HK1207542B - Article of footwear having an upper incorporating a knitted component - Google Patents

Abstract

The invention relates to article of footwear having an upper incorporating a knitted component. An article of footwear (10) has an upper (30) that includes a knitted component and a sole structure (20) secured to the upper. The knitted component may define a tube (42) formed of unitary knit construction, and a strand (43) may extend through a length of the tube. As another example, the knitted component may have a pair of at least partially coextensive knitted layers formed of unitary knit construction, and a plurality of floating yarns may extend between the knitted layers. In some configurations, the knit type or yarn type may vary in different regions of the knitted component to impart different properties. Additionally, the knitted component may incorporate a thermoplastic yarn that is fused in different regions of the knitted component to impart different properties. A flat knitting process or a variety of other knitting processes may be utilized to form the knitted component.

Description

Article of footwear having an upper incorporating a knitted component

The present application is a divisional application of the application entitled "article of footwear having an upper incorporating a knitted component" filed on even 14/9/2009 with application No. 200980150405.0.

Technical Field

The invention relates to an article of footwear and a method of manufacturing the same.

Background

Conventional articles of footwear generally include two primary elements, an upper and a sole structure. The upper is secured to the sole structure and forms a void on the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. For example, in some articles of athletic footwear, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to relieve pressure on the foot and leg during walking, running, and other ambulatory activities. The outsole is secured to a lower surface of the midsole and forms a ground-contacting portion of a sole structure that is formed from a durable and wear-resistant material. The sole structure may also include a sockliner (sockliner) disposed within the void and proximate a lower surface of the foot to enhance footwear comfort.

The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some articles of footwear, such as basketball shoes and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the void on the interior of the upper is typically provided by an ankle opening in the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet of different sizes. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter (heel counter) to limit movement of the heel.

Various materials are commonly utilized in the manufacture of footwear uppers. For example, the upper of athletic footwear may be formed from multiple material elements. The material may be selected according to various characteristics including, for example, stretch-resistance, abrasion-resistance, flexibility, breathability, compressibility, and moisture wicking. In the case of the exterior layer (exterior) of the upper, the toe area and the heel area may be formed of leather, synthetic leather, or a rubber material to impart a relatively high degree of wear-resistance. Leather, synthetic leather, and rubber materials may not exhibit the desired degree of flexibility and breathability for the other different areas of the outer layer. Thus, other areas of the outer layer may be formed of a synthetic fabric, for example. Accordingly, the exterior layer of the upper may be formed from multiple material elements that each impart different properties to the upper. A middle or central layer of the upper may be formed from a lightweight polymer foam material that provides cushioning and enhances comfort. Similarly, the interior layer (interior) of the upper may be formed of a comfortable and moisture-wicking textile that removes perspiration from the area immediately surrounding the foot. The various material elements and other components may be joined using adhesives or stitching. Accordingly, the conventional upper is formed from various material elements that each impart different properties to different areas of the footwear.

Summary of The Invention

A flat knitting process or many other knitting processes may be used to form a knitted component of an upper for an article of footwear. Various features may be incorporated into the knitted component. For example, the knitted component may define a tube formed of unitary knit construction (unity knit construction), and the strands may extend through a length of the tube. As another example, a knitted component may have a pair of at least partially coextensive knitted layers formed of unitary knit construction, and a plurality of floating yarns (floating yarns) may extend between the knitted layers. In some configurations, the weave type or yarn type may vary in different regions of the knitted component to impart different properties. In addition, the knitted component may incorporate thermoplastic yarns that are fused in different areas of the knitted component to impart different properties.

The invention provides an article of footwear having an upper and a sole structure secured to the upper, the upper comprising: a knitted component defining a tubular structure formed of unitary knit construction; and a yarn having a one-dimensional material configuration, the yarn extending through at least a portion of the length of the tubular structure.

In some embodiments, the knitted component may extend along a lateral side of the upper, along a medial side of the upper, on a forefoot region of the upper, and around a heel region of the upper.

In some embodiments, the tubular structure may be disposed on a lateral side of the upper and oriented to extend upward from an area proximate the sole structure, and the yarns may extend outward from ends of the tubular structure to form loops that receive a lace.

In some embodiments, the tubular structure may be disposed in the heel region and around at least a portion of an ankle opening of the upper, and the yarn and a plurality of additional yarns may be disposed within the tubular structure.

The invention also provides an article of footwear having an upper and a sole structure secured to the upper, the upper comprising: a first knit layer forming at least a portion of an exterior surface of the upper; a second woven layer formed of unitary woven construction with the first woven layer, the second woven layer disposed adjacent to and at least partially coextensive with the first woven layer to define a tube therebetween; and a strand having a one-dimensional configuration of material, the strand extending through the tube and between the first and second braided layers.

In some embodiments, the first knit layer may extend along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper.

In some embodiments, the tubes may be oriented to extend upwardly from an area proximate the sole structure, and a portion of the strands may extend outwardly from ends of the tubes and form loops that receive a lace.

In some embodiments, the first knit layer may define an aperture adjacent the end of the tube, and the lace may extend through the aperture.

In some embodiments, the strand may extend into another tube formed by the first braided layer and the second braided layer.

The invention also provides an article of footwear having an upper and a sole structure secured to the upper, the upper comprising: a knitted component defining a first tube and a second tube, the first tube and the second tube each being formed of unitary knit construction, the first tube and the second tube extending in an upward direction from a region proximate the sole structure, and ends of the first tube and the second tube being disposed in an upper region of the upper; a strand extending through the first tube and the second tube, a portion of the strand extending outward from the ends of the first tube and the second tube to form a loop; and a lace extending through the loops.

In some embodiments, the first tube and the second tube may be proximate and parallel to each other.

In some embodiments, the knitted component may define apertures adjacent the ends of the first and second tubes, and the lace may extend through the apertures.

In some embodiments, the knitted component may include: a pair of at least partially coextensive braided layers, which may be formed of unitary braided construction; and a plurality of floats extendable between the woven layers.

In some embodiments, the knit layer and the floating yarns may be disposed adjacent an ankle opening of the upper.

The invention also provides an article of footwear having an upper and a sole structure secured to the upper, the upper comprising: a knitted component defining a plurality of tubes formed of unitary knit construction, a first portion of the tubes disposed on a lateral side of the footwear and a second portion of the tubes disposed on a medial side of the footwear; at least one strand extending through the tube and outwardly from an end of the tube to form a plurality of loops, the strand having a configuration of one-dimensional material; and a lace extending through the loops.

In some embodiments, the knitted component may define an aperture adjacent the end of the tube, and the lace may extend through the aperture.

In some embodiments, at least two of the tubes may be proximate and parallel to each other.

In some embodiments, the knitted component may form a majority of an exterior surface of the upper.

In some embodiments, the knitted component may include: a pair of at least partially coextensive braided layers, which may be formed of unitary braided construction; and a plurality of floating yarns positionable between the woven layers and extending in a direction substantially parallel to the woven layers, the woven layers and the floating yarns positionable adjacent an ankle opening of the upper.

In some embodiments, a first zone of the knitted component may have a first knit type and a second zone of the knitted component may have a second knit type, the first knit type may be different than the second knit type.

In some embodiments, a first zone of the knitted component may have a first yarn type and a second zone of the knitted component may have a second yarn type, the first yarn type may be different than the second yarn type.

The present invention also provides an article of footwear having an upper that includes a lacing system, the lacing system including: a knitted component defining (a) a tube formed of unitary knit construction and (b) an aperture disposed adjacent an end of the tube; a strand extending through the tube and forming a loop; and a lace extending through the loops and the apertures.

The present invention also provides an article of footwear having an upper and a sole structure secured to the upper, the upper including a knitted component including: a first woven layer and a second woven layer at least partially coextensive with each other and formed of unitary woven construction; and a plurality of floating yarns disposed between the first woven layer and the second woven layer and extending in a direction substantially parallel to the first woven layer and the second woven layer.

In some embodiments, the upper may define an interior void that may be used to receive a foot and an ankle opening that may provide access to the void, and the first woven layer, the second woven layer, and the floating yarns may be disposed adjacent the ankle opening.

In some embodiments, the first knitted layer, the second knitted layer, and the floating yarns may be disposed on a medial side of the upper and on a lateral side of the upper.

In some embodiments, the knitted component may define a tube formed of unitary knit construction, and the strands may extend through a length of the tube.

In some embodiments, a first zone of the knitted component may have a first knit type and a second zone of the knitted component may have a second knit type, the first knit type may be different than the second knit type.

In some embodiments, a first zone of the knitted component may have a first yarn type and a second zone of the knitted component may have a second yarn type, the first yarn type may be different than the second yarn type.

The present invention also provides an article of footwear having an upper and a sole structure secured to the upper, the upper including a knitted component including: a first knit layer and a second knit layer formed of unitary knit construction, the first knit layer being at least partially coextensive with the second knit layer to define an interior volume between the first knit layer and the second knit layer; and a plurality of floating yarns disposed within the interior volume and extending between the first woven layer and the second woven layer.

In some embodiments, the upper may define an interior void that may be used to receive a foot and an ankle opening that may provide access to the void, and the first woven layer, the second woven layer, and the floating yarns may be disposed adjacent the ankle opening.

In some embodiments, the first knitted layer, the second knitted layer, and the floating yarns may be disposed on a medial side of the upper, on a lateral side of the upper, and extend around a heel region of the upper.

The present invention also provides an article of footwear having an upper and a sole structure secured to the upper, the upper defining an interior void for receiving a foot of a wearer, and the upper having an ankle opening that provides access to the void, the upper including a knitted component comprising: a first knit layer forming at least a portion of an exterior surface of the upper adjacent to the ankle opening; a second knit layer forming at least a portion of an interior surface of the upper adjacent to the ankle opening; and a plurality of floating yarns disposed between the first woven layer and the second woven layer, wherein the first woven layer and the second woven layer are interconnected at the ankle opening and at a location spaced from the ankle opening to define a spaced area between the first woven layer and the second woven layer, and the floating yarns are disposed in the spaced area.

In some embodiments, the knitted component may extend along a lateral side of the upper, along a medial side of the upper, on a forefoot region of the upper, and around a heel region of the upper.

In some embodiments, the floating yarns may be substantially parallel to the first woven layer and the second woven layer.

In some embodiments, a portion of the knitted component disposed in a midfoot region of the footwear may define a tube formed of unitary knit construction, and a strand may extend through a length of the tube.

The invention also provides a method of manufacturing an article of footwear, the method comprising: forming a knitted component using a flat knitting process, the knitted component including at least one yarn incorporating a thermoplastic polymer material; heating at least a region of the knitted component to fuse the yarns incorporating the thermoplastic polymer material; and incorporating the knitted component into an upper of the article of footwear.

In some embodiments, the step of using a flat knitting process may include positioning the yarns incorporating the thermoplastic polymer material throughout the knitted component.

In some embodiments, the step of using a flat knitting process may include positioning the yarns incorporating the thermoplastic polymer in only the regions of the knitted component.

In some embodiments, the step of incorporating may include positioning the region of the knitted component in a heel region of the footwear.

In some embodiments, the step of bonding may include positioning the region of the knitted component in a forefoot region of the footwear.

The invention also provides a method of manufacturing an article of footwear, the method comprising: forming a knitted component using a flat knitting process, the knitted component including a first knit layer, a second knit layer, and a plurality of yarns secured to and extending from the first knit layer to the second knit layer; and incorporating the knitted component into an upper of the article of footwear.

In some embodiments, the method may further comprise the steps of: the yarns are selected as monofilament yarns.

The advantages and features of novelty characterizing various aspects of the invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various configurations and concepts related to the invention.

Drawings

The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings.

Fig. 1 is a perspective view of an article of footwear.

Fig. 2 is a lateral elevational view of the article of footwear.

Fig. 3 is a medial side view of the article of footwear.

Fig. 4 is a top plan view of the article of footwear.

Figures 5A-5D are cross-sectional views of the article of footwear, as defined by section lines 5A-5D, respectively, in figure 2.

FIG. 6 is a top plan view of a knitted component forming a portion of an upper of an article of footwear.

Fig. 7A-7G are side views corresponding with fig. 2 and depicting further configurations of the article of footwear.

Fig. 8A and 8B are cross-sectional views corresponding with fig. 5D and depicting further configurations of the article of footwear.

Detailed description of the invention

The following discussion and accompanying figures disclose an article of footwear having an upper that includes a knitted component. An article of footwear is disclosed as having a general configuration suitable for walking or running. Concepts associated with the footwear, including the upper, may also be applied to a variety of other athletic footwear styles, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking shoes, for example. These concepts may also be applied to footwear styles that are generally considered to be non-athletic, including dress shoes, loafers (loafers), sandals, and work boots. Accordingly, the concepts disclosed herein are applicable to a wide variety of footwear styles.

Conventional footwear construction

Article of footwear 10 is depicted in figures 1-5D as including a sole structure 20 and an upper 30. For reference purposes, footwear 10 may be divided into three general regions: forefoot region 11, midfoot region 12, and heel region 13, as shown in fig. 2 and 3. Footwear 10 also includes a lateral side 14 and a medial side 15. Forefoot region 11 generally includes portions of footwear 10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 12 generally includes portions of footwear 10 corresponding with the arch area of the foot, while heel region 13 corresponds with rear portions of the foot, including the calcaneus bone. Lateral side 14 and medial side 15 extend through each of regions 11-13 and correspond with opposite sides of footwear 10. Regions 11-13 and sides 14-15 are not intended to demarcate precise areas of footwear 10. Rather, regions 11-13 and sides 14-15 are intended to represent general areas of footwear 10 to aid in the following discussion. In addition to footwear 10, regions 11-13 and sides 14-15 may also be applied to sole structure 20, upper 30, and individual elements thereof.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when footwear 10 is worn. The primary elements of sole structure 20 are a midsole 21, an outsole 22, and a sockliner 23. Midsole 21 is secured to a lower surface of upper 30 and may be formed from a compressible polymer foam element (e.g., polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further configurations, midsole 21 may incorporate a fluid-filled bladder that supplements the ground reaction force attenuation characteristics, or midsole 21 may be primarily formed from a fluid-filled bladder. Outsole 22 is secured to a lower surface of midsole 21 and may be formed of a wear-resistant rubber material having a structure that imparts traction. Sockliner 23 is positioned within upper 30 and is positioned to extend under a lower surface of the foot. Although this configuration of sole structure 20 provides an example of a sole structure that may be used with upper 30, various other conventional or nonconventional configurations for sole structure 20 may also be used. Accordingly, the structure and features of sole structure 20 or any sole structure utilized with upper 30 may vary significantly.

Upper 30 defines a void within footwear 10 for receiving and securing a foot with respect to sole structure 20. The void is shaped to receive the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Access to the void is provided by an ankle opening 31 located in at least heel region 13. As described in greater detail below, lace 32 extends through portions of upper 30 and allows the wearer to modify dimensions of upper 30 to accommodate the size of the foot. More specifically, lace 32 allows the wearer to tighten upper 30 around the foot, and lace 32 allows the wearer to loosen upper 30 to facilitate entry and removal of the foot from the void (i.e., through ankle opening 31). In addition, upper 30 includes a tongue 33 that extends under lace 32.

A majority of upper 30 is formed from knitted component 40, with knitted component 40 being manufactured, for example, by a flat knitting process. Knitted component 40 extends through each of regions 11-13, along lateral side 14 and medial side 15, over forefoot region 11, and around heel region 13. In addition, knitted component 40 forms an interior surface and an opposite exterior surface of upper 30. As such, knitted component 40 defines at least a portion of a void within upper 30, and knitted component 40 also defines ankle opening 31 to provide access to the void. In some configurations, knitted component 40 may also extend under the foot. For purposes of example in the various figures, however, strobel sock 34 is secured to knitted component 40 and forms a majority of the portion of upper 30 that extends under the foot. In this configuration, insole 23 extends over strobel inner sole 34 and forms a surface on which the foot rests.

Structure of knitted component

Knitted component 40 incorporates various knit types that impart different properties to different areas (separate areas) of upper 30. As depicted in the examples of fig. 1, 4, and 5A, knitted component 40 forms a plurality of apertures 41, with plurality of apertures 41 extending through upper 30 in forefoot region 11, while many other regions of upper 30 have a more continuous configuration or a configuration with few apertures. In addition to imparting higher permeability (which allows air to circulate within upper 30), apertures 41 may increase the flexibility and extensibility of upper 30 in forefoot region 11. As a further example, other properties that may be altered by selecting a particular knit type for a particular region of knitted component 40 include liquid permeability, direction in which knitted component 40 stretches or resists stretching, stiffness of knitted component 40, and compressibility of knitted component 40. Additional examples of knitted components having areas with different knit types for footwear uppers to impart different properties may be found in U.S. patent No. 6,931,762 to Dua and U.S. patent No. 7,347,011 to Dua et al, both of which are incorporated by reference herein in their entireties. As a matter of relevance, the weave density within knitted component 40 may vary in different areas of upper 30 to, for example, make low permeability or stiffer portions. Accordingly, knitted component 40 may exhibit different characteristics in different areas depending on the particular knitting types selected for those areas.

Knitted component 40 may also incorporate various yarn types that impart different properties to different areas of upper 30. Moreover, by combining various yarn types with different stitch types, knitted component 40 may impart a range of different properties to different areas of upper 30. The properties that a particular yarn type will impart to an area of knitted component 40 depend, in part, on the materials forming the various filaments (filaments) and fibers within the yarn. For example, cotton provides a soft hand, natural aesthetics, and biodegradability. Each of the elastic (elastane) and stretch polyester (stretch polyester) provides substantial stretch and recovery, and the stretch polyester also provides recyclability. Rayon (rayon) provides high luster and moisture absorption. The fleece provides high moisture absorption in addition to insulating properties. Nylon is a durable and wear resistant material with high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects associated with the yarns may affect the properties of upper 30. For example, the yarns may be monofilament or multifilament yarns. The yarn may also include different filaments, each formed of a different material. The yarn may also include filaments, each filament being formed of two or more materials, such as a bicomponent yarn having filaments of a sheath-core (sheath-core) construction or a bicomponent yarn having two halves formed of different materials. Different twists and crimps, as well as different deniers, may affect the characteristics of upper 30 in which the yarn is placed. Accordingly, the materials forming the yarns, as well as other aspects of the yarns, may be selected to impart various properties to different areas of upper 30.

Knitted component 40 may incorporate various knit structures in addition to knit types and yarn types. For example, referring to fig. 2 and 3, knitted component 40 includes a plurality of tubes 42 in which strands 43 are placed. The tube 42 is generally a hollow structure formed from two overlapping and at least partially coextensive layers of woven material, as depicted in fig. 5B and 5C. While the sides or edges of one layer of the braided material forming tube 42 may be secured to another layer, the intermediate region is typically unsecured such that another element (e.g., strand 43) may be placed between the two layers of braided material and through tube 42. Additional examples of knitted components having overlapping or at least partially coextensive layers for footwear uppers may be found in U.S. patent application publication 2008/0110048 to Dua et al, which is incorporated herein by reference.

Tube 42 extends upwardly along lateral side 14 and medial side 15. Each tube 42 is adjacent to at least one other tube 42 to form a tube pair (tube pair). Generally, one of strands 43 passes through first tube 42 of the pair, extends outward from an upper end of first tube 42, forms a loop 44 on the exterior layer of upper 30, extends into an upper end of second tube 42 of the pair, and passes through second tube 42. That is, each strand 43 passes through at least two tubes 42, and the exposed portions of strands 43 form loops 44.

A single strand 43 may only pass through two adjacent tubes 42 (i.e., a single tube pair) such that the strand 43 forms a single loop 44. In this configuration, the ends of strands 43 exit the lower ends of two adjacent tubes 42 and may be secured to sole structure 20, for example, under strobel sock 34 to prevent the end portions from being pulled out of one of tubes 42. In another configuration, a single strand 43 may pass through each tube 42, thereby passing through multiple tube pairs and forming multiple loops 44. In another configuration, one strand 43 may pass through each tube 42 on lateral side 14, while another strand 43 may pass through each tube 42 on medial side 15. Thus, in general, a single strand 43 passes through at least one tube pair to form at least one loop 44, but may pass through multiple tube pairs to form multiple loops 44.

Referring to fig. 1-4, lace 32 extends through each loop 44 and also through a plurality of apertures 41 formed in knitted component 40 adjacent to each loop 44. The combination of lace 32, apertures 41 through which lace 32 extends, respective tubes 42, strands 43, and loops 44 on lateral side 14 and medial side 15 provide an efficient lacing system for upper 30. Tension may also be introduced into strands 43 when lace 32 is tightened (i.e., when the wearer ties lace 32). In the absence of strands 43, other portions of knitted component 40 would be subjected to tensile forces and stresses created by tying lace 32. However, the presence of strands 43 provides a separate element that is subject to tensile and stress forces. In addition, a majority of knitted component 40 may generally be formed by selecting a knit type and a yarn type to stretch when taut, thereby allowing upper 30 to conform with the contours of the foot. In contrast with upper 30, however, strands 43 may generally be non-stretch.

Strands 43 may be formed from a variety of materials and may have a configuration such as a rope, wire, ribbon, cable, yarn, filament, or chain. In some configurations, the strands are located within tubes 42 during the knitting process that forms knitted component 40. As such, strands 43 may be formed from any conventional one-dimensional material that may be used in a knitting machine or other device that forms knitted component 40. As used with respect to the present invention, the term "one-dimensional material" or variants thereof is intended to encompass conventional elongated materials that exhibit a length that is much greater than a width and thickness. Accordingly, suitable materials for strands 43 include various filaments, fibers, and yarns formed from rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramid (e.g., para-aramid and meta-aramid fibers), ultra-high molecular weight polyethylene, and liquid crystal polymers. In addition to filaments and yarns, other one-dimensional materials may be used for strands 43. While one-dimensional materials will often have a cross-section that is substantially equal in width and thickness (e.g., a circular or square cross-section), some one-dimensional materials may have a width that is slightly greater than the thickness (e.g., a rectangular, oval, or other elongated cross-section). A material may be considered one-dimensional despite the greater width if the length of the material is much greater than the width and thickness of the material.

Another structure formed by knitted component 40 is a padded collar (padded tubular) 45 that extends at least partially around ankle opening 31. Referring to fig. 1-3, collar 45 exhibits a greater thickness than many other portions of knitted component 40. In general, collar 45 is formed from two overlapping and at least partially coextensive layers of knitted material (i.e., tubular structures) and a plurality of floating yarns 46 extending between the layers, as depicted in FIG. 5D. While the sides or edges of one layer of the knitted material forming collar 45 may be secured to another layer of the knitted material, the central region is typically unsecured. As such, the layer of knitted material effectively forms a tube or tubular structure like tube 42, and floating yarns 46 may be located or placed between two layers of knitted material to pass through the tube. That is, floating yarns 46 extend between the layers of woven material, generally parallel to the surface of the woven material, and also penetrate and fill the interior volume between the layers. Whereas a majority of knitted component 40 is formed from yarns that are mechanically manipulated to form the knitted component, floating yarns 46 are generally free or otherwise disposed in the interior volume between the layers of knitted material forming the outer layer of collar 45.

However, tube 42 includes a single strand 43 and collar 45 includes a plurality of floating yarns 46 extending through the area between the layers of knitted material. Accordingly, knitted component 40 may form a generally tubular structure having one or more yarns within the tubular structure. In addition, floating yarns 46 may be formed from a variety of materials and may be placed in collar 45 during the knitting process that forms knitted component 40. As such, floats 46 may be formed from any conventional one-dimensional material that may be used in a knitting machine or other apparatus that forms knitted component 40.

The presence of floating yarns 46 imparts a compressible aspect to collar 45, thereby enhancing the comfort of footwear 10 in the area of ankle opening 31. Many conventional articles of footwear incorporate a polymer foam element or other compressible material into the collar region. Unlike conventional articles of footwear, collar 45 uses floating yarns 46 to provide a compressible structure.

The combination of tubes 42 and strands 43 provide upper 30 with structural elements that resist stretch, for example, in a lacing system. Similarly, the combination of collar 45 and floating yarns 46 provide upper 30 with structural elements that compress, for example, to impart greater comfort around ankle opening 31. While these braided structures provide different benefits to upper 30, these braided structures are similar in the following respects: each comprising: (a) a tubular structure formed from two overlapping and at least partially coextensive layers of woven material formed of unitary woven construction, and (b) at least one yarn, strand or other one-dimensional material disposed or otherwise located in the tubular structure and extending through at least a portion of a length of the tubular structure.

Flat knitting process

Knitted component 40 may be manufactured using a flat knitting process. Flat knitting is a method of preparing a knitted material that is periodically turned (i.e., the material is knitted from alternating sides). The two sides of the material (otherwise referred to as faces) are generally designated as the front face (i.e., the side facing outward, toward the viewer) and the back face (i.e., the side facing inward, away from the viewer). While flat knitting provides a suitable method of forming knitted component 40, other knitting processes may be used depending on the features incorporated into knitted component 40. Examples of other knitting processes that may be used include wide tube circular knitting (wide tube circular knitting), narrow tube jacquard circular knitting (narrow tube circular knitting), single jacquard circular knitting (single knit circular knitting), double jacquard circular knitting, tricot warp knitting (warp knit tricot), raschel warp knitting (warp knit warp), and double needle bar raschel.

One advantage of using a flat knitting process to manufacture knitted component 40 is that each of the above-described features may be imparted to knitted component 40 by the flat knitting process. That is, the flat knitting process may form knitted component 40 to have, for example, (a) various knit types that impart different properties to different areas of upper 30, (b) various yarn types that impart different properties to different areas of upper 30, (c) a knit component of construction having overlapping knit layers in tubes 42, (d) a material, such as strands 43, placed in tubes 42, (e) a knit component of construction having overlapping knit layers in collar 45, and (f) floating yarns between layers of knit material in collar 45. In addition, each of these features, as well as others, may be incorporated into knitted component 40 through a single flat knitting process. As such, upper 30 may be substantially formed using a flat knitting process to have various properties and structural features that may be beneficial to footwear 10.

While one or more yarns may be mechanically manipulated by a single individual to form knitted component 40 (i.e., knitted component 40 may be formed by hand), flat knitting machines may provide an efficient way of forming a relatively large number of knitted components 40. A flat knitting machine may also be used to vary the dimensions of knitted component 40 to form upper 30 for footwear having different dimensions based on one or both of the length and width of the foot. In addition, a flat knitting machine may be used to change the configuration of knitted component 40 to form upper 30 for both the left foot and the right foot. Various aspects of knitted component 40 may also be altered to provide for individual tailoring. Accordingly, using a mechanical flat knitting machine may provide an efficient way of forming multiple knitted components 40 having different sizes and configurations.

Knitted component 40 incorporates a number of features and structures formed from unitary knit construction. In general, features and structures are formed of unitary knit construction when the features and structures are incorporated into knitted component 40 by a flat knitting process, rather than by other processes performed after the flat knitting process (e.g., stitching, bonding, forming). As one example, portions of tube 42 and collar 45 are formed from overlapping and at least partially coextensive layers of woven material, and the sides or edges of one layer may be secured to the other layer. The two layers of woven material are typically formed during a flat weaving process and do not include supplemental stitching, bonding, or forming processes. Thus, the overlapping layers are formed of unitary knit construction through a flat knitting process. As another example, the areas of knitted component 40 that define apertures 41 that are formed from a knit type are formed of unitary knit construction via a flat knitting process. As another example, floating yarns 46 are formed of unitary knit construction.

A further advantage of using a flat knitting process to form knitted component 40 is that a three-dimensional appearance (aspect) may be incorporated into upper 30. Upper 30 has a curved or other three-dimensional structure that extends around the foot and conforms to the shape of the foot. For example, a flat knitting process may form an area of knitted component 40 having a certain curvature to complement the shape of the foot. An example of a knitted component having a three-dimensional appearance for a footwear upper may be found in U.S. patent application publication 2008/0110048 to Dua et al, which is incorporated herein by reference.

In fig. 6, knitted component 40 is separated from footwear 10 and depicted in accordance with a flat knitting process. Although many textile material edges are cut to reveal ends of the yarns forming the textile material, knitted component 40 may be formed to have a trimmed configuration (finished configuration). That is, knitted component 40 may be formed using flat knitting or other knitting techniques such that ends of yarns within knitted component 40 are substantially absent from edges of knitted component 40. One advantage of a trimmed configuration formed by flat knitting is that the yarns forming the edges of knitted component 40 are less likely to unravel, a problem inherent in weft knitted materials. By forming trimmed edges, the integrity of knitted component 40 is enhanced and little or no post-processing steps are required to prevent unraveling. In addition, loose yarns are also less likely to interfere with the aesthetic appearance of upper 30. In other words, the trimmed configuration of knitted component 40 may enhance the durability and aesthetic qualities of upper 30 while increasing manufacturing efficiencies.

Knitted component 40 provides one example of a configuration for upper 30 of footwear 10. For example, a knitted component similar to knitted component 40 may be formed by flat knitting to have desired characteristics, depending upon the intended use of the article of footwear, desired characteristics of the article of footwear, and advantageous structural attributes of the article of footwear. That is, flat knitting may be used to (a) set a particular knit type in the area of the desired knitted component, (b) set a particular yarn type in the area of the desired knitted component, (c) form an overlapping knit layer similar to tube 42 and collar 45 in the area of the desired knitted component, (d) place strands or floats similar to strands 43 and floats 46 between knit layers, (e) form a three-dimensional appearance in the knitted component, and (f) impart a finished edge. More specifically, for example, any of the above-described features may be mixed and matched within a knitted component to form particular characteristics or structural attributes of a footwear upper.

Further construction

The features of upper 30 described above provide one example of a suitable configuration for footwear 10. Many other configurations may also be used. As one example, some of the above-described features may not be present in knitted component 40 in some configurations of footwear 10. Referring to fig. 7A, collar 45 is not present in knitted component 40 such that a single layer of knitted material forms an area that extends around ankle opening 31. Similarly, tube 42 and strand 43 are not present in fig. 7B. For example, footwear 10 may have only a minimal configuration with necessary or advantageous elements by utilizing only structures or features that are conducive to a particular athletic activity.

As discussed above, because different knit types or yarn types are used in different areas of upper 30, those areas may have different properties. Another way of altering the properties of certain areas involves fusing the thermoplastic material from the yarns in those areas. That is, the specific regions may be formed by yarns incorporating thermoplastic polymer materials. By heating the thermoplastic polymer material, adjacent yarns, filaments or fibers may fuse with one another in those areas to lock the braided rings together, thereby increasing stiffness or abrasion resistance. In some configurations, a single layer of knitted component 40 (e.g., an outer or inner layer of tube 42 or collar 45) or yarns placed in knitted component 40 (i.e., strands 43 or floats 46) may be formed from yarns that incorporate a thermoplastic polymer material. Alternatively, the entire knitted component 40 may be formed from yarns incorporating thermoplastic polymer materials, and only the portions corresponding to fused regions 47 may be heated to change properties. Referring to fig. 7C, knitted component 40 includes two fused regions 47. One fused region 47 is in heel region 13 and may impart greater rigidity to effectively provide a heel counter for footwear 10. An example of a footwear upper having a fused region may be found in U.S. patent No. 6,910,288 to Dua, which is incorporated herein by reference. Another fused region 47 is in forefoot region 11 and may impart greater wear resistance to the forefoot region. Fusing may also be utilized to reinforce the apertures 41, provide areas of reduced bending, or reduce permeability.

While the fused regions of knitted component 40 may impart greater stiffness and abrasion resistance to these regions, another approach may be to increase the knit density in certain regions. Referring to fig. 7D, knitted component 40 includes two densified regions 48. One densified region 48 is in heel region 13 and may impart greater rigidity to effectively provide a heel counter for footwear 10. Another densified region 48 is in forefoot region 11 and may impart greater wear resistance to the forefoot region. As with the formation of fused regions 47, the formation of a denser weave (denser knit) may also serve to reinforce the apertures 41, provide areas of reduced curvature, or reduce permeability.

Knitted component 40 forms an interior surface and an opposite exterior surface of upper 30. In some configurations of footwear 10, other elements may be used in combination with knitted component 40, and the other elements may form a portion or all of one of the interior or exterior surfaces. Referring to fig. 7E, heel counter 35 is secured to knitted component 40 in heel region 13 and may be formed from a relatively rigid polymer material. A bonding process may be used to attach heel counter 35 to knitted component 40. In other configurations, the liner may extend over an interior surface, thereby forming a portion of the void within upper 30. Other materials may be welded, adhered, or bonded to the exterior surface to protect the knitted structure of knitted component 40 or to provide other benefits to footwear 10.

The tube 42 is depicted in fig. 2 and 3 as being immediately adjacent to at least one other tube 42. However, the relative position of the tubes 42 may vary significantly. Referring to fig. 7F, the tubes 42 are separated from each other and form a V-shaped structure. While tubes 42 may be used as part of the lacing system, tubes 42 or similar structures may also be used to impart longitudinal stretch resistance. Referring to FIG. 7G, tube 42 extends longitudinally, and strands 43 within tube 42 may oppose stretch throughout each of regions 11-13.

The manner in which yarn 46 is incorporated into collar 45 may vary significantly. In the above configuration, floating yarns 46 are generally parallel to the layer of knitted material forming collar 45 when passing through the tubular structure. Referring to fig. 8A, yarns 46 extend from one layer of woven material to another layer of woven material and are generally perpendicular to the layers, thereby imparting a structure similar to a spacer-knit material (space-knit material) formed in a flat knitting process. As depicted in the enlarged area of fig. 8A, yarns 46 may extend around the yarns forming the knit layer. In one configuration, yarns 46 may be the same yarns that form the knit layer. That is, yarn 46 may be a raveled portion of the yarn forming the knit layer. In another configuration, yarns 46 may be unsecured or otherwise separated from (i.e., not extend around) the yarns forming the knit layer. Accordingly, yarn 46 may be incorporated into knitted component 40 in a variety of ways. As a further example, some configurations of upper 30 may include a polymer foam material that is placed between layers of knitted material after knitted component 40 is manufactured.

As discussed above, collar 45 may have a structure similar to a spacer knit material, with yarns 46 extending from one layer of knit material to another and in a direction generally perpendicular to the layers. Although collar 45 is a suitable area having this structure, a flat knitting process may be used to impart the structure of the spacer knit material to any area of knitted component 40. For example, a spacer knit construction may be disposed on either of sides 14 and 15 in forefoot region 11 or midfoot region 12 in order to impart a cushioning or compressible aspect to upper 30. Portions of strobel sock 34 or tongue 33 may also be formed by a flat knitting process to have a spaced knit construction. In addition, various yarn types may be used for regions of knitted component 40 having a spaced-apart knit construction, including monofilament or textured yarns.

In the various configurations described above, footbed 23 is a separate element located within a cavity in upper 30, and strobel sock 34 is a separate element connected to an edge of knitted component 40. A flat knitting process may also be used to form the footbed 23 and strobel inner sole 34 of unitary knit construction, as depicted in fig. 8B. Like collar 45, footbed 23 of unitary knit construction may be formed to include floating yarns that impart a compressible configuration. Other elements of unitary knit construction, such as tongue 33, may also be formed using flat knitting processes.

Efficiency of manufacture

As discussed in the background section above, for example, an upper for athletic footwear may be formed from multiple material elements that each impart different properties to different areas of the footwear. To manufacture a conventional upper, the material elements are cut into the desired shape and then joined together, typically using stitching or adhesive bonding. As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, storing, cutting, and joining the material elements may also increase. As the number and type of material elements incorporated into the upper increases, waste material from the cutting and stitching process also accumulates to a greater extent. In addition, footwear having a greater amount of material, material elements, and other components may be more difficult to reuse than an upper formed from a smaller amount of elements and materials. Thus, by reducing the number of elements and materials used in the upper, waste may be reduced while manufacturing efficiency and recyclability are improved.

Knitted component 40 may be formed through a single flat knitting process, although a conventional upper requires multiple manufacturing steps involving numerous material elements. A relatively small number of steps may be required to incorporate knitted component 40 into footwear 10 after this flat knitting process. More specifically, strobel sock 34 is attached to edges of knitted component 40, connects two edges in heel region 13, incorporates lace 32, and secures substantially complete upper 30 with sole structure 20. The use of knitted component 40 may reduce the total number of manufacturing steps compared to conventional manufacturing processes. Furthermore, waste can be reduced while increasing reusability.

The present invention is disclosed above and in the accompanying drawings with reference to a variety of configurations. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous changes and modifications may be made to the configurations described above without departing from the scope of the present invention, as defined by the appended claims.

Claims (13)

1. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component formed of unitary knit construction, the knitted component including a first knit layer and a second knit layer at least partially coextensive with each other, the knitted component including a plurality of tubular structures including the first knit layer and the second knit layer overlapping along opposing edges and connected to each other to define sides of a first tube and a second tube formed of the first knit layer and the second knit layer to have unitary knit construction so as to be a single piece element with a remainder of the knitted component; and

a strand extending through the first tube and the second tube, a portion of the strand extending between a first end of the first tube and a first end of the second tube to form a loop;

wherein the first end of the first tube and the first end of the second tube are separated by a first distance; and is

Wherein the second end of the first tube and the second end of the second tube are separated by a second distance, wherein the second distance is greater than the first distance.

2. The article of footwear recited in claim 1, wherein the strand exits the second end of the first tube and the second end of the second tube and is secured to the sole structure.

3. The article of footwear recited in claim 1, wherein the knitted component defines apertures adjacent to the first end of the first tube and the first end of the second tube, and further includes a lace extending through the apertures and the loops.

4. The article of footwear recited in claim 1, wherein a spacing between the first tube and the second tube gradually increases from (a) between the first end of the first tube and the first end of the second tube to (b) between the second end of the first tube and the second end of the second tube.

5. The article of footwear recited in claim 1, wherein the first tube and the second tube cooperate to define a V-shaped structure.

6. The article of footwear recited in claim 1, wherein the knitted component defines a medial side of the upper and a lateral side of the upper;

wherein both the first tube and the second tube are disposed on one of the medial side and the lateral side;

wherein the second end of the first tube and the second end of the second tube are disposed proximate to the sole structure; and is

Wherein the first end of the first tube and the first end of the second tube are spaced apart from the sole structure.

7. An article of footwear having an upper and a sole structure secured to the upper, the upper having a medial side and a lateral side, the upper comprising:

a knitted component formed of unitary knit construction, the knitted component including a first knit layer and a second knit layer at least partially coextensive with each other;

a plurality of tubular structures disposed on said knitted component, at least one of said tubular structures including said first knit layer and said second knit layer overlapping along opposite edges and connected to each other to define sides of a first pair of adjacent tubes on said medial side, another of said tubular structures including said first knit layer and said second knit layer overlapping along opposite edges and connected to each other to define sides of a second pair of adjacent tubes on said lateral side; and

at least one yarn having a configuration of one-dimensional material, the at least one yarn extending through the first pair of adjacent tubes, the at least one yarn extending through the second pair of adjacent tubes;

wherein the first and second pairs of adjacent tubes have a unitary knit construction so as to be a one-piece element with the remainder of the knitted component;

wherein the first pair of adjacent tubes comprises a first end, wherein the first pair of adjacent tubes comprises a second end spaced apart a greater distance than the first end;

wherein the second pair of adjacent tubes comprises a third end, wherein the second pair of adjacent tubes comprises a fourth end spaced apart a greater distance than the third end;

wherein the second ends of the first pair of adjacent tubes are disposed proximate to the sole structure;

wherein the first ends of the first pair of adjacent tubes are spaced apart from the sole structure;

wherein the fourth ends of the second pair of adjacent tubes are disposed proximate the sole structure; and is

Wherein the third ends of the second pair of adjacent tubes are spaced apart from the sole structure.

8. The article of footwear recited in claim 7, wherein the at least one yarn extends between the first ends of the first pair of adjacent tubes to define a first loop, and wherein the at least one yarn extends between the third ends of the second pair of adjacent tubes to define a second loop, and further comprising a lace received by the first loop and the second loop.

9. The article of footwear recited in claim 8, wherein the knitted component defines a first aperture adjacent to the first end of the first pair of adjacent tubes, wherein the knitted component defines a second aperture adjacent to the third end of the second pair of adjacent tubes, and wherein the lace is received by the first loop, the first aperture, the second loop, and the second aperture.

10. The article of footwear recited in claim 7, wherein a first spacing between the first pair of adjacent tubes gradually increases from the first end to the second end, and wherein a second spacing between the second pair of adjacent tubes gradually increases from the third end to the fourth end.

11. The article of footwear recited in claim 7, wherein the first pair of adjacent tubes defines a first V-shaped structure, and wherein the second pair of adjacent tubes defines a second V-shaped structure.

12. The article of footwear of claim 7, wherein the at least one yarn includes a first yarn and a second yarn; and is

Wherein the first yarn extends through the first pair of adjacent tubes, and wherein the second yarn extends through the second pair of adjacent tubes.

13. The article of footwear recited in claim 12, wherein the first yarn extends out of the second ends of the first pair of adjacent tubes and is attached to the sole structure; and is

Wherein the second yarn extends out of the fourth end of the second pair of adjacent tubes and is attached to the sole structure.