Patent Grant
10294592
The present disclosure generally relates to articles of footwear. More specific aspects of the present disclosure relate to articles of footwear incorporating an upper at least partially formed from knitted textile materials.
Conventional articles of footwear generally include two primary elements, an upper and a sole structure. The upper and the sole structure, at least in part, define a foot-receiving chamber that may be accessed by a user's foot through a foot-receiving opening.
In one aspect, the disclosure provides a knitted lacing element. The knitted lacing element comprises a lace aperture, a boundary, and a plurality of knit courses. The plurality of knit courses comprise a first knit course and a second knit course extending from the boundary, wherein the lace aperture is disposed between the first knit course and the second knit course. The plurality of knit courses further comprise a contour section having at least one shortened knit course extending between the lace aperture and the boundary. Further, the first knit course and the second knit course are interlooped with the contour section in an area extending from the lace aperture toward the boundary, and the first knit course is interlooped with the second knit course in an area on an opposite side of the lace aperture.
In another aspect, the disclosure provides an article of footwear having an upper and a sole structure secured to the upper, wherein the upper incorporates a knitted component. The knitted component includes a first lacing element having a first inner boundary and a first lace aperture disposed proximate the first inner boundary. The first lacing element is formed by a first plurality of knit courses and comprises a first contour section comprising at least one shortened knit course extending between the first lace aperture and the first inner boundary. The first plurality of knit courses further comprises a first knit course and a second knit course extending from the first inner boundary, wherein the first lace aperture is disposed between the first knit course and the second knit course. Additionally, the first knit course and the second knit course are interlooped with the first contour section between the first inner boundary and the first lace aperture, and the first knit course is interlooped with the second knit course on an opposite side of the first lace aperture. Further, the knitted component and the first lacing element are formed of unitary knit construction.
In another aspect, the disclosure provides a method of making a knitted component for incorporating into an upper of an article of footwear. The method comprises knitting a first portion of the knitted component with at least one course, wherein the first portion extends from a first boundary toward a second boundary. The method then comprises knitting a second portion of the knitted component, wherein the second portion is formed of unitary knit construction with the first portion and comprises at least one course that extend from the first boundary toward a first aperture located between the first boundary and the second boundary. The method next comprises knitting a third portion of the knitted component, wherein the third portion is formed of unitary knit construction with the second portion and the first portion and comprises at least one course. The third portion further extends from the first boundary toward the second boundary and is interlooped with the second portion between the first boundary and the first aperture, and the third portion is interlooped with the first portion between the first aperture and the second boundary.
Other systems, methods, features and advantages of the aspects will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the aspects, and be protected by the following claims.
The aspects can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the aspects. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
The following discussion and accompanying figures disclose a variety of concepts relating to knitted components and the manufacture of knitted components. Although the knitted components may be utilized in a variety of products, the present disclosure sets forth an article of footwear that incorporates a knitted component forming a lacing element having a non-linear or curved edge. The curved edge may be described, in an exemplary aspect, as an undulate edge that has a smooth wave-like transition from convex to concave forms.
The curved edge forming the undulating structure of the knitted component may be formed, in part, through providing a greater number of knit courses on a first side of an aperture than on an opposite side of the aperture, as is depicted in
Additionally and/or alternatively, the undulating structure of the knitted component may be formed, in part, through a varied course width and/or stitch tension on a first side of the aperture relative to the opposite side of the aperture. This varied course width and/or stitch tension may provide for a convex form on the first side of the aperture and a concave form on the opposite side of the aperture. As will be discussed herein, the manipulation of knitting techniques, such as the inclusion of a shortened knit course that does not extend the same length as an adjacent knit course, allows for the formation of curved edges with reduced strain on the knitted component when in forming a curved edge. The reduction in strain may reduce unintended deformations, such as puckering (e.g., a bulge). Therefore, the manipulation of knitting techniques may provide for a curved edge with greater aesthetic and functional utility, in exemplary aspects.
Further to knit construction techniques that may or may not be implemented on opposing sides of an aperture, it is contemplated that a post-knitting process may enhance and/or form the curved edge of the knitted component. For example, the knitted component, in an exemplary aspect, may be releasably secured with one or more elements, such as a lace aperture positioning element that is provided hereinafter with respect to
Additionally, it is contemplated that an application of thermal energy, such as in the form of water-based steam, may be applied to the knitted component. As will be provided herein, the application of thermal energy may alter the characteristics of the knitted component, such as physical and/or chemical characteristics. Further to this example, the material of yarn, as will be discussed in greater detail herein after, may react to the thermal energy to lock, bind, integrate, and/or otherwise secure one or more loops/courses to another loop/course of the knitted component. This securing may be accomplished through physical changes to the material(s) and/or chemical changes to the material(s), in exemplary aspect. In a specific example, it is contemplated that the knitted component is formed, at least in part, with a thermally fuseable material, such as a fuseable yarn, that when exposed to sufficient thermal energy, the material bonds, either mechanically and/or chemically, with another element (e.g., loop and/or course) of the knitted component.
Additionally or alternatively, it is contemplated that a backing material may be secured with at least a portion of the knitted component to maintain and/or form the curved edge. For example, a thermoplastic polyurethane (“TPU”) material may be affixed to at least a portion of a surface of the knitted component. The TPU, in this example, may be secured through adhesion, which may be achieved, in part, by an application of thermal energy to the TPU and knitted component. The TPU may coat and/or permeate the knitted component as the TPU is elevated to a softening and/or melting temperature. Upon a reduction in temperature from the softening and/or melting temperature, the TPU may secure, either fixedly or moveably, elements of the knitted component together in a defined configuration, such as a curved edge.
Therefore, it is contemplated that a knit configuration of the knitted component may be manipulated to form a curved edge, such as by including additional courses extending less than a full length (e.g., a shortened knit course) of a neighboring course. The additional shortened knit course(s) provides additional material effective to push apart adjacent courses that the shortened knit course is disposed between. The knit configuration manipulated may be further aided in forming a curved edge through a releasable securing of the knitted component to tooling (e.g., a positioning element) that forms, in part, a curved edge of the knitted component. Application of thermal energy to the knitted component may further form and/or secure the curved edge by physically and/or chemically altering the materials of the knitted component. For example, when the knitted component is formed, at least in part, with a thermally fuseable yarn, the thermal energy may cause the thermally fuseable yarn to secure one or more portions of the knitted component into a shape that is present during the application of the thermal energy. As such, it is contemplated that one or more techniques may be implemented individually or together to form a knitted component having a curved edge, such as an undulating edge in an exemplary aspect.
In particular, in some aspects, a lacing element for an article of footwear may be formed by providing at least one contour section containing at least one shortened knit course. The shortened knit course(s) may define a curved or non-linear boundary of the lacing element. For example, in some cases, the shortened knit course(s) may define a curved or non-linear edge of the lacing element, while in other cases the shortened knit courses may define an area where the appearance of the knitted component changes.
In some aspects, the lacing element can include a plurality of contour sections. The plurality of contour sections may each include shortened knit courses that are unitarily knit with each other and/or another knit course of the lacing element. In some aspects, the contour sections may comprise several rows of additional shortened knitted courses that are unitarily knit on alternating sides of a plurality of lace apertures, causing the lace apertures to be offset from each other. By incorporating contour sections into the knitted component, the lace apertures may be offset from each other creating a curved edge shape, and providing distribution of tension applied by a lace along the footwear upper. As such, the configuration of the lacing element may impart both aesthetic and functional qualities to the article of footwear.
The following Detailed Description is organized with a variety of discussion focus segments hereinafter that are generally provided as:
Turning to
The upper 104 is secured to the sole structure 102 and forms a void on the interior of the footwear for receiving a foot in a comfortable and secure manner. The upper 104 may secure the foot with respect to the sole structure 102. The upper 104 may extend around the ankle, over the throat, and across the toe areas of the foot. The upper 104 may also extend along the medial and lateral sides of the foot as well as the heel of the foot. The upper 104 may also incorporate a fastening system that permits the wearer to adjust the dimensions of the upper to tighten and secure the upper around the foot. In addition, the upper 104 may be configured to protect the foot and provide ventilation, thereby cooling the foot. Further, the upper 104 may include additional material to provide extra support in certain areas.
The sole structure 102, in an exemplary aspect, is secured to a lower area of the upper 104, such as proximate an outer perimeter boundary of the upper, as discussed herein, thereby positioned between the upper 104 and the ground. The sole structure 102 may include a midsole and an outsole. The midsole often includes a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. Additionally, the midsole may include fluid-filled chamber, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. The outsole is secured to a lower surface of the midsole and provides a ground-engaging portion of the sole structure formed from a durable and wear-resistant material, such as rubber. The sole structure may also include a sockliner positioned within the void and proximal a lower surface of the foot to enhance footwear comfort.
As shown in
Further, reference may be made to directional descriptions. “Longitudinal direction” as used throughout this detailed description and in the claims refers to a direction extending the length of an article or component or portions thereof. In some cases, the longitudinal direction may extend from forefoot region 106 to heel region 110 or portions. The term “lateral direction” as used throughout this detailed description and in the claims refers to a direction extending a width of an article or portions thereof. In other words, the lateral direction may extend between lateral side 114 and medial side 116 of an article. Furthermore, the term “vertical direction” as used throughout this detailed description and in the claims refers to a direction extending from the sole structure 102 to a throat area 120 of article 100. For example, a vertical direction 140 on a lateral side of the article is indicated by a dashed line in
In an aspect, sole structure 102 is secured to upper 104 and extends between the foot and the ground when article 100 is worn. In some aspects, the primary elements of sole structure 102 may include a midsole, an outsole, and a sockliner. In an exemplary aspect, sole structure 102 may include an outsole. In an aspect, the outsole may be secured to a lower surface of upper 104. The outsole may also be secured to a base portion configured for securing sole structure 102 to upper 104. Although the configuration for sole structure 102 provides an example of a sole structure that may be used in connection with upper 104, many other conventional or nonconventional configurations for sole structure 102 may be utilized. Accordingly, the features of sole structure 102, or any sole structure used with upper 104, may vary in other aspects.
For example, in other aspects, sole structure 102 may include a midsole and/or a sockliner. The midsole may be secured to a lower surface of an upper and may be formed from a compressible polymer foam element (e.g., a 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 other configurations, midsole may incorporate plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motions of the foot. In still other cases, the midsole may be primarily formed from a fluid-filled chamber that is located within an upper and is positioned to extend under a lower surface of the foot to enhance the comfort of article of footwear 100.
In some aspects, upper 104 defines a void within article 100 for receiving and securing a foot relative to sole structure 102. The void is shaped to accommodate a foot and extends along the 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 118 located in at least the heel region 110. The foot may be inserted into upper 104 through ankle opening 118. The foot may be withdrawn from upper 104 through ankle opening 118. In some aspects, a throat area 120 may extend forward from ankle opening 118 over an area corresponding approximately to an instep of the foot in midfoot region 108 to the forefoot region 106.
In some aspects, upper 104 may include a tongue portion 122. Tongue portion 122 may be disposed between lateral side 114 and medial side 116 of upper 104 in the throat area 120. Tongue portion 122 may be integrally attached to upper 104. In some aspects, tongue portion 122 may be formed of unitary knit construction, which is defined in further detail below, with portions of upper 104. Accordingly, upper 104 may extend substantially continuously across throat area 120 between lateral side 114 and medial side 116. In some aspects, tongue portion 122 may be attached along lateral side 114 and medial side 116 of throat area 120. In other aspects, tongue portion 122 may be disconnected along the sides of throat area 120 allowing for tongue portion 122 to be moveable between the sides of throat area 120.
A lace 126 or other fastening system may extend through various lace apertures 128 to secure article 100 to the wearer's foot and to further enhance the comfort of article 100. Lace 126 may allow for the wearer to modify the dimensions of upper 104 to accommodate proportions of the foot. In some aspects, lace 126 may extend through lace apertures 128 that are disposed along either side of throat area 120. In some aspects, lace apertures 128 are integrally formed in a lacing element 124 of upper 104. In some aspects, an inlaid strand or tensile element 130 may also be integrally formed with upper 104 and form a loop 132 for receiving lace 126, providing additional structure to upper 104. Lace 126 may permit the wearer to tighten upper 104 around the foot. Lace 126 may also permit the wearer to loosen upper 104 to facilitate entry and removal of the foot from the void. In addition, tongue portion 122 of upper 104 in throat area 120 extends under lace 126 to enhance the comfort of article 100. In some aspects, lace apertures 128 may include another material, for example, a reinforcing material. In still other aspects, the fastening system may incorporate other structures, such as hook-and-loop fasteners, zippers or other fastening techniques contemplated by a skilled artisan. In further configurations, upper 104 may include additional elements, such as (a) a heel counter in heel region 110 that enhances stability, (b) a toe guard in forefoot region 106 that is formed of wear-resistant material, and (c) logos, trademarks, and placards with care instructions and material information.
Many conventional footwear uppers are formed from multiple material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) that are joined through stitching or bonding, for example. In contrast, in some aspects, a majority of upper 104 is formed from a knitted component 134, which will be discussed in more detail below. Knitted component 134 may, for example, be manufactured through a flat knitting process and extend through one of more of forefoot region 106, midfoot region 108, and heel region 110 along both lateral side 114 and medial side 116.
In an exemplary aspect, knitted component 134 forms most or substantially all of upper 104 including exterior surface 136, and a majority or a relatively large portion of interior surface 138 (see
Although seams may be present in knitted component 134, a majority of knitted component 134 may have a substantially seamless configuration. Moreover, knitted component 134 may be formed of unitary knit construction. As utilized herein, a knitted component (e.g., knitted component 134) is defined as being formed of “unitary knit construction” when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures of knitted component 134 without the need for significant additional manufacturing steps or processes. A unitary knit construction may be used to form a knitted component having structures or elements that include one or more courses of yarn, strands, or other knit material that are joined such that the structures or elements include at least one course in common (i.e., sharing a common yarn), include courses that are interlooped with each other, and/or include courses that are substantially continuous between each of the structures or elements. The structures or elements formed of unitary knit construction may also be referred to as being “unitarily knit.” With this arrangement, a one-piece element of unitary knit construction is provided.
Although portions of knitted component 134 may be joined to each other (e.g., as heel edges 208 and 210 may be joined to form seam 144) following the knitting process, knitted component 134 remains formed of unitary knit construction because it is formed as a one-piece knit element. Moreover, knitted component 134 remains formed of unitary knit construction when other elements (e.g., a lace, logos, trademarks, placards with care instructions and material information, structural elements) are added following the knitting process.
Knitted component 134 may incorporate various types of yarn that impart different properties to separate areas of upper 104. That is, one area of knitted component 134 may be formed from a first type of yarn that imparts a first set of properties, and another area of knitted component 134 may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout upper 104 by selecting specific yarns for different areas of knitted component 134. The properties that a particular type of yarn will impart to an area of knitted component 134 partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability.
In addition to materials, other aspects of the yarns selected for knitted component 134 may affect the properties of upper 104. For example, a yarn forming knitted component 134 may be a monofilament yarn or a multifilament yarn. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of upper 104. Further still, a yarn having heat fusible properties may be selected. Such a heat fusible yarn would allow the structure and integrity to be altered where heat is applied to the knitted component. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of upper 104.
Referring to
Knitted component 134 may be formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a variety of courses and wales. That is, knitted component 134 has the structure of a knit textile. It will be further understood that a variety of types of knit structures may be used to create knitted component 134. In some cases, weft knitting techniques may be used to create knitted component 134. For example, flat knitting techniques may be used, including for example, flat knitting techniques incorporating various stitch structures such as single jersery knit, double jersey knit, and links-links. In other cases, various warp knitting techniques may be used. In an exemplary aspect, knitted component 134 may be formed using weft knitting techniques on a flat knitting machine, described in more detail below.
A knit course, as discussed throughout the description and claims, refers to interlooped yarns or strands forming a row of loops that are being joined to successive courses through a knitting process. The knitting direction may be generally defined relative to the direction of the knit material being formed during the knitting process. For example, during a flat knitting process, successive courses of interlooped yarns are joined together to form a knit element by manipulating a yarn through knitting a course or row along a first direction to increase the size of the knitted component along a second direction, the second direction being generally perpendicular to the first direction. In addition, courses or portions of courses may be skipped or altered to alter the look and orientation of a final knitted product. As discussed in further detail below, altered knit courses along a lacing structure area of a knitted component may result in desirable characteristics in lacing tension.
In some cases, extra elements may be incorporated into and/or with knitted component 134 to provide support, stretchability, or other desirable qualities to article 100. In one aspect, a tensile element 130 may be utilized to provide additional support and to prevent excessive stretch of the knit yarns around a wearer's foot. The tensile element 130 may be inlaid, tunneled, or otherwise moveably or immovably secured with the knitted component 134. For example, tensile element 130 may extend through knitted component 134 and pass through various loops within knitted component 134 as an inlaid tensile element. When inlaid, tensile element 130 may generally extend along the courses within knitted component 134; however, in some aspects, a tensile element 130 may extend along the wales within knitted component 134. When knitted component 134 is incorporated into article 100, tensile element 130 may impart stretch resistance in certain areas within article 100. With respect to the methods and systems for incorporating a tensile element 130 into knitted component 134, reference is made to U.S. Pat. No. 8,839,532, filed on Mar. 15, 2011, which is incorporated herein by reference, in its entirety. It will also be understood, however, that in some aspects knitted component 134 and article 100 may also be configured without tensile element 130 and still fall within the spirit and scope of the present disclosure.
In some aspects, tensile element 130 may be incorporated such that tensile element 130 interacts with lace 126. More particularly, tensile element 130 may extend along knit courses running in a generally vertical direction, from sole structure 102 to throat area 120. In some aspects, tensile element 130 may be used to form loop 132. Accordingly, in some aspects, the portion of tensile element 130 forming loop 132 may augment lace aperture 128. In some cases, tensile element 130 may exit knitted component 134, such as an outer perimeter of the upper and/or the throat area 120. Thus, the exposed portions of tensile element 130 may interact with sole structure 102 and lace 126. The interaction with lace 126 and/or sole structure 102 may assist with securing upper 104 around the foot.
Lace apertures 128 may extend through knitted component 134 from exterior surface 136 to interior surface 138 (as shown in
Some aspects may include provisions to distribute the tension applied by a fastening system, e.g. lace 126, that may ultimately act upon a knitted component, and an upper. In some aspects, tension distribution may be achieved by providing a lacing element with at least one contour section containing at least one shortened knit course. The shortened knit course(s) may define a curved or non-linear boundary, such as a terminal edge, of the lacing element, as can be seen in
In an exemplary aspect, a knitted component may be provided with a curved lacing structure disposed in throat area 120. In one aspect, the curved lacing structure can include lace apertures that are shifted to alternating vertical positions. By inserting additional, shortened, knitted courses on alternating sides of a lace aperture, a curved lacing structure may be achieved, allowing for alternating vertical distribution of the lace apertures, and thus, the vertical distribution of tension through throat area 120. In at least one aspect, the curved lacing structure can include one or more curved lacing elements on either side of throat area 120. Each curved lacing element may include a plurality of lace apertures that are shifted to alternating vertical positions to form the curved lacing structure.
As depicted
As seen in
However, in other aspects, including in one aspect discussed below in relation to
In at least one aspect, each curved boundary of lateral lacing element 124 and medial lacing element 125 may alternate between a convex and concave orientation to impart a “wavy” or undulating appearance. Referring to the close up representation of lateral lacing element 124 in
Lateral lacing element 124 and medial lacing element 125 may be formed and incorporated into upper 104 in a variety of ways. In some aspects, curved lateral lacing element 124 and medial lacing element 125 may be integrally knit and formed of unitary knit construction with adjacent rows of knitted component 134. However, in other aspects, lacing elements may be formed as independent knitted elements (discussed in further detail below). In at least one aspect, referring to
According to at least one aspect, lateral lacing element 124 and medial lacing element 125 may be formed on a standard flat knitting machine as integral and unitary portions of knitted component 134. In
To form curved lateral lacing element 124 and medial lacing element 125, shortened knit courses may be incorporated into portions of knitted component 134 to form contour sections along curved inner lateral boundary 300, curved outer lateral boundary 304, curved inner medial boundary 302 and/or curved outer medial boundary 306.
The left portion of
Also positioned near top lace aperture 128 are shortened knit course 318, shortened knit course 320 and shortened knit course 322 (collectively, contour section 326). In particular, in at least one aspect, shortened knit course 318, shortened knit course 320 and shortened knit course 322 may be positioned between lace aperture 128 and outer lateral boundary 304. In some aspects, shortened knit course 318, shortened knit course 320 and shortened knit course 322 may terminate at outer lateral boundary 304 and lace aperture 128. In other cases, however, shortened knit course 318, shortened knit course 320 and shortened knit course 322 may also extend beyond outer lateral boundary 304.
According to the aspect depicted in
Referring to the left side of
As may be seen in
In some cases, a knitted component may need to be further manipulated after the knitting process to achieve a desired shape and or desired characteristics. In some cases, for example, if fusible yarn is utilized for a knitted component, a heat and/or steam treatment may need to be applied. In other cases, a knitted component may be misshapen after knitting due to inconsistent yarn tensions or the use of varying knit courses, and the shaped of the knitted component may need to be manipulated. According to at least one aspect, knitted component 134 may be treated with steam to manipulate the knitted yarns into a final desired shape.
According to techniques described herein, the shape and configuration of knitted component 134 may be manipulated after knitting. In some cases, knitted component 134 may be stretched using a rigid shaping mechanism to force knitted component 134 into a predefined shape. In other cases, heat and/or steam may be applied to knitted component 134 to allow the yarns to expand and/or contract to the desired shape. In at least one exemplary aspect, knitted component 134 may be fitted on a rigid positioning element and subjected to thermal energy, such as water-based steam, to effect a proper configuration or the desired shape of the knitted component.
Further, once the shape of knitted component 134 has been finalized, it may be desirable to further reinforce the shape to create integrity and to prevent the shape and dimensions from deforming over time. For example, in some cases, a facing or backing material may be cut to the same size and shape as knitted component 134 to be sewn, glued or otherwise affixed to a back surface of knitted component 134. In other cases, a heat fusible backing may be applied to knitted component 134. As provided herein, a TPU backing may be applied to one or more portions of the knitted component 134. In still other cases, where heat-fusible yarn is utilized for knitting, the yarn itself may be partially or fully fused together with heat. In addition, other reinforcements known in the art may also be applied to knitted component 134 and still fall within the scope of the present disclosure.
At a block 1804, a step is illustrated for knitting a second portion of the knit component from the first boundary toward the first aperture. In an exemplary aspect, the second portion is comprised of at least one course. As such, it is contemplated that any number of courses may be implemented, such as three in an exemplary aspect. The second portion is interlooped with the first portion between the first boundary and the first aperture. In an exemplary aspect, the first portion and the second portion are of a unitary knit construction. The second portion may be referred to as a shortened knit course, such as the shortened knit course 318, 319, or 320 of
At a block 1806, a step is illustrated for knitting a third portion of the knit component from the first boundary toward the second boundary. In an exemplary aspect, the third portion is comprised of at least one course. It is contemplated that any number of courses may be implemented. In an exemplary aspect, the third portion is interlooped with the second portion between the first boundary and the first aperture. Continuing with this exemplary aspect, it is contemplated that the third portion is also interloped with the first portion between the first aperture and the second boundary. For illustrative purposes, the third portion of block 1806 may be depicted as the second knit course 316 of
A block 1808, which may be optional in exemplary aspects, illustrates a step is illustrated for placing the knitted component on a positioning element. The positioning element may be similar to the positioning element 500 of
A block 1810, which may be optional in exemplary aspects, illustrates a step of applying thermal energy to the knitted component. In an exemplary aspect, the thermal energy is water-based steam. The knitted component may be releasably secured to the positioning element of block 1808 when the thermal energy is applied. Alternatively, the knit component is not secured to the positioning element when the thermal energy is applied. The thermal energy, as discussed with respect to
At a block 1812, which may be optional in exemplary aspects, illustrates a step of securing a backing material to the knitted component. In an exemplary aspect, the backing material is a TPU that is secure by adhering the TPU with at least a portion of the knit component. For example, an interior surface of the knitted component that faces the interior cavity of an article of footwear (e.g., interior surface 138 of
In some cases, a lacing element may be knitted and attached to a separately formed upper.
Similar to previously discussed aspects, article 600 includes an upper 604 with a lateral side 614 and a medial side (not shown). Upper 604 is attached to sole structure 602. Along a throat region, upper 604 may include a lateral edge 608 and a medial edge 610, configured so that separately formed lateral lacing element 624 and medial lacing element 625 may be attached thereto. Upper 604 may be formed according to techniques known in the art. For example, in some cases, upper 604 may incorporate materials such as leather or polymers. In other cases, upper 604 may comprise a separately formed knitted component. Upper 604 may also include tensile elements or other structure features that are integrally formed with upper 604 (similar to previously discussed aspects) or otherwise attached to upper 604. Those skilled in the art will appreciate the full range of materials and configurations of separately formed upper 604, and will understand that upper 604 is not limited by only those materials and configurations discussed herein.
Similar to previously discussed aspects, lateral lacing element 624 and medial lacing element 625 may be configured to distribute tension along upper 604. For example, in some aspects, lateral lacing element 624 and medial lacing element 625 may have an offset boundary to facilitate offset placement of the lace apertures. In some cases, lateral lacing element 624 may include curved inner lateral boundary 612 and curved outer lateral boundary 616, and a vertically offset lace apertures 628. Similarly, medial lacing element 625 may also include curved inner medial boundary 614 and curved outer medial boundary 618, and vertically offset lace apertures 628. Further, in at least one case, each curved boundary of lateral lacing element 624 and medial lacing element 625 may alternate between a convex and concave orientation so that each lacing element has a “wavy” appearance. For example, referring to the aspect of
Lateral lacing element 624 and medial lacing element 625 may be formed on a standard flat knitting machine, such as knitting machine 400, in the same way as described above for lateral lacing element 124, and medial lacing element 125, as well as knitted component 134. In particular, lateral lacing element 624 and medial lacing element 625 may be formed by incorporating shortened knit courses in a contour section in the same way as described in relation to
Lateral lacing element 624 and medial lacing element 625 may be attached to the separately formed upper 604 using a variety of techniques known in the art. In particular, lacing element 624 may be glued or sewn to upper 604. In other aspects, lacing element 624 may be fused to upper 604 using heat. As shown in the magnified portion of
Referring to
Similar to previously discussed aspects, curved lacing element 724 may be formed on a standard flat knitting machine, such as knitting machine 400. In particular, to form curved lacing element 724, shortened knit courses may be incorporated into portions of knitted component 700 as described in relation to
Further, similar to aspects discussed above, once the shape of knitted component 700, and lacing element 724 has been finalized, lacing element 724 may also be reinforced as previously described. For example, in some cases, a facing may be cut to the same size and shape as lacing element 724 and can be sewn, glued or otherwise affixed to a back surface of lacing element 724. In other cases, where heat-fusible yarn is utilized in knitting of the knitted component 700, heat may be applied to partially fuse the structure of knitted component 700.
Lacing element 724 may be attached to a separately formed upper as described above in relation to lateral lacing element 624 and medial lacing element 625. In particular, lacing element 724 may be glued or sewn to upper 604. In other aspects, lacing element 724 may be fused to upper 604 using heat. In addition, lacing element 724 may be formed as a unitary knit article with a full knitted component, such as described above in relation to the knitted component 134.
Although knitting may be performed by hand, commercial manufacturing of knitted components is generally performed by knitting machines. An example of a knitting machine capable of producing a knitted component, such as knitted component 134 described herein, is depicted in
In some aspects, knitting machine 400 may include two needle beds 402. In some cases, needle beds 402 may be angled thereby forming a v-bed. Each needle bed 402 contains a plurality of individual needles 404 that lay on a common plane. That is, needles 404 of one needle bed 402 lie in one plane while needles 404 of the other needle bed 402 lie in a different plane. The first plane and second plane are angled such that the intersection of the planes extends along a majority of the width of the knitting machine 400. As described in further detail below, needles 404 may have a first position where they are retracted, a second position where they are extended, and a third position where they are partially extended. In the first position the needles are spaced from the intersection point. In the second position the needles may pass through the intersection point. In the third position the needles are located between the first position and the second position.
A rail 406 extends above and parallel to the intersection of needle beds 402. The rail may provide attachment points for feeders 408. The feeders 408 may supply yarn 410 to needles 404 in order for the needles 404 to manipulate yarn 410. Due to the action of a carriage, feeders 408 may move along the rail 406 and needle bed 402, thereby supplying yarn 410 to needles 404. In
Knitting machine 400 may operate to manufacture knitted component 134. More particularly, needles 402 pull sections of yarn 410 fed by feeder 408 through loops of a prior course, thereby forming another course of knitted component 134. It should be understood that the general structure of knitting machine 400 is simplified for purposes of explaining knitted component 134 as well as the method of forming knitted component 134. In addition, the knit courses for knitted component 134 are depicted in the figures as separate yarns, i.e., the yarn courses are not depicted as being looped together through prior course. However, those skilled in the art will readily understand that the figures have been simplified for discussion purposes and will appreciate that to effectuate knitted component 134, yarn courses will be looped together to form a series of courses and wales.
While various aspects have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more aspects and implementations are possible that are within the scope of the aspects. For example, in addition to footwear, the knitted components may be utilized in other types of apparel (e.g., shirts, pants, socks, jackets, undergarments), athletic equipment (e.g., golf bags, baseball and football gloves, soccer ball restriction structures), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats). The knitted components may also be utilized in bed coverings (e.g., sheets, blankets), table coverings, towels, flags, tents, sails, and parachutes. The knitted components may be utilized as technical textiles for industrial purposes, including structures for automotive and aerospace applications, filter materials, medical textiles (e.g. bandages, swabs, implants), geotextiles for reinforcing embankments, agrotextiles for crop protection, and industrial apparel that protects or insulates against heat and radiation. Accordingly, the knitted components and other concepts disclosed herein may be incorporated into a variety of products for both personal and industrial purposes, and the aspects are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.
This application having entitled “Article of Footwear Incorporating a Curved Knitted Lacing Element” claims the benefit of priority of U.S. Provisional Application No. 62/162,305, entitled “Article of Footwear Incorporating a Curved Knitted Lacing Element,” filed May 15, 2015. The entirety of the aforementioned application is incorporated by reference herein.
| Number | Name | Date | Kind |
|---|---|---|---|
| 1185933 | Powell | Jun 1916 | A |
| 2403201 | Wildt | Jul 1946 | A |
| 2657561 | Holmes | Nov 1953 | A |
| 4838045 | Cournoyer | Jun 1989 | A |
| 4941331 | Cournoyer | Jul 1990 | A |
| 6871515 | Starbuck et al. | Mar 2005 | B1 |
| 9032763 | Meir | May 2015 | B2 |
| 9732451 | Lee | Aug 2017 | B2 |
| 20080110048 | Dua | May 2008 | A1 |
| 20100154256 | Dua | Jun 2010 | A1 |
| 20110078921 | Greene et al. | Apr 2011 | A1 |
| 20120233884 | Greene | Sep 2012 | A1 |
| 20150059209 | Dekovic et al. | Mar 2015 | A1 |
| Number | Date | Country |
|---|---|---|
| 2438733 | Jul 2001 | CN |
| 196 00 720 | Aug 1997 | DE |
| 200530449 | Sep 2005 | TW |
| Entry |
|---|
| International Search Report and Written Opinion for International Application No. PCT/US2016/032724, dated Sep. 6, 2016, 13 pages. |
| Office Action, and English language translation thereof, in corresponding Taiwanese Application No. 105114216, dated Apr. 21, 2017, 11 pages. |
| Number | Date | Country | |
|---|---|---|---|
| 20160331083 A1 | Nov 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62162305 | May 2015 | US |
