knitted layer folded upon itself. This allows both the inner and outer collar to be knitted in a single knitting operation.

The distance between the free edge of the inner collar and a point where the inner collar and outer collar are joined may be greater than a distance between the free edge of the outer collar and the point where the inner collar and outer collar are joined. In other words, the inner collar extends higher on the wearer's leg relative to the outer collar when the shoe is worn. Thus, for example, the inner collar may be higher than the outer collar to reduce pressure on the foot or leg while still providing adequate support.

The inner collar can be thicker than the outer collar. As explained, this allows the inner collar to protect the Achilles tendon, for example, while the outer collar could act as a tab for gripping and/or pulling a shoe that encompasses the upper.

The inner collar and outer collar may have been produced on a circular knitting machine, preferably a small circular knitting machine and most preferably a small intarsia circular knitting machine. An intarsia knitting machine comprises a cylinder capable of reciprocating movements to produce intarsia sequences. A circular knitting machine allows the knitted outer fabric to be formed into a tubular structure that conforms to the natural shape of an outer fabric. Unlike knitting on a flat knitting machine, few or no additional steps are required to bring the outer fabric into its final shape. According to ISO 8117:2003, a small circular knitting machine has a diameter between 2 1/4 and 6 1/2 inches, which corresponds to 57.15 mm to 165.1 mm.

The inner collar and/or the outer collar can be filled with padding. This allows the ankle area, particularly the Achilles tendon, to be protected and increases the comfort of a shoe that incorporates the upper. Padding is particularly advantageous in the back of the collar and on the left and right sides below the ankle. In this case, the padding can be inserted directly during knitting, or a corresponding foam element can be inserted subsequently with appropriate preparation, for example, by creating an opening and/or pocket.

The knitted outer material may comprise a plurality of outer collars. The additional outer collars may have the same features as described herein with respect to the (single) outer collar. Thus, what is described herein with respect to the (single) outer collar is also applicable to multiple outer collars, in particular with respect to the functions, features, embodiments, and advantages of the (single) outer collar. Furthermore, additional outer collars may provide additional functions for the outer material. For example, the inner collar could provide moisture permeability and a soft feel, a first outer collar arranged on the inner collar could comprise abrasion-resistant yarn to protect the inner collar, and a second outer collar arranged on the first outer collar could comprise highly abrasive reflective yarns to meet safety aspects. This would not be possible with a single collar, as the abrasive yarn would come into contact with the wearer's skin or sock, which would be perceived as unpleasant.

The knitted upper may further comprise an inner sock and an outer sock knitted integrally with the inner sock. By folding the inner sock inside the outer sock, a complete upper is obtained. The inner sock and the outer sock may provide different functions for the upper. For example, the inner sock may be softer than the outer sock and/or be moisture-permeable. The outer sock may be more abrasion-resistant and/or stiffer than the inner sock.

The knitted upper may further comprise a knitted tongue that is knitted integrally with the inner sock and has a double-layer construction. The knitted tongue may be knitted similarly to the inner collar and outer collar. Thus, the number of additional components of the knitted upper is significantly reduced, as are the manufacturing costs and time.

The knitted tongue can be formed by a single knitted layer folded upon itself to create a double-layered construction. This allows the tongue and inner sock to be knitted in a single knitting operation, similar to the inner collar and outer collar.

The invention also relates to a shoe comprising a knitted upper of the type described herein and a sole structure. It is understood that what is described herein with respect to the knitted upper is also applicable to the shoe comprising such an upper, particularly with respect to the functions, features, embodiments, and advantages of the knitted upper.

1. (a) Stricken eines ersten Abschnitts des Obermaterials auf eine Reihe von Nadeln;
2. (b) Übertragen mindestens eines Abschnitts einer Strickreihe von der Reihe von Nadeln auf Haltemittel;
3. (c) Stricken des inneren Kragens oder des äußeren Kragens;
4. (d) Übertragen des Abschnitts der Strickreihe, der auf den Haltemitteln gehalten wird, zurück auf die Reihe von Nadeln;
5. (e) Stricken mindestens einer Reihe oder eines Abschnitts davon;
6. (f) Wiederholen der Schritte (b)-(e), um den anderen des äußeren Kragens oder des inneren Kragens zu erhalten.

The invention also relates to a method for producing a knitted outer material according to the type described herein. The method comprises the steps:

1. (a) knitting a first section of the upper material onto a row of needles;
2. (b) transferring at least a portion of a knitting row from the row of needles to holding means;
3. (c) knitting the inner collar or the outer collar;
4. (d) transferring the portion of the knitting row held on the holding means back to the row of needles;
5. (e) knitting at least one row or section thereof;
6. (f) Repeating steps (b)-(e) to obtain the other of the outer collar or the inner collar.

It is understood that in step (c) either the inner collar or the outer collar is knitted and that in step (f) the outer collar is knitted if the inner collar was knitted in step (c) and vice versa. It is also understood that what is described herein with regard to the knitted outer material is also applicable to the method for producing the knitted outer material, in particular with regard to the functions, features, embodiments and advantages of the knitted outer material. The row of needles can be, for example, a needle bed of a flat knitting machine or a circular needle carrier such as a cylinder of a circular knitting machine. In general, the invention is not limited to any particular type of knitting.

In one embodiment, a circular knitting machine is used to perform the method. Preferably, a small circular knitting machine is used, and most preferably, a small intarsia circular knitting machine is used. In step (e), 1-10 rows can be knitted, more preferably 2-6, and most preferably 4-5.

4. Short description of the characters

• 1: zeigt eine Ausführungsform der vorliegenden Erfindung mittels eines gestrickten Obermaterials, umfassend einen inneren Kragen und einen äußeren Kragen;
• 2: zeigt eine kleine Intarsia-Rundstrickmaschine, die im Rahmen der vorliegenden Erfindung verwendet werden kann;
• 3A-J: zeigen weitere Ausführungsformen eines gestrickten Obermaterials gemäß der Erfindung;
• 4: veranschaulicht ein Strickprogramm für eine Strickmaschine, das zu einem gestrickten Obermaterial gemäß der Erfindung führt;
• 5: veranschaulicht ein Strickprogramm ähnlich 4 unter Bezugnahme auf ein gestricktes Obermaterial mit einer integral gestrickten Zunge;
• 6: zeigt ein beispielhaftes gestricktes Obermaterial, das aus einem Strickprogramm ähnlich 5 resultiert; und
• 7A-C: zeigen verschiedene Ausführungsformen eines gestrickten Obermaterials, das aus einem Strickprogramm ähnlich 5 resultiert.

In the following, the invention is described in more detail with reference to the following figures:

• 1 : shows an embodiment of the present invention by means of a knitted upper material comprising an inner collar and an outer collar;
• 2 : shows a small intarsia circular knitting machine that can be used in the context of the present invention;
• 3A -J: show further embodiments of a knitted upper material according to the invention;
• 4 : illustrates a knitting program for a knitting machine resulting in a knitted upper material according to the invention;
• 5 : illustrates a knitting program similar to 4 referring to a knitted upper with an integrally knitted tongue;
• 6 : shows an example knitted upper material, which is made from a knitting program similar 5 results; and
• 7A-C : show different embodiments of a knitted upper material, which is produced from a knitting program similar to 5 results.

5. Detailed description of preferred embodiments

In the following, only a few possible embodiments of the invention are described in detail. However, the present invention is not limited to these, and a variety of other embodiments are applicable without departing from the scope of the invention. The illustrated embodiments can be modified and combined with each other in a number of ways whenever compatible, and certain features can be omitted where they appear unnecessary. In particular, the disclosed embodiments can be modified by combining certain features of one embodiment with one or more features of another embodiment.

It should be understood that not all features of the described aspects/embodiments need to be present to realize the technical advantages provided by the present disclosure, which is defined by the subject matter of the claims. The disclosed aspects/embodiments may be modified by combining certain features of one aspect/embodiment with one or more features of another aspect/embodiment. In particular, those skilled in the art will understand that features and/or functional elements of one aspect/embodiment may be combined with technically compatible features and/or functional elements of any other aspect/embodiment of the present disclosure, provided that the resulting combination falls within the definition of the present disclosure.

While the following embodiments are described primarily with reference to a knitted upper material for a shoe, in particular for a sports shoe, those skilled in the art will recognize that the disclosure of the invention can equally be applied to a variety of different technical fields and/or applications.

In the present figures and description, the same reference numerals refer to the same elements. For clarity and conciseness, certain aspects of components or steps of certain embodiments are presented without undue detail when such details would be obvious to one of ordinary skill in the art in light of the teachings herein and/or when such details would obscure an understanding of more relevant aspects of the embodiments.

As will be understood by those skilled in the art and/or to avoid redundancies, reference is also made to the explanations in the preceding sections, which also apply to the following detailed description. Furthermore, for the sake of brevity and clarity, not all features, parts, elements, aspects, components, and/or steps are expressly indicated by reference numerals. This is especially true if those skilled in the art recognize that such features, parts, elements, aspects, components, and/or steps exist in plurality.

1 shows an embodiment of the present invention using a knitted upper material 1. Since the present invention focuses on the collar portion of the knitted upper material 1, 1 only the collar section is shown. The outer material according to the invention is a knitted outer material, which means that it is knitted on a knitting machine. In the example of 1 The upper was knitted on a circular knitting machine, more precisely a so-called small circular knitting machine, which comprises a circular row of needles with a diameter suitable for knitting socks and shoe uppers. Common diameters include 3, 3.5, 4, and 4.5 inches (corresponding to 76.2, 88.9, 101.6, and 114.3 mm, respectively). In other embodiments, a knitted upper according to the invention could be knitted on a flat knitting machine. Also, the embodiment of 1 on a circular knitting machine with a single row of needles, so that a single knitted layer is obtained at a time (which can be folded as follows In other embodiments, a machine with more than a single row of needles may be used so that more than a single layer is obtained at a time.

The knitted upper 1 comprises an inner collar 2 with a circumferential free edge 3. This means that the free edge 3 would completely surround a foot or leg of a wearer of a shoe comprising the knitted upper 1. The knitted upper 1 also comprises an outer collar 4, which also comprises a free edge 5. In the example of 1 The free edge 5 of the outer collar 4 is also circumferential, but this is not a requirement according to the invention. As can be seen, in other embodiments, the free edge 5 of the outer collar 4 is not circumferential.

The inner collar 2 and the outer collar 4 are knitted as one piece in a single knitting operation, which means that in particular the entire outer material 1, which is 1 shown, or at least a portion of it was obtained in a single operation. To illustrate this process, 2 a small intarsia circular knitting machine 10 with a plurality of needles 11 and a plurality of hold-down devices 12 arranged in a cylinder 13. The knitted upper material 1 of 1 is essentially designed as a tubular structure on such a knitting machine. The exemplary knitting machine of 1 has electronic needle plates that allow the stitch tension in the collar area to be adjusted, as they allow the applied tension to be adjusted and different tensions to be applied in different needle sections. The machine can handle thicker materials due to the additional hold-down devices 12 to press the knitted material down after it has been created. All hold-down devices 12 can be considered a manual take-off device. Unlike other machines, no rubber rollers or combs with hooks that pull are required. The hold-down devices 12 press each loop down after it has been formed in the stitch formation zone. Other machines have a vacuum system that pulls the knitted material down after it has been created. The machine used in 2 shown allows partial knitting/sequential knitting so that in addition to full collars, part of a collar or shaped collars can be produced and collars incorporating different block colourings can also be produced.

As the knitting process approaches the collar portion of the knitted outer material 1, the last knitted row or a portion thereof is taken up by the hold-down devices 12. The hold-down devices 12 essentially form a horizontal back row of needles comprising hooks that are not capable of creating loops/stitches, but are only used to hold the threads and/or transfer loops/stitches. The knitting process then continues on the needles 11, forming the inner collar 2. Alternatively, the outer collar 4 is formed first. When the inner collar 2 is completed, the threads that were held on the hold-down devices 12 are moved back to the cylinder 13 and a few rows (e.g. 4-5) are knitted to secure the just formed collar to the rest of the material. This process is then repeated to form the other collar, i.e. if the inner collar 2 has been formed first, the outer collar 4 is now knitted, and if the outer collar 4 has been formed first, the inner collar 2 is now knitted.

As can be seen, although collars 2 and 4 are formed by a single knitted layer (because the 2 illustrated knitting machine has only a single row of needles), this single layer is folded upon itself to form the inner collar 2 and the outer collar 4. Thus, a two-layer knitted structure is obtained for each collar. In some embodiments, the cavity thus obtained can be filled with padding. For this purpose, an opening could be left in the knitted fabric through which padding can later be introduced, and the opening then closed. Padding could also be created during knitting, for example by creating a quantity of floating yarns.

Suitable yarns for knitting a knitted outer material 1 according to the invention include polyester, spandex, and TPU yarns, but other yarns could also be used. In particular, the yarns of the inner collar 2 and the outer collar 4 can be different. Generally, an elastic yarn, such as elastane, can be used for the inner collar 2 and/or the outer collar 4. Elastane creates a more comfortable collar area and is also smoother against the skin.

3A -J show further embodiments of a knitted upper material 1 according to the invention. 3A shows a knitted outer material 1 with an inner collar 2 with a circumferential free edge 3, a first outer collar 4 with a circumferential free edge 5 and a second outer collar 6 with a circumferential free edge 7. The second outer collar 6 is obtained in the same way as the first outer collar 4, namely as described above.

3B shows a knitted outer material 1 with an inner collar 2 with a circumferential free edge 3 and an outer collar 4 with a circumferential free edge 5. In this exemplary embodiment, the inner collar 2 extends much higher on the leg of a wearer than the outer collar 4. This embodiment can also be based on the in 2 Such an embodiment could be obtained using the knitting machine shown. Such an embodiment could be used for a football boot, and the inner collar would function as an integrated sock. Shin guards could be placed in the cavity of the inner collar. An opening should be left for this purpose.

3C shows a section of a knitted upper 1 with an inner collar 2 with a circumferential free edge 3, a first outer collar 4 with a circumferential free edge 5, and a second outer collar 6 with a circumferential free edge 7. The second outer collar 6 is obtained in the same way as the first outer collar 4, namely as described above. In this example, the first and second outer collars 4 and 6 are arranged on the front side of the collar portion of the knitted upper 1, facing the instep area.

3D shows a portion of a knitted upper 1 having an inner collar 2 with a free edge 3, a first outer collar 4 with a free edge 5, and a second outer collar 6 with a free edge 7. The second outer collar 6 is obtained in the same way as the first outer collar 4, namely as described above. In particular, partial knitting can be used to obtain the collars. In this example, the first and second outer collars 4 and 6 are arranged on the back of the collar portion of the knitted upper 1, facing the area of the Achilles tendon. In this way, the outer collars provide a cushioning effect on a sensitive area.

3E shows a section of a knitted upper 1 with an inner collar 2 with a circumferential free edge 3 and an outer collar 4 with a free edge 5. In this exemplary embodiment, the outer collar 4 is also circumferential and comprises a varying height with a lower portion at the front of the collar portion. In this way, constriction at the transition from the collar to the rest of the shoe is reduced, as the collar keeps the opening wider.

3F shows a section of a knitted upper 1 with an inner collar 2 with a circumferential free edge 3 and an outer collar 4 with a free edge 5. In this exemplary embodiment, the outer collar 4 is also circumferential and comprises a varying height with a lower section at the front of the collar section and a higher section at the back of the collar section. The back section is formed as two flaps, tabs, or slats to enable gripping or pulling the upper at the heel section. The outer collar 4 is obtained using a partial knitting technique. Furthermore, both collars comprise two differently colored yarns, with the inner collar 2 comprising a striped pattern and the outer collar 4 comprising two different areas with different colors. The striped pattern is achieved by using two yarns with different colors. Additionally, the yarns could also have different functions. For example, one yarn could be an elastane yarn and the other yarn could be a polyester yarn. The elasticity of the yarns could be different.

3G shows a section of a knitted outer material 1 with an inner collar 2 with a circumferential free edge 3 and an outer collar 4 with a circumferential free edge 5. In this exemplary embodiment, the inner collar 2 is substantially higher than the outer collar 4. The inner and outer collars are made of polyester and elastane yarns, with the outer collar 4 additionally comprising a TPU yarn. TPU can contribute to the abrasion resistance of the collar. It is also possible for a reflective yarn in the outer collar 4 to increase visibility at night. 3H shows a section of a knitted upper 1 having an inner collar 2 with a circumferential free edge 3 and an outer collar 4 with a circumferential free edge 5. In this exemplary embodiment, the height of both the inner collar 2 and the outer collar 4 varies. The outer collar 4 is substantially higher than the inner collar 2 at the front and back of the collar section. On the lateral side of the collar section, the inner collar 2 is higher than the outer collar 4 and forms a flap on the lateral side. In other embodiments, a similar flap could be arranged on the medial side. The flaps generally increase wearing comfort.

31 shows a section of a knitted upper material 1 with an inner collar 2 with a circumferential free edge 3, a first outer collar 4 with a free edge 5 and a second outer collar 6 with a circumferential free edge 7. The second outer collar 6 is obtained in the same way as the first outer collar 4, namely as described above. In this example, the inner collar 2 is the highest. At the front of the collar portion, the first outer collar 4 has a height between the heights of the inner collar 2 and the second outer collar 6, whereas at the back of the collar portion, the height of the second outer collar 6 is between the heights of the inner collar 2 and the first outer collar 4. This embodiment provides a soft wearing experience.

3 years shows a section of a knitted upper 1 having an inner collar 2 with a circumferential free edge 3 and an outer collar 4 with a circumferential free edge 5. In this exemplary embodiment, the height of both the inner collar 2 and the outer collar 4 varies. The outer collar 4 is substantially higher than the inner collar 2 at the front and back of the collar section. At the lateral sides of the collar section, the inner collar 2 is higher than the outer collar 4. The outer collar 4 includes fairly thick padding at the front of the collar section. This is due to a knitted structural change that adds more material and thickens this area.

4 illustrates a knitting program 20 for a knitting machine resulting in a knitted upper material according to the invention. The knitting direction is generally indicated by arrow 21. The diagram illustrates the operation of each needle of the knitting machine along the knitting direction. The needles are arranged in a horizontal direction of the diagram. As a color, each point of the diagram shows which needle picks up which yarn from a corresponding yarn feeder. At a point that has no color (white), no operation is performed by the corresponding needle.

The knitted upper material, which is produced by the knitting program 20 of 4 comprises an inner sock 22 and an outer sock 23. In the final upper, the outer sock 23 is pulled or twisted over the inner sock 22. In general, however, according to the invention, the upper 1 may have only a single layer or "sock". As in 4 As shown, knitting begins with the inner sock 22. Thereafter, the inner collar 2 is knitted as described above, i.e., using hold-downs to park a knitting row or a portion of a knitting row. Once the inner collar 2 is joined to the fabric by one or more rows, the outer collar 4 is knitted, again using the hold-downs. The outer collar 4 is then joined to the fabric by one or more rows, and the outer sock 23 is finally knitted.

With the knitting technique thus described, an integrally knitted tongue can be integrated into a knitted upper. Such a knitted upper could be the knitted upper 1 described above with an inner collar 2 and an outer collar 4, but it could also be another knitted upper that does not have an inner collar 2 and an outer collar 4. The method is described with reference to 5 described which has a knitting program 30 similar 4 but this time with reference to a knitted upper 40 with an integrally knitted tongue 41. 6 shows a knitted upper material 40, which is made from a knitting program similar 5 results before the outer sock 43 is pulled or turned over the inner sock 42. 7A , 7B and 7C show various embodiments of a knitted upper material 40 after the outer sock 43 has been placed over the inner sock 42.

For presentation reasons, the knitting program is in 5 divided into two parts, the first part being on the left side of 5 is carried out first and corresponds to the tongue 41 and the inner sock 42. Then the second part of the program is carried out on the right side of 5 corresponding to the outer sock 43. This does not mean that the knitting program is interrupted, but only for illustration purposes.

The program 30 begins with the knitting of a toe cap portion 31 of the inner sock 42 and continues with the tongue portion 32 corresponding to the tongue 41 of the resulting knitted upper of 6 The tongue portion 32 is knitted in a similar manner to the inner collar 2 or the outer collar 4 of the knitted upper material 1 described above. For this purpose, a knitting row or a portion thereof is held on hold-down devices of a knitting machine, such as the machine shown in 2 shown and described with reference thereto. The hold-down devices pick up the loops from the row of needles and move them away from the row of needles. The tongue 41 is then knitted as shown in the corresponding tongue section 32 of the knitting program 30. Thereafter, the tongue 41 is connected to the knitting row or a section thereof held on the hold-down devices by knitting a row or a few rows. For this purpose, the hold-down devices are returned to the row of needles Next, a quarter 33 of the inner sock is knitted with integrally knitted lace loops 38. Then, an inner heel section 34 is knitted.

The knitting program 30 then continues with the outer sock 43, namely with an outer heel section 35. It continues with a quarter 36 of the outer sock, which has lace loops 38 corresponding to the lace loop 38 of the quarter section 33 of the inner sock. Finally, an outer toe cap section 37 is knitted.

6 shows a knitted upper material 40, which is made from a knitting program similar 5 which has an integrally knitted tongue 41, an inner sock 42 and an outer sock 43. As in 6 As shown, the tongue 41 is a double-layered knitted construction while being folded upon itself, just like the inner collar 2 and the outer collar 4 described above. The tongue includes so-called "folded edges" or "feigned seams" to allow for better folding. This is achieved by altering the knitted structure on two needles in the edge area.

7A , 7B and 7C show various embodiments of a knitted upper material 40 after the outer sock 43 has been placed over the inner sock 42. Accordingly, the inner sock in the 7A , 7B and 7C not visible.

1. 1. Gestricktes Obermaterial für einen Schuh, umfassend:
   • eine innere Socke;
   • eine äußere Socke, die integral mit der inneren Socke gestrickt ist;
   • eine gestrickte Zunge, die integral mit der inneren Socke gestrickt ist und eine doppellagige Konstruktion aufweist.
2. 2. Gestricktes Obermaterial nach Ausführungsform 2, wobei das gestrickte Obermaterial auf einer Rundstrickmaschine, vorzugsweise einer kleinen Rundstrickmaschine und am meisten bevorzugt einer kleinen Intarsia-Rundstrickmaschine, gestrickt worden ist.
3. 3. Gestricktes Obermaterial nach einer der Ausführungsformen 1-2, wobei die gestrickte Zunge durch eine einzige gestrickte Lage gebildet ist, die auf sich selbst gefaltet ist, um die doppellagige Konstruktion zu erhalten.
4. 4. Gestricktes Obermaterial nach einer der Ausführungsformen 1-3, wobei die gestrickte Zunge ein anderes Garn als die innere Socke und/oder die äußere Socke umfasst.
5. 5. Gestricktes Obermaterial nach einer der Ausführungsformen 1-4, umfassend:
   • einen gestrickten inneren Kragen, der eine umlaufende erste freie Kante des Obermaterials definiert und dazu ausgelegt ist, einen Abschnitt eines Beins eines Trägers des Schuhs vollständig zu umgeben;
   • mindestens einen gestrickten äußeren Kragen, der den inneren Kragen mindestens teilweise umgibt und eine zweite freie Kante des Obermaterials definiert,
   • wobei der innere Kragen und der äußere Kragen eine einstückige gestrickte Konstruktion sind.
6. 6. Gestricktes Obermaterial nach Ausführungsform 5, wobei der innere Kragen und der äußere Kragen integral mit der inneren Socke und/oder der äußeren Socke gestrickt sind.
7. 7. Schuh, umfassend ein gestricktes Obermaterial nach einer der Ausführungsformen 1-6; und eine Sohlenstruktur.
8. 8. Verfahren zur Herstellung eines gestrickten Obermaterials nach einer der Ausführungsformen 1-7, umfassend die Schritte:
   1. (a) Stricken eines ersten Abschnitts der inneren Socke auf eine Reihe von Nadeln;
   2. (b) Übertragen mindestens eines Abschnitts einer Strickreihe von der Reihe von Nadeln auf Haltemittel;
   3. (c) Stricken der Zunge;
   4. (d) Übertragen des Abschnitts der Strickreihe, der auf den Haltemitteln gehalten wird, zurück auf die Reihe von Nadeln;
   5. (e) Stricken eines zweiten Abschnitts der inneren Socke; und
   6. (f) Stricken der äußeren Socke.

Further embodiments of a knitted upper with an integrally knitted tongue are defined below:

1. 1. A knitted upper material for a shoe, comprising:
   • an inner sock;
   • an outer sock knitted integrally with the inner sock;
   • a knitted tongue that is knitted integrally with the inner sock and has a double-layer construction.
2. 2. Knitted upper material according to embodiment 2, wherein the knitted upper material has been knitted on a circular knitting machine, preferably a small circular knitting machine and most preferably a small intarsia circular knitting machine.
3. 3. Knitted upper according to any one of embodiments 1-2, wherein the knitted tongue is formed by a single knitted layer folded upon itself to obtain the double-layered construction.
4. 4. Knitted upper material according to any one of embodiments 1-3, wherein the knitted tongue comprises a different yarn than the inner sock and/or the outer sock.
5. 5. Knitted upper material according to any one of embodiments 1-4, comprising:
   • a knitted inner collar defining a circumferential first free edge of the upper and configured to completely surround a portion of a leg of a wearer of the shoe;
   • at least one knitted outer collar at least partially surrounding the inner collar and defining a second free edge of the outer material,
   • wherein the inner collar and the outer collar are a one-piece knitted construction.
6. 6. Knitted upper material according to embodiment 5, wherein the inner collar and the outer collar are knitted integrally with the inner sock and/or the outer sock.
7. 7. A shoe comprising a knitted upper material according to any one of embodiments 1-6; and a sole structure.
8. 8. A method for producing a knitted upper material according to any one of embodiments 1-7, comprising the steps:
   1. (a) knitting a first section of the inner sock onto a row of needles;
   2. (b) transferring at least a portion of a knitting row from the row of needles to holding means;
   3. (c) knitting the tongue;
   4. (d) transferring the portion of the knitting row held on the holding means back to the row of needles;
   5. (e) knitting a second section of the inner sock; and
   6. (f) Knitting the outer sock.

Thus, it is understood that the embodiments of the knitted upper comprising an integrally knitted tongue can be combined with the embodiments of the knitted upper comprising an inner collar and an outer collar as described herein. Thus, by combination, an embodiment can be obtained that includes features of one or more embodiments of the knitted upper comprising an integrally knitted tongue and one or more embodiments of the knitted upper comprising a inner collar and an outer collar.

List of reference symbols

1

Knitted upper material

2

inner collar

3

Edge of the inner collar

4

outer collar

5

Edge of the outer collar

6

second outer collar

7

free edge of the second outer collar

10

knitting machine

11

needles

12

hold-down device

13

cylinder

20

Knitting program for knitted upper material with inner and outer collar

21

Knitting direction

22

inner sock

23

outer sock

30

Knitting program for knitted upper with integral tongue

31

Toe cap section

32

tongue section

33

Quarter of the inner sock

34

inner heel section

35

outer heel section

36

Quarter of the outer sock

37

outer toe cap section

38

Lace loops

40

knitted upper with integral tongue

41

knitted tongue

42

inner sock

43

outer sock

Claims (25)

A knitted upper (1) for a shoe, comprising: a knitted inner collar (2) defining a circumferential first free edge (3) of the upper (1) and configured to completely surround a portion of a leg of a wearer of the shoe; at least one knitted outer collar (4) at least partially surrounding the inner collar (2) and defining a second free edge (5) of the upper (1), wherein the inner collar (2) and the outer collar (4) are a one-piece knitted construction. Knitted upper material (1) after Claim 1 , with the inner collar (2) and the outer collar (4) being knitted in a single knitting operation. Knitted upper material (1) according to one of the Claims 1 or 2 , wherein the outer collar (4) is designed in the form of a tab or a lamella. Knitted upper material (1) according to one of the Claims 1 - 3 , wherein the inner collar (2) and the outer collar (4) overlap in a heel area of the upper material (1). Knitted upper material (1) according to one of the Claims 1 - 4 , wherein the inner collar (2) comprises a first yarn and the outer collar (4) comprises a second yarn, wherein the first yarn is different from the second yarn. Knitted upper material (1) after Claim 5 , with the first yarn being more moisture permeable than the second yarn. Knitted upper material (1) according to one of the Claims 5 - 6 , with the second yarn being more abrasion-resistant than the first yarn. Knitted upper material (1) according to one of the Claims 1 - 7 , wherein the inner collar (2) is arranged proximal to a foot of a wearer wearing a shoe comprising the knitted upper material (1), and wherein the outer collar (4) is arranged distal to the foot. Knitted upper material (1) according to one of the Claims 1 - 8 , wherein the inner collar (2) and/or the outer collar (4) comprise an elastic yarn. Knitted upper material (1) according to one of the Claims 1 - 9 wherein at least one of the inner collar (2) and the outer collar (4) was obtained by partial knitting. Knitted upper material (1) according to one of the Claims 1 - 10 , wherein the yarn tension in the inner collar (2) differs from the yarn tension in the outer collar (4). Knitted upper material (1) according to one of the Claims 1 - 11 , whereby the knitting structure of the inner collar (2) differs from the knitting structure of the outer collar (4). Knitted upper material (1) according to one of the Claims 1 - 12 , wherein the shape of the inner collar (2) differs from the shape of the outer collar (4). Knitted upper material (1) according to one of the Claims 1 - 13 , wherein the outer collar (4) defines a circumferential second free edge (5) of the upper material (1) which is designed to surround a portion of a leg of a wearer of the shoe. Knitted upper material (1) according to one of the Claims 1 - 14 , wherein the inner collar (2) and the outer collar (4) are each formed by a single knitted layer folded upon itself. Knitted upper material (1) according to one of the Claims 1 - 15 , wherein the distance between the free edge of the inner collar (2) and a point at which the inner collar (2) and the outer collar (4) are connected is greater than a distance between the free edge of the outer collar (4) and the point at which the inner collar (2) and the outer collar (4) are connected. Knitted upper material (1) according to one of the Claims 1 - 16 , whereby the inner collar (2) is thicker than the outer collar (4). Knitted upper material (1) according to one of the Claims 1 - 17 , wherein the inner collar (2) and the outer collar (4) have been produced on a circular knitting machine, preferably a small circular knitting machine and most preferably a small intarsia circular knitting machine. Knitted upper material (1) according to one of the Claims 1 - 18 , wherein the inner collar (2) and/or the outer collar (4) are filled with padding. Knitted upper material (1) according to one of the Claims 1 - 19 comprising a plurality of outer collars (4). Knitted upper material (1) according to one of the Claims 1 - 20 , further comprising: an inner sock; an outer sock knitted integrally with the inner sock. Knitted upper material (1) after Claim 21 , further comprising: a knitted tongue knitted integrally with the inner sock and having a double-layer construction. Knitted upper material (1) after Claim 22 , the knitted tongue being formed by a single knitted layer folded upon itself to obtain the double-layer construction. Shoe, comprising: a knitted upper material (1) according to one of the Claims 1 - 23 ; and a sole structure. Method for producing a knitted upper material (1) according to one of the Claims 1 - 24 , comprising the steps of: (a) knitting a first portion of the upper material (1) onto a row of needles; (b) transferring at least a portion of a knitting row from the row of needles to holding means; (c) knitting the inner collar (2) or the outer collar (4); (d) transferring the portion of the knitting row held on the holding means back onto the row of needles; (e) knitting at least one row or a portion thereof; (f) repeating steps (b)-(e) to obtain the other of the outer collar (4) or the inner collar (2).

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