Article of Footwear Incorporating a Knitted Component with Monofilament Areas in Body and Heel Portions

Abstract

An article of footwear includes an upper incorporating a knitted component formed of unitary knit construction. The knitted component includes areas formed using monofilament strands. The monofilament areas may be bounded by multifilament areas. The multifilament areas may be configured to form a welt that includes a tensile element.

Description

BACKGROUND

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. The sole structure is secured to a lower area of the upper, thereby being positioned between the upper and the ground.

In athletic footwear, for example, the sole structure 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 chambers, 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.

A variety of material elements (e.g. textiles, polymer foam, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing the upper. In athletic footwear, for example, the upper may have multiple layers that each includes a variety of joined material elements. As examples, the material elements may be selected to impart stretch-resistance, wear resistance, flexibility, air-permeability, compressibility, comfort, and moisture-wicking to different areas of the upper. In order to impart the different properties to different areas of the upper, material elements are often cut to desired shapes and then joined together, usually with stitching or adhesive bonding. Moreover, the material elements are often joined in layered configuration to impart multiple properties to the same areas.

As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, stocking, cutting, and joining the material elements may also increase. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and type of material elements incorporated into the upper increases. Moreover, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from fewer types and number of material elements. Further, multiple pieces that are stitched together may cause a greater concentration of forces in certain areas. The stitch junctions may transfer stress at an uneven rate relative to other parts of the article of footwear which may cause failure or discomfort. Additional material and stitch joints may lead to discomfort when worn. By decreasing the number of material elements utilized in the upper, therefore, waste may be decreased while increasing the manufacturing efficiency, the comfort, performance, and the recyclability of the upper.

SUMMARY

In one aspect, an article of footwear includes a knitted component, the knitted component forms a substantial majority of the upper. The knitted component includes at least one monofilament area comprised of a monofilament strand, the at least one monofilament area having a shape. The article of footwear further includes a first welt formed using multifilament yarn, the first welt is constructed of at least two overlapping knit layers forming a first central unsecured area. The article further includes a second welt formed using multifilament yarn, the second welt constructed of at least two overlapping knit layers forming a second central unsecured area. At least one of the first welt and the second welt defines a portion of the shape of the at least one monofilament area and a tensile element extends through at least a portion of at least one of the first welt and the second welt.

In another aspect, an upper for an article of footwear includes a knitted component, the knitted component forms a substantial majority of the upper. The knitted component includes at least one monofilament area comprised of a monofilament strand, the at least one monofilament area having a shape. The upper further includes a first welt formed using multifilament yarn, the first welt is constructed of at least two overlapping knit layers forming a first central unsecured area. The upper further includes a second welt formed using multifilament yarn, the second welt constructed of at least two overlapping knit layers forming a second central unsecured area. At least one of the first welt and the second welt defines a portion of the shape of the at least one monofilament area and a tensile element extends through at least a portion of at least one of the first welt and the second welt.

In another aspect, a method of manufacturing an article of footwear comprising includes knitting a knitted component, the knitted component comprising a substantial majority of the upper the knitted component including at least one monofilament area comprised of a monofilament strand, the at least one monofilament area having a shape. The method further comprising, knitting a first welt formed using a multifilament yarn, the first welt constructed of at least two overlapping knit layers forming a void. The method further comprising knitting a second welt formed using a multifilament yarn, the second welt constructed of at least two overlapping knit layers forming a void. The at least one of the first welt and the second welt defining a portion of the shape of the at least one monofilament area.

Other systems, methods, features and advantages of the embodiments 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 embodiments, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention 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 invention. Moreover, in the Figures, like reference numerals designate corresponding parts throughout the different views.

The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the accompanying Figures.

FIG. 1 is an isometric view of an embodiment of an article of footwear;

FIG. 2 is a lateral side view of an embodiment of an article of footwear;

FIG. 3 is a medial side view of an embodiment of an article of footwear;

FIG. 4 is a top view of an embodiment of an article of footwear;

FIG. 5 is a rear view of an embodiment of an article of footwear;

FIG. 6 is a top view of an embodiment of a knitted component incorporated into an upper of an article of footwear;

FIG. 7 is a top view of an embodiment of a heel portion of a knitted component;

FIG. 8 is a top view of an embodiment of a body portion of a knitted component;

FIG. 9 is an exploded view of the components of an embodiment of an article of footwear with an upper incorporating a knitted component;

FIG. 10 is an enlarged view of an embodiment of welts within a body portion of a knitted component;

FIG. 11 is an enlarged view of an embodiment of welts within a forefoot region of a body portion of a knitted component;

FIG. 12 is an enlarged view of an embodiment of welts within a heel portion of a knitted component;

FIG. 13 is a top view of an embodiment of a heel portion of a knitted component subjected to a tensile force;

FIG. 14 is a cross-section of an embodiment of a welt enveloping a tensile element;

FIG. 15 is a looping diagram of an embodiment of the knitting configuration for a welt enclosing a tensile element;

FIG. 16 is a looping diagram of an embodiment of a knitting configuration for securing different yarn types;

FIG. 17 is a cross-section of an embodiment of a welt;

FIG. 18 is a looping diagram of an embodiment of the knitting configuration for a welt.

DETAILED DESCRIPTION

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, an article of footwear that incorporates one of the knitted components is disclosed below as an 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.

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term “longitudinal” as used throughout this Detailed Description and in the claims refers to a direction extending a length or major axis of an article. In some cases, the longitudinal direction may extend from a forefoot region to a heel region of the article. Also, the term “lateral” as used throughout this Detailed Description and in the claims refers to a direction extending a width or minor axis of an article. In other words, the lateral direction may extend between a medial side and a lateral side of an article. Furthermore, the term “vertical” as used throughout this Detailed Description and in the claims refers to a direction generally perpendicular to a lateral and longitudinal direction. For example, in cases where an article is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of an article, including an upper, a knitted component and portions thereof, and/or a sole structure.

Footwear Configuration

FIGS. 1 through 5 illustrate an exemplary embodiment of an article of footwear 100, also referred to simply as article 100. In some embodiments, article 100 may include a sole structure 110 and an upper 120. Although article 100 is illustrated as having a general configuration suitable for basketball, concepts associated with article 100 may also be applied to a variety of other athletic footwear types, including baseball shoes, soccer shoes, cycling shoes, football shoes, tennis shoes, running shoes, training shoes, walking shoes, and hiking boots, for example. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed with respect to article 100 may be applied to a wide variety of footwear types.

For reference purposes, article 100 may be divided into three general regions: a forefoot region 10, a midfoot region 12, and a heel region 14, as shown in FIGS. 1, 2, and 3. Forefoot region 10 generally includes portions of article 100 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 12 generally includes portions of article 100 corresponding with an arch area of the foot. Heel region 14 generally corresponds with rear portions of the foot, including the calcaneus bone. Article 100 also includes a lateral side 16 and a medial side 18, which extend through each of forefoot region 10, midfoot region 12, and heel region 14 and correspond with opposite sides of article 100. More particularly, lateral side 16 corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot), and medial side 18 corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Forefoot region 10, midfoot region 12, and heel region 14 and lateral side 16, medial side 18 are not intended to demarcate precise areas of article 100. Rather, forefoot region 10, midfoot region 12, and heel region 14, and lateral side 16 and medial side 18 are intended to represent general areas of article 100 to aid in the following discussion. In addition to article 100, forefoot region 10, midfoot region 12, and heel region 14 and lateral side 16, medial side 18 may also be applied to sole structure 110, upper 120, and individual elements thereof.

In an exemplary embodiment, sole structure 110 is secured to upper 120 and extends between the foot and the ground when article 100 is worn. In some embodiments, sole structure 110 may include one or more components, including a midsole, an outsole, and/or a sockliner or insole. In an exemplary embodiment, sole structure 110 may include an outsole 112 that is secured to a lower surface of upper 120 and/or a base portion configured for securing sole structure 110 to upper 120. In one embodiment, outsole 112 may be formed from a wear-resistant rubber material that is textured to impart traction. In this embodiment, outsole 112 is configured to provide traction suitable for use on a basketball court. Although this configuration for sole structure 110 provides an example of a sole structure that may be used in connection with upper 120, a variety of other conventional or nonconventional configurations for sole structure 110 may also be used. Accordingly, in other embodiments, the features of sole structure 110 or any sole structure used with upper 120 may vary.

In other embodiments, sole structure 110 may include a midsole and/or a sockliner. A midsole may be secured to a lower surface of an upper and in some cases 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 cases, a 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 an article.

In some embodiments, upper 120 defines a void within article 100 for receiving and securing a foot relative to sole structure 110. The void is shaped to accommodate 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. Upper 120 includes an exterior surface 121 and an opposite interior surface 122. Exterior surface 121 faces outward and away from article 100, whereas interior surface 122 faces inward and defines a majority or a relatively large portion of the void within article 100 for receiving the foot. Moreover, interior surface 122 may lay against the foot or a sock covering the foot. Access to the void is provided by a throat opening 140 located in at least heel region 14. More particularly, the foot may be inserted into upper 120 through throat opening 140, and the foot may be withdrawn from upper 120 through throat opening 140. In some embodiments, an instep area 150 extends from throat opening 140 in heel region 14 over an area corresponding to an instep of the foot to an area adjacent to forefoot region 10.

A lace 154 extends through a plurality of lace apertures 156 in upper 120 and permits the wearer to modify dimensions of upper 120 to accommodate proportions of the foot. More particularly, lace 154 permits the wearer to tighten upper 120 around the foot, and lace 154 permits the wearer to loosen upper 120 to facilitate entry and removal of the foot from the void (i.e., through throat opening 140). In some embodiments, lace 154 may additionally pass through loops 158, which may further permit the wear to tighter upper 120 around the foot. In addition, a tongue 152 extends through instep area 150 from a forward portion of upper 120 in forefoot region 10 to a top portion of upper 120 adjacent to throat opening 140 in heel region 14. In this embodiment, tongue 152 extends under lace 154 to enhance the comfort of article 100. In addition to, or in alternative of lace apertures 156, article 100 may include other lace-receiving elements, such as D-rings, hooks, or various looped tensile elements. In further configurations, upper 120 may include additional elements, such as (a) a heel counter in heel region 14 that enhances stability, (b) a toe guard in forefoot region 10 that is formed of a 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 embodiments, a majority of upper 120 is formed from a knitted component 130, which will be discussed in more detail below. Knitted component 130 may, for example, be manufactured through a flat knitting process and extends through each of each of forefoot region 10, midfoot region 12, and heel region 14, along both lateral side 16 and medial side 18, over forefoot region 10, and around heel region 14. In an exemplary embodiment, knitted component 130 forms substantially all of upper 120, including exterior surface 121 and a majority or a relatively large portion of interior surface 122, thereby defining a portion of the void within upper 120. In some embodiments, knitted component 130 may also extend under the foot. In some embodiments, knitted component 130 may be secured to upper surface 114 of sole structure 110. In other embodiments, however, a strobel sock or thin sole-shaped piece of material is secured to knitted component 130 to form a base portion of upper 120 that extends under the foot for attachment with sole structure 110.

In some embodiments, knitted component 130 may be formed from multiple knitted components. In an exemplary embodiment, knitted component 130 may include a body portion 124 and a heel portion 126. In some embodiments, body portion 124 may be formed from a knitted textile material and may extend along article 100 in a longitudinal direction from forefoot region 10 of upper 120 through midfoot region 12 and extending over a vamp portion of upper 120 that corresponds with an instep of a foot of a wearer. In an exemplary embodiment, at least a portion of body portion 124 may further extend rearwards from midfoot region 12 into heel region 14. Additionally, body portion 124 may extend continuously between lateral side 16 and medial side 18 around forefoot region 10 of upper 120. With this configuration, body portion 124 of knitted component 130 may be configured to substantially cover a foot of a wearer.

In some embodiments, heel portion 126 may be formed from a knitted textile material and may extend along article 100 in a vertical direction in heel region 14 from sole structure 110 towards the top of throat opening 140. In an exemplary embodiment, heel portion 126 may further extend at least partially into midfoot region 12 of upper 120 along the longitudinal direction of article 100. Additionally, heel portion 126 may extend continuously between lateral side 16 and medial side 18 around heel region 14 of upper 120. With this configuration, heel portion 126 of knitted component 130 may be configured as a cuff to cover at least a portion of an ankle of the wearer. Together, body portion 124 and heel portion 126 may be joined along corresponding edges to form knitted component 130, as will be described in more detail below. For example, edge 127 of body portion 124 may be connected to heel portion 126 along edge 128 of heel portion 126.

In addition to covering the foot, therefore, upper 120 extends upward and covers a portion of the ankle. For reference purposes, upper 120 may be divided into two general regions: a foot region 20 and an ankle region 30, as shown in FIGS. 1, 2, and 3. Foot region 20 extends through each of forefoot region 10, midfoot region 12, and heel region 14 and generally encompasses portions of upper 120 corresponding with the foot. In many configurations of article 100, foot region 20 corresponds with portions of upper 120 that are intended to be below the lateral malleolus and the medial malleolus (i.e., the bony prominences on each side of the ankle) of the wearer. Ankle region 30 is primarily located in heel region 14 and generally encompasses portions of upper 120 corresponding with the ankle. In many configurations of article 100, ankle region 30 corresponds with portions of upper 120 that are intended to cover and extend above the lateral malleolus and the medial malleolus, including a cuff.

In this embodiment, body portion 124 of knitted component 130 is primarily and substantially associated with foot region 20 of upper 120 and heel portion 126 is associated with at least a portion of foot region 20 and a substantial majority of ankle region 30. As seen in FIG. 5, heel portion 126 extends from a lower area of upper 120 adjacent to sole structure 110 to a top edge of upper 120 extending around throat opening 140. In some embodiments, heel portion 126 extends upwards above an ankle of a foot of a wearer when disposed within article 100 to form a cuff. In an exemplary embodiment, heel portion 126 may be joined or attached to body portion 124 along adjacent edges, for example edge 127 and edge 128, that extend approximately from instep area 150 in a downwards direction towards sole structure 110. In addition, in some embodiments, edge 127 and edge 128 may extend in an approximately diagonal direction from instep area 150 towards a rear of article 100 at heel region 14.

Heel portion 126 forms a cuff having an approximately C-shape with front perimeter edges extending along opposite sides of instep area 150 to provide support for ankle of a wearer of article 100 by surrounding and substantially encircling the ankle of the wearer when disposed within upper 120 through throat opening 140. Heel portion 126 includes a top edge forming a cuff extending around throat opening 140 from lateral side 16 to medial side 18 in a continuous manner around heel region 14 at the back of article 100, as shown in FIG. 5, while remaining open along the front of article 100 at instep area 150 to accommodate tongue 152. In an exemplary embodiment, tongue 152 may fit between opposite front perimeter edges of heel portion 126.

In some embodiments, upper 120 may include distinct areas with differing properties. In some embodiments, a portion of upper 120 may include multifilament yarn. In some embodiments, a portion of upper 120 may include monofilament strands. Monofilament strands may be made from a plastic or polymer material that is extruded to form the monofilament strand. Generally, monofilament strands may be lightweight and have a high tensile strength, i.e., are able to sustain a large degree of stress prior to tensile failure or breaking, so as to provide a large amount or degree of resistance to stretch to upper 120. In an exemplary embodiment, portions of upper 120 that include monofilament strands may be located in one or more monofilament areas. The term “monofilament areas” is used to reference a portion of upper 120 that is formed substantially entirely from knitted monofilament strands.

In some embodiments, monofilament groups may be located on various portions of upper 120. Monofilament groups may be used to refer to a general region of a group of monofilament areas. In an exemplary embodiment, one or more monofilament groups may be located throughout article 100. In one embodiment, a medial monofilament group 160 is disposed on medial side 18 of upper 120 and a lateral monofilament group 164 disposed on lateral side 16 of upper 120. Medial monofilament group 160 and lateral monofilament group 164 may be generally located in midfoot region 12. In some embodiments, a forefoot monofilament group 162 is disposed forward of instep area 150 in forefoot region 10 of upper 120. Additionally, in some embodiments, monofilament groups may further include a heel monofilament group 166. Monofilament groups may comprise multiple monofilament areas described in detail later in the detailed description. Additionally, in some embodiments, monofilament groups may comprise monofilament areas that are arranged in a certain orientation. For example, referring to lateral monofilament group 164, some of the monofilament areas are oriented in a similar diagonal orientation. Likewise, heel monofilament group 166 may include monofilament areas that are oriented in a largely horizontal manner. Although monofilament groups may include similarly situated monofilament areas, in other embodiments monofilament groups may include variously oriented monofilament areas.

As described above, in some embodiments, upper 120 may incorporate knitted component 130 that extends throughout upper 120 and forms a majority of exterior surface 121 and/or a majority of interior surface 122, thereby defining a portion of the void within upper 120. In an exemplary embodiment, upper 120 incorporates knitted component 130 that includes multiple knitted component portions, including body portion 124 and heel portion 126. Referring now to FIGS. 6 through 9, knitted component 130 and respective portions, including body portion 124 and heel portion 126, are depicted individually and separate from a remainder of article 100. Knitted component 130 is 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 130 has the structure of a knit textile.

Moreover, individual component portions of knitted component 130, including body portion 124 and/or heel portion 126, are each formed of unitary knit construction. Although seams may be present in the component portions of knitted component 130, a majority of the knitted component portions (e.g., body portion 124 and heel portion 126) have a substantially seamless configuration. As utilized herein, a knitted component portion (e.g., body portion 124 and/or heel portion 126 of knitted component 130) 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 the knitted component portion without the need for significant additional manufacturing steps or processes. A unitary knit construction may be used to form a knitted component portion having structures or elements that include one or more courses of yarn 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) and/or include courses that are substantially continuous between each of the structures or elements. With this arrangement, a one-piece element of unitary knit construction is provided.

Although the respective knitted component portions forming knitted component 130 may be joined to each other (e.g., edge 127 of body portion 124 and edge 128 of heel portion 126 being joined together) following the knitting process, each individual knitted component portion remains formed of unitary knit construction because it is formed as a one-piece knit element. Moreover, knitted component portions remain 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.

Although the configurations of knitted component 130 may vary in different embodiments, in an exemplary embodiment, knitted component 130 may be formed from multiple individual knitted component portions that are each formed of unitary knit construction. FIG. 6 illustrates one embodiment of knitted component 130 including two separate knitted component portions, body portion 124 and heel portion 126, that are joined along adjacent edges to form knitted component 130.

Examples of various configurations of knitted components, including configurations that include an inlaid strand or tensile element, that may be used for one or more of the component portions of knitted component 130 are disclosed in U.S. Pat. No. 6,931,762 to Dua; U.S. Pat. No. 7,347,011 to Dua, et al.; U.S. Patent Application Publication 2008/0110048 to Dua, et al.; and U.S. Patent Application Publication 2010/0154256 to Dua, the disclosures of each of which are entirely incorporated herein by reference.

As shown in FIG. 6, knitted component 130 includes body portion 124 forming a portion of exterior surface 121 and opposite interior surface 122 of upper 120. Knitted component 130 further includes heel portion 126 that similarly forms a portion of exterior surface 121 and opposite interior surface 122 of upper 120. Together, body portion 124 and heel portion 126 may be joined together to form a substantial majority of exterior surface 121 and opposite interior surface 122 of upper 120.

Knitted Component Configuration

Although a knitting process that forms knitted component 130 and/or the knitted component portions may be performed by hand, the commercial manufacture of multiple knitted components 130 and/or the knitted component portions, including body portion 124 and heel portion 126, will generally be performed by knitting machines. In general, knitting involves forming courses and wales of intermeshed loops of a yarn or multiple yarns. In production, knitting machines may be programmed to mechanically-manipulate one or more yarns into the configuration of a knitted component or a knitted component portion, for example, body portion 124 and heel portion 126. That is, respective portions of knitted component 130 may be formed by mechanically-manipulating one or more yarns to form a one-piece textile element that has the shape and features of body portion 124 and heel portion 126. As such, knitted component portions may be formed of unitary knit construction utilizing a knitting machine.

Although the respective portions of knitted component 130 may be formed through a variety of different knitting processes and using a variety of different knitting machines, including but not limited to warp knitting or weft knitting, including flat knitting (i.e., the use of a flat knitting machine) or circular knitting, with the capability of forming knitted component 130 and/or knitted component portions, including body portion 124 and heel portion 126, to have the various features discussed above. In general, weft knitting involves forming a plurality of courses and wales. As an example, courses are rows of intermeshed loops of knit material that extend approximately laterally across each of body portion 124 and heel portion 126. That is, courses may extend along the width of body portion 124 and along the width of heel portion 126. As shown in FIG. 6, however, courses within heel portion 126 are approximately perpendicular to courses in body portion 124 when aligned with body portion 124. Wales are columns of loops that extend perpendicular to the courses and extend generally along a length of each of body portion 124 and heel portion 126.

In the exemplary embodiment, a flat knitting process may be used to form knitted component 130 and/or the knitted component portions, including body portion 124 and heel portion 126. In other embodiments, circular knitting (i.e., the use of a circular knitting machine) may be used to form knitted component 130 and/or the knitted component portions, including body portion 124 and heel portion 126. Although general or conventional knitting processes may be used to form knitted component 130 and/or the knitted component portions, including body portion 124 and heel portion 126, specific examples of knitting processes that may be used include, but are not limited to: warp knitting or weft knitting, including flat knitting or circular knitting, wide tube circular knitting, narrow tube circular knitting, narrow tube circular knit jacquard, single knit circular knit jacquard, double knit circular knit jacquard, and warp knit jacquard, for example.

Knitted component 130 may be formed from a single type of yarn that imparts common properties to each of the individual component portions, including body portion 124 and/or heel portion 126. In order to vary the properties of knitted component 130, however, different yarns may be utilized in different component portions of knitted component 130. That is, body portion 124 and/or heel portion 126, as well as different areas of body portion 124 and/or heel portion 126, may be formed from different yarns to vary the properties between portions or areas of knitted component 130. Further, monofilament areas may be formed from a monofilament strand imparting different properties within monofilament areas as compared to other areas of knitted component 130. In some embodiments, monofilament areas may be formed using a single monofilament strand. In other embodiments, monofilament areas may be formed using a monofilament strand and fusible thermoplastic yarn. In some embodiments, the fusible thermoplastic yarn and monofilament strand may be in a plated orientation. In some embodiments, the thermoplastic yarn may stabilize or strengthen monofilament areas or portions of monofilament areas. Moreover, one portion of knitted component 130 may be formed from a first type of yarn or combination of yarns that imparts a first set of properties, and another portion of knitted component 130 may be formed from a second type of yarn or combination of yarns that imparts a second set of properties. Properties may vary throughout the individual component portions of knitted component 130, therefore, by selecting specific yarns for different portions of knitted component 130. Examples of properties that may be varied through choice of yarn include color, pattern, luster, stretch, recovery, loft, hand, moisture absorption, biodegradability, abrasion-resistance, durability, and thermal conductivity. It should also be noted that two or more yarns may be utilized in combination to take advantage of properties from both yarns, such as when yarns are plated or form different courses in the same area.

The properties that a particular type of yarn will impart to a component portion of knitted component 130 or an area of body portion 124 and/or heel portion 126 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 durable, abrasion-resistant, and has relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. Yarns that incorporate thermoplastic materials may also permit portions or areas of knitted component 130 to be fused or stabilized through the application of heat.

In addition to materials, other aspects of the yarns selected for portions or areas of knitted component 130 may affect properties. For example, a yarn forming knitted component 130, including body portion 124 and/or heel portion 126, may be a monofilament strand 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 bi-component 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 knitted component 130 and the individual portions thereof. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate portions of knitted component 130 or areas of body portion 124 and/or heel portion 126.

In some embodiments, multifilament yarn may be used to form a portion of knitted component 130. In some embodiments, multifilament yarn may have differing properties than the properties of monofilament strands. In some embodiments, multifilament yarn may have a higher resistance to abrasion than monofilament strands. Multifilament yarn may be formed from many different materials as discussed previously in the detailed description.

In some embodiments, portions of knitted component 130 may be formed from monofilament strands. In addition, other portions of knitted component 130 may be formed from multifilament yarn. Additionally, although certain areas of knitted component 130 may be formed from different strands or yarns, knitted component 130 may still be of unitary knit construction. For example, monofilament areas or portions may be knit adjacent to multifilament portions and thereby form a unitary knit structure. As previously discussed, a monofilament area refers to a monofilament portion of knitted component 130. In some embodiments, a monofilament area may be comprised solely of a monofilament structure. That is, in some embodiments, monofilament areas may not include other multifilament yarn. In some embodiments, monofilament areas may be adjacent to or bounded by multifilament structures.

In some embodiments, monofilament areas may be adjacent to tubes or channels or welts. Generally, welts can be areas of knitted component 130 constructed with two or more co-extensive and overlapping knit layers. Knit layers may be portions of knitted component 130 that are formed from knitted material, for example, threads, yarns, or strands. Two or more knit layers may be formed of unitary knit construction in such a manner so as to form tubes or tunnels, identified as welts 170, in knitted component 130. Although the sides or edges of the knit layers forming welts 170 may be secured to the other layer, a central area is generally unsecured to form a hollow between the two layers of knitted material forming each knit layer. In some embodiments, the central area of welts 170 may be configured such that another element (e.g., a tensile element) may be located between and extend or pass through the hollow between the two knit layers forming welts 170. In an exemplary embodiment, each of the layers forming welts 170 may be associated with one of exterior surface 121 and interior surface 122 of knitted component 170. For example, in one embodiment, welts 170 may include an interior portion associated with interior surface 122 and an exterior portion associate with exterior surface 121.

In some embodiments, tubes or welts may be formed from multifilament yarn. In some embodiments, welts may include inlaid strands or tensile elements which extend through the welts. Mesh knit structures, mock mesh knit structures, and other suitable knit structures with accompanying looping diagrams for knitting such knit structures for use in the present embodiments are described in U.S. Patent Application Publication 2012/0233882 to Huffa et al., which is incorporated herein.

In some embodiments, welts 170 may be located throughout upper 120. In other embodiments, welts 170 may be located adjacent to monofilament areas. In some embodiments, welts 170 may comprise an interior portion 172 and an exterior portion 173. Interior portion 172 may be located adjacent the foot of a user. Exterior portion 173 may be connected to interior portion 172 along the edges of interior portion 172 so as to form an opening between exterior portion 173 and interior portion 172. In some embodiments, exterior portion 173 may extend away from the foot of a user.

In some embodiments, monofilament areas may be located toward interior surface 122 of knitted component 130. That is, monofilament areas may be located toward the foot of a user. In some embodiments, monofilament areas may be aligned with interior portion 172 of welts 170. That is, in some embodiments, monofilament areas may extend along a plane that is similarly aligned with the plane along which interior portion 172 is formed. As such, monofilament areas may be set back from exterior portion 173 of welts 170. In some embodiments, such a configuration may be utilized in order to increase the likelihood that exterior portion 173 may be contacted before monofilament areas. In this manner, monofilament areas may be protected from abrasion.

In some embodiments, the width of monofilament areas may reduce the likelihood of monofilament areas being subjected to abrasion. In some embodiments, monofilament areas may be relatively narrow, for example, approximately four courses wide. In other embodiments, monofilament areas may be wider. Additionally, in some embodiments, welts 170 may be approximately the same width as monofilament areas. In other embodiments, welts 170 may be wider or narrower. In embodiments in which welts 170 and monofilament areas are approximately the same width, approximately 50% of the area encompassed by welts 170 and monofilament areas may comprise a purely monofilament structure. That is, in some embodiments, approximately half of the surface area of knitted component 130 may be comprised of monofilament areas. In some embodiments, this may allow for a see-through nature, or opaque view of a large area of knitted component 130. Although a large area of knitted component 130 may include monofilament areas, because monofilament areas are relatively narrow and set back toward the foot of a user from exterior portion 173 of welts 170, monofilament areas may be protected from abrasion.

In some embodiments, the spacing of monofilament areas and welts 170 may be varied. For example, in some embodiments, some monofilament areas may be approximately four courses wide, while other monofilament areas may be eight courses wide. Additionally, in some embodiments, other monofilament areas may be of varying widths. Furthermore, in some embodiments, welts 170 may be of varying widths. For example, in some embodiments, some welts may be four courses wide, while other welts may be eight courses in width. Additionally, the width of individual welts may be varied throughout knitted component 130. The combination of different widths of welts 170 and different widths of monofilament areas may provide for varied spacing of monofilament areas. Due to welts 170 being located between monofilament areas, welts 170 may impact the spacing of monofilament areas.

In some embodiments, the height of welts may additionally provide protection to monofilament areas. The height 1412 (Shown in FIG. 14) of welt 1400 may be defined as the distance between exterior portion 173 and exterior surface 121 of monofilament areas. In some embodiments, welts 170 may have additional courses in exterior portion 173 and fewer courses in interior portion 172. Because exterior portion 173 and interior portion 172 are attached to each other at an edge, exterior portion 173 may have a bulge or bump. In some embodiments, the bulge or bump may then extend away from interior portion 172 and monofilament area 1408 and monofilament area 1410. In some embodiments, the larger bump or bulge may further protect monofilament areas from abrasion. A larger bump or bulge may be formed by including more courses in exterior portion 173 and fewer courses in interior portion 172. In combination with narrow monofilament areas, a larger height of welts may limit the likelihood of an impact between an object and monofilament areas, because an impact may be absorbed by the welts.

In some embodiments, welts 170 may include an inlaid strand or tensile element. In some embodiments, the tensile element may be used as a loop 158 in the configuration of an article of footwear. Loop 158 may be configured to receive lace 154. Additionally, in conjunction with lace 154, loop 158 may assist in adjusting the fit and feel of article 100. In some embodiments, tensile elements may provide support to welts 170, which in turn may support monofilament areas. Additionally, in some embodiments, tensile elements may allow for greater support when used as a loop 158, because the tensile elements may allow for the tension from a lace 154 to extend over a portion of upper 120.

In some embodiments, monofilament areas may be formed from a translucent material. In some embodiments, monofilament areas may be substantially clear such that light may pass through monofilament areas. In addition, in some embodiments, monofilament areas may allow for the interior void of article 100 to be viewed through knitted component 130. Additionally, in some embodiments, monofilament areas may include coloring. In some embodiments, monofilament areas may be tinted to a certain hue. For example, in some embodiments, monofilament areas may be tinted a black or grey color. In other embodiments, monofilament areas may be tinted another color. In still further embodiments, monofilament areas may be a solid opaque color. That is, in some embodiments, monofilament areas may not permit light to pass from exterior surface 121 to interior surface 122 of a monofilament area. Therefore, the transparency of monofilament areas may be impacted by the transparency or lack thereof of a monofilament strand forming the respective monofilament area.

In some embodiments, the transparency of monofilament areas may be impacted by the diameter of monofilament strands. In some embodiments, a single monofilament strand may have a diameter of approximately 0.125 mm that may be used to form monofilament areas. In other embodiments, a single monofilament strand may have a diameter of approximately 0.08 mm. In other embodiments, larger diameter monofilament strands may be used to form monofilament areas. A larger diameter monofilament strand may inhibit the passing of light through the monofilament strand. Additionally, various stitch densities may be utilized in the formation of a monofilament area. In some embodiments, a high density configuration may inhibit light from passing through exterior surface 121 to the interior void formed by knitted component 130.

In some embodiments, monofilament areas within monofilament groups may be oriented in a particular direction. For example, in some embodiments, monofilament areas may be oriented in a largely vertical manner. That is, in some embodiments, monofilament areas may extend from sole structure 110 toward instep area 150. In some embodiments, monofilament areas may extend in a diagonal manner. That is, in some embodiments, monofilament areas may be oriented such that monofilament areas do not extend in a directly vertical manner. Further, in some embodiments, monofilament areas may extend along the longitudinal direction. For example, the monofilament areas of heel monofilament group 166 are shown in FIGS. 7 and 12 to extend in a substantially longitudinal direction. Additionally, in some embodiments, monofilament areas may be parallel to one another. In other embodiments, monofilament areas may be oriented independently from one another.

In some embodiments, monofilament areas may be of a substantially elongated shape. Referring to FIGS. 3 and 10, monofilament areas of medial monofilament group 160 may have a substantially rectangular or oval shape. For example, monofilament area 181, may be elongated and generally in a rectangular shape. As shown, the shape of monofilament area 181 may be defined by welt 184 on an end located closer to heel region 14, and by welt 185 on an end located close to forefoot region 20. Additionally, the shape of monofilament area 181 may further be defined by instep border portion 186. Instep border portion 186 may be an area of upper 120 that surrounds instep area 150. In some embodiments, instep border portion 186 may include lace apertures 156. The shape of monofilament area 181 may additionally be defined by sole border portion 187. In some embodiments, sole border portion 187 may be located adjacent to sole structure 110. Additionally, in some embodiments, a portion of sole border portion 187 may be covered by sole structure 110 for aesthetic or other purposes. In some embodiments, sole border portion 187 may extend under a foot of a user and attach to a central portion of sole structure 110. The shape of monofilament area 181 is therefore defined by welt 184, welt 185, instep border portion 186 and sole border portion 110. Therefore, as the shape and orientation of welt 184, welt 185, instep border portion 186 and sole border portion 187 change, so too may the shape of monofilament area 181. It should be recognized that monofilament area 181 may occupy the space enveloped by welt 184, welt 185, instep border portion 186, and sole border portion 187.

In some embodiments, welts that surround monofilament areas may include a tensile element at least partially extending through the welts. For example, as shown in FIG. 10, welt 184 and welt 185 include a tensile element which extends through the welts. Additionally, other monofilament areas may be surrounded by welts that do not include tensile elements extending through the welts, as for example welt 188. Additionally, in some embodiments, the tensile element may exit and enter a particular welt multiple times. That is, the tensile element may be exposed along various portions of a welt.

In some embodiments, multifilament areas between and surrounding monofilament areas may be constructed similarly to welts as discussed above. That is, in some embodiments the multifilament areas may include an interior portion and an exterior portion. In some embodiments the exterior portion may extend beyond monofilament areas in a vertical direction. In other embodiments, multifilament areas may be constructed along the same plane as monofilament areas.

Additionally, in some embodiments, monofilament areas may be an oval or triangular shape, for example monofilament area 182. As shown, monofilament area 182 is bounded by welt 185, as well as welt 188. In some embodiments, monofilament area 182 may be located at an edge of medial monofilament group 160. That is, in some embodiments, monofilament area 182 may not interrupt or augment the shape of other monofilament areas in a group. In other embodiments, the boundaries of monofilament area 182 may share some boundaries of elongated monofilament area 189.

As shown in FIGS. 3 and 10, monofilament area 182 is located near sole border portion 187. Additionally, monofilament area 182 is located adjacent to monofilament area 189. As such, the border of monofilament area 182 may share a boundary 190 with monofilament area 189. In such a case, the length of monofilament area 189 is influenced by the boundary of monofilament area 182, as opposed to sole border portion 187. Monofilament areas therefore may be differently shaped. Additionally, monofilament areas may be placed in different location within knitted component 130.

In some embodiments, boundary 190 may be constructed in a similar manner as welts 170. That is, in some embodiments, boundary 190 may include an exterior portion and an interior portion. As such, in some embodiments, boundary 190 may protrude or extend beyond the plane of monofilament area 189 and monofilament area 182. In other embodiments, boundary 190 may be constructed in a different manner than welts 170. For example, in some embodiments, boundary 190 may be formed along the same approximate plane along which monofilament area 189 and monofilament area 182 are constructed.

In some embodiments, monofilament areas may be located in forefoot region 10 of article 100. In some embodiments, monofilament areas may be surrounded by multifilament portions. That is, in some embodiments, the shape of monofilament areas may be defined by a border of multifilament yarn. As shown in FIG. 11, forefoot monofilament group 162 of forefoot region 10 includes multiple monofilament areas 1100. In an exemplary embodiment, each of the monofilament areas of monofilament areas 1100 may have an approximately triangular shape, including a wider base that narrows to a tip at one end. Referring to monofilament area 1102, the shape of monofilament area 1102 may be triangular in appearance. Additionally, monofilament areas 1100 may be oriented in a similar manner. For example, base 1104 of monofilament area 1102 may be oriented along the lateral direction. Additionally, base 1104 may be located toward heel region 14. In some embodiments, tip 1106 of monofilament are 1102 may be oriented opposing base 1104. As such, monofilament area 1102 be approximately triangular and may resemble the shape of a shark tooth. Other monofilaments areas within monofilament areas 1100 may be similarly shaped. In other embodiments, however, other geometric or non-geometric shapes of monofilament areas 1100 may be utilized.

In some embodiments, monofilament areas 1100 may be arranged such that strength and stability are imparted into the forefoot region 10. In comparison to medial monofilament group 160 of midfoot region 12, forefoot monofilament group 162 of forefoot region 10 includes smaller areas of monofilament strands.

In some embodiments, multifilament yarn may assist in supporting article 100 in order to maintain its shape while also providing abrasion resistance. In some embodiments, forefoot region 10 may include a greater percentage of multifilament yarn because in some instances forefoot region 10 may experience a greater likelihood of abrasion and increased force upon knitted component 130. For example, a user may move laterally or cut which may cause the foot to press against forefoot region 10 of article. Additionally, a user may encounter greater obstacles or objects in forefoot region 10 as compared to other regions of article 100.

In some embodiments, the design or shape of monofilament areas may assist in force distribution. For example, referring to FIG. 11, the triangular or shark-tooth design of monofilament areas 1100 may allow for force to be distributed through forefoot region 10 at many different angles. The offset nature of monofilament areas 1100 allows for multifilament yarn to be oriented between monofilament areas 1100. The orientation of multifilament yarn allows for force to be transferred through multifilament yarn along multiple different angles. The specific design of the multifilament yarn area allows any force to be split or distributed through different channels of multifilament yarn. For example, a lateral force may be distributed through the multifilament yarn in an indirect manner. That is, a purely lateral force may be distributed into lateral and longitudinal components, thereby reducing stress along any one direction in forefoot region 10.

In other embodiments, the shark-tooth shaped monofilament areas 1100 may be combined with differently shaped monofilament areas. For example, in some embodiments, the shark-tooth-shaped monofilament areas 1100 may be used in conjunction with oval-shaped monofilament areas or rectangular or elongated monofilament areas as discussed above. The shark-tooth design may provide strength to the forefoot region 10 while also allowing for monofilament areas 1100 to be present and add to the design of article 100.

In some embodiments, multifilament areas between and surrounding monofilament areas 1100 may be constructed similarly to welts 170 as discussed above. That is, in some embodiments the multifilament areas may include an interior portion and an exterior portion. In some embodiments the exterior portion may extend beyond monofilament areas 1100 in a vertical direction. In other embodiments, multifilament areas may be constructed within the same plane as monofilament areas 1100.

Referring to FIGS. 12 and 13, heel portion 126 is shown. Heel monofilament group 166 includes elongated monofilament areas 1300 that are located between lateral side 16 and medial side 18 of heel portion 126. As shown, elongated monofilament areas 1300 extend toward spine 1302. In some embodiments, spine 1302 may be located in a central location between lateral side 16 and medial side 18. In some embodiments, spine 1302 may act as a barrier, or separation area between lateral side 16 and medial side 18 of heel portion 126. In some embodiments, oval-shaped monofilament areas 1304 may be located along the length of spine 1302. As such, oval-shaped monofilament areas 1304 may be located adjacent to elongated monofilament areas 1300. In other embodiments, oval-shaped monofilament areas 1304 may be located at different locations within heel portion 126. For example, in some embodiments, oval shaped monofilament areas 1304 may be located adjacent to collar 1306.

In some embodiments, the shape and layout of oval-shaped monofilament areas 1304 and elongated monofilament areas 1300 may assist in stretch prevention or restriction. For example, heel portion 126 is shown being subjected to a tensile force in FIG. 13. As heel portion 126 is stretched, spine 1302 may absorb a substantial portion of the force. That is, force may be directed to pass along spine 1302, thus minimizing the amount of force experienced by monofilament areas. As shown, force may be oriented along spine 1302 as well as along multifilament areas 1308 that encircle oval shaped monofilament areas 1304. By creating multifilament areas or paths for a force to travel along, stress and other force experienced by monofilament areas may thereby be diminished. Additionally, this design may allow for a large area of heel portion 126 to be a monofilament structure while providing a durable, stylish, and stretch-resistant heel portion 126.

In some embodiments, monofilament areas 1300 may be oriented in a horizontal or lateral direction. In other embodiments, monofilament areas 1300 may be oriented in a vertical direction. In still further embodiments, monofilament areas 1300 may be oriented in other directions.

In some embodiments, multifilament areas 1308 may be constructed similarly to welts 170 as discussed above. That is, in some embodiments, multifilament areas 1308 may include an interior portion and an exterior portion that forms a welt. In other embodiments, multifilament areas 1308 may be of similar construction to monofilament areas 1300 and monofilament areas 1304. That is, in some embodiments, multifilament areas 1308 may be located in the same plane as the monofilament areas 1300.

In some embodiments, multifilament areas 1308 may include a tensile element which extends through welts (Shown in FIG. 14). In other embodiments, the welts may be hollow or unfilled (Shown in FIG. 17).

Referring to FIG. 14, a cross-section of welt 1400 is shown. As discussed above welts 170 are generally hollow structures formed by two overlapping and at least partially coextensive layers of knitted material. Although the sides or edges of one layer of the knitted material forming welts 170 may be secured to the other layer, a central area is generally unsecured such that another element may be located between the two layers of knitted material and extend through welts 170. Another example of knitted components for footwear uppers that have overlapping or at least partially coextensive layers may be found in U.S. Patent Application Publication 2008/0110048 to Dua et al., which is incorporated herein by reference.

In some embodiments welts 170 extend upward along lateral side 16 and medial side 18. In some embodiments, each welt includes a tensile element 1402 that extends through welt 1400, extends outward from an upper end of welt 1400 and forms a loop 158 on the exterior of upper 120 and extends into an upper end of a second welt 1404. Tensile element 1402 may extend through second welt 1404 and exit second welt 1404 through a lower end. In some embodiments, tensile element 1402 may exit and enter the same welt multiple times. In some embodiments, tensile element 1402 may extend to other welts and extend through the other welts. In other embodiments, separate strands may extends through additional welts. In still further embodiments, welts 170 may not all include strands which extend through welts 170. That is, in some embodiments, some welts may be tubular, however, strands may not be present within the hollow structure (Shown in FIG. 17).

In some embodiments, welts 170 may be constructed of natural or synthetic twisted fiber multifilament yarn 1406. In some embodiments, the yarn of welts 170 may be void of monofilament strand 1408 that is used to form monofilament area 1410 and other monofilament areas. In some embodiments, tensile element 1402 may extend through welt 1400 without contacting monofilament strand 1408 that is used to construct monofilament area 1410. That is, in some embodiments, tensile element 1402 may be set apart from monofilament strand 1408. As shown in FIG. 14, tensile element 1402 contacts interior portion 172 and exterior portion 173 of welt 1400 which are constructed completely of multifilament yarn 1406 that are represented by a solid sinusoidal line. Additionally, monofilament strand 1408, represented by a dashed sinusoidal line, is not present in interior portion 172 or exterior portion 173 of welt 1400. As such, tensile element 1402 may not come into contact with monofilament strand 1408 within welt 1400. Therefore, as tensile element 1402 is tightened or moved, tensile element 1402 may contact multifilament yarn 1406, thereby reducing the amount of wear that monofilament strands may experience.

Referring to FIG. 15, an exemplary looping diagram 1500 depicting a portion of knitted component 130 is shown. In this embodiment, looping diagram 1500 illustrates the sequence of stitches and movements performed by a knitting machine, for example, a flat-knitting machine, to form a portion of monofilament area 1410 and welt 1400. As shown in FIG. 15, the spaced apart dots represent the needles of a knitting machine and the illustrated steps represent the direction of movement of yarn or strands between the needles of each of a front bed and a back bed of a knitting machine. Needles located on the front bed may be referred to as “front needles” while needles located in the back bed may be referred to as “back needles.” Additionally, “pass” may be used to refer to the operation of a feeder of a knitting machine moving across needle beds so that a strand or yarn interacts with and/or is manipulated by the needles of a needle bed. “Course” may refer to yarn or strand after the yarn or strand has interlooped with another yarn or strand. In many embodiments, a pass across a needle bed may be associated with a course of interlooped strands or yarns. In some embodiments, however, multiple passes may be used to form one course of a knit material. A method of manufacturing utilizing a knitting machine with a combination feeder is disclosed in previously referenced U.S. Patent Application Publication 2012/0233882 to Huffa, et al., the disclosure of which is entirely incorporated herein by reference.

As shown in FIG. 15, monofilament strand 1408 may be used to knit a portion of a monofilament area 1410. The looping diagram is not meant to be a specific layout or orientation of strands, but as an exemplary diagram. As shown, a first pass may form monofilament course 1502 knit using monofilament strand 1408 on back needles of a knitting machine. As shown, monofilament course 1502 does not interact with every needle on the back needle bed. Rather, monofilament course 1502 interacts with every other needle on the back needle bed. In some embodiments, such a configuration may increase the strength of monofilament areas as opposed to monofilament areas that utilize a plain jersey stitch that interacts with each needle. Additionally, a second pass of the feeder forms monofilament course 1504 which is also knit using monofilament strand 1408 on back needles. Monofilament course 1504 may also utilizes a knit stitch that interacts with every other needle on the back needle beds. In an exemplary embodiment, each of monofilament course 1502 and monofilament course 1504 may interact with alternating every other needles. As such, in some embodiments, monofilament course 1502 and monofilament course 1504 may not interloop with one another. Rather, in some embodiments, monofilament course 1502 may interact with other courses that were previously formed. In some embodiments, monofilament strand 1408 may be used for knitting on back needles of a knitting machine. In some embodiments, by knitting on the back needles, the knit structure formed may extend toward interior surface 122. Additionally, portions of the knitted component that are knit on the back needles may generally extend away from portions of the knitted component that a knit on the front needles.

A third pass of a feeder may be used to form both multifilament course 1506 on the back needle bed as well as multifilament course 1508 on the front needle bed. Therefore, two courses may be formed from one pass of a feeder. Multifilament course 1506 is knit using multifilament yarn 1406 on back needles and multifilament course 1508 is knit using multifilament yarn 1406 on front needles. In some embodiments, multifilament portion 1508 may be considered the beginning of exterior portion 173 of welt 1400. As shown, multifilament course 1506 and multifilament course 1508 are formed using the same multifilament yarn 1406, but are not interlooped with one another; rather each is formed on a different set of needle beds. Because multifilament course 1506 is formed on the back needle bed, multifilament course 1506 may interact and interloop with monofilament course 1504. In some embodiments, multifilament course 1506 may be considered the beginning of interior portion 172 of welt 1400. A fifth pass of a feeder may form multifilament course 1512 on the back needle bed which interloops with multifilament course 1506.

In some embodiments, multiple multifilament courses may be formed on the front needle bed after the formation of multifilament course 1510. Additional courses on the front needle bed may be formed in order to adjust the shape and size of exterior portion 173 of welt 1400. For example, an embodiment which includes four additional courses on the front needle bed after multifilament pass 1510 may produce a larger exterior portion than exterior portion 173 in FIG. 14.

In some embodiments, tensile element 1402 may be placed within the partially completed welt 1400. Tensile element 1402 may be inlaid between the back bed and the front bed. In some embodiments, tensile element 1402 may be inlaid with a separate feeder. In some embodiments, tensile element 1402 may contact multifilament course 1508 as well as multifilament course 1510. In some embodiments, an additional course, multifilament course 1512 may be formed on the back bed. In some embodiments additional passes of the feeder may be made on the back bed with multifilament yarn 1406 to form courses that interact and interloop with multifilament course 1512. By increasing the number of courses formed on the back bed after multifilament course 1512, the size of interior portion 172 may increase.

In some embodiments, the course remaining on the front bed (in this case multifilament course 1510) may be transferred to the back bed after the preferred number of courses are formed on the back bed and the front bed. After such an action, the final course on the front bed may interact and interloop with the course formed on the back bed. This action may complete the formation of a welt such as welt 1400. Welt 1400 may therefore surround or enclose a substantial portion of strand 1400.

Referring to FIG. 16, a looping diagram of a portion of heel portion 126 is shown. In some embodiments, monofilament strands may be limited in seam border portion 1600. That is, in some embodiments, monofilament strands from monofilament area 1602 may not extend into seam border portion 1600 or may have a limited presence. Seam border portion 1600 may be an area of heel portion 126 that, when assembled, is located adjacent to body portion 124. In some embodiments, seam border portion 1600 may be adjacent to edge 128 of heel portion 126. Additionally, in some embodiments, seam border portion 1600 may be adjacent to edge 127 when heel portion 126 is assembled to body portion 124.

Referring to enlarged area 1604, monofilament area 1602 is shown along with seam border portion 1600. As illustrated, a portion of monofilament area 1602 is substantially located to the left of seam border line 1606. Seam border line 1606 is not meant to be a precise demarcation of an area, rather seam border line 1606 is used to show a general boundary between monofilament area 1602 and seam border portion 1600. Although as shown in enlarged area 1604, monofilament area 1602 does not extend into seam border portion 1600, in some embodiments, monofilament strands may extend into seam border portion 1600. That is, although not visible in the Figure depicted, in some embodiments, some loops of monofilament strands may be present in a portion of seam border portion 1600 as discussed in detail below.

Additionally, in some embodiments, edge 127 of body portion 124 may also include limited monofilament strands, or may be devoid of monofilament strands. As such, the seam area between heel portion 126 and body portion 124 may largely be devoid of monofilament strands. Therefore, as heel portion 126 and body portion 124 are sewn or joined together, monofilament strands may be absent from the sewing or joining portion. As such, stress or force imparted onto monofilament strands may be reduced.

Referring to the looping diagram 1608 of FIG. 16, monofilament courses formed from monofilament strand 1408 may be skip every other needle within a needle bed, in a similar manner as discussed in reference to looping diagram 1500 of FIG. 15. A first pass may be used to form monofilament course 1610 which may extend beyond seam border line 1606 of monofilament area 1602. As discussed with reference to looping diagram 1608, each course may be created from a single pass. As shown, monofilament course 1610 may include two loops formed beyond seam border line 1606. In other embodiments, monofilament course 1610 may extend a greater number of loops into seam border portion 1600, or a fewer number of loops into seam border portion 1600. In some embodiments, monofilament course 1610 may extend to edge 128 of heel portion 126, however, in an exemplary embodiment, there may be no monofilament strands that extend to edge 128 of heel portion 126. As shown, monofilament course 1612 may extend a single loop beyond seam border line 1606. Monofilament course 1614 may extend beyond seam border line 1606. In some embodiments, monofilament course 1614 may form a tuck stitch between monofilament course 1614 and monofilament course 1616.

As shown, monofilament course 1610 may interact and interloop with monofilament course 1612, monofilament course 1612 may interact and interloop with monofilament course 1614 and monofilament course 1614 may interact and interloop with monofilament course 1614. That is, the monofilament courses may interact with one another to form monofilament area 1602. As shown, a tuck stitch is used to transition from monofilament course 1614 to monofilament course 1616 during the next pass of the feeder.

Due to the lack of courses throughout edge 128 of heel portion 126, additional courses may be introduced to form the edge or finish heel portion 126. As shown, multifilament course 1618 and multifilament course 1620 formed on front needle beds by multifilament yarn 1406 may be introduced and interact with the monofilament courses. In this sense, multifilament courses may form a cohesive and continuous edge of heel portion 126. In some embodiments, the placement of multifilament yarn with monofilament courses may allow for the edge of heel portion 126 to include multifilament yarn, while removing monofilament strands from the edge. As such, when combined, joined or sewn together with edge 128 of body portion 124, the connection yarn may not interact with a monofilament strand. In some embodiments, it may be advantageous to set apart the monofilament strands from the joining mechanism in order to avoid stress or other forces being exerted on the monofilament strands through the joining mechanism.

In other embodiments, monofilament strands may be limited in other areas of article 100 that may experience higher stress or force. For example, in some embodiments, instep border portion 186 may be constructed in a similar manner as heel edge 128. Because instep border portion 186 may include lace apertures 156 which may include lace 154, instep border portion 186 may experience increased stress or force in certain areas. In some embodiments, to avoid or limit the exposure of monofilament strands to increased stress, instep border portion 186 may include limited or no monofilament strands in a similar manner as discussed above.

Referring to FIG. 17, a cross section of a welt 1700 in heel portion 126 is shown. Welt 1700 is shown located between monofilament area 1706 and monofilament area 1708. In the embodiment shown, welt 1700 is largely composed of multifilament yarn whereas the monofilament areas are largely composed of monofilament strands.

In some embodiments, welt 1700 may enclose a tensile element. As shown, welt 1700 does not include a tensile element extending through welt 1700 in contrast to welt 1400 of FIG. 14. In some embodiments, other portions of heel portion 126 may include a tensile element. Although welt 1700 does not include a tensile element, welt 1700 may still form a bulge or bump along exterior surface 121 of heel portion 126. As discussed above, a bump or bulge in exterior surface 121 of multifilament yarn may be able to protect monofilament areas from contact or abrasion. For example, exterior portion 1702 of welt 1700 may extend away from interior portion 1704 of welt 1700. Exterior portion 1702 and interior portion 1704 may form a cavity or tubular structure.

In some embodiments, the geometry of interior portion 1704 and exterior portion 1702 may assist in retaining the shape of exterior portion 1702. In some embodiments, interior portion 1704 may be of a shorter or smaller overall length than exterior portion 1702. In some embodiments, the edges or ends of interior portion 1704 and exterior portion 1702 may be joined or held in a relatively fixed relationship to one another. Due to this geometry and configuration, exterior portion 1702 may extend outwards from interior portion 1704. Additionally, as exterior portion 1702 is pressed or force is placed upon exterior portion 1702, exterior portion 1702 may resist the force. Because exterior portion 1702 is fixed at the ends of exterior portion 1702, exterior portion 1702 may resist force and largely return to a shape when force is release.

Other areas of article 100 may also include welts which do not contain tensile elements. For example, some welts within midfoot region 12 of body portion 124 may not include tensile elements. Welts may be utilized throughout upper 120 to further protect monofilament areas from outside forces that may damage monofilament areas.

Referring to FIG. 18, a looping diagram 1800 is shown depicting an embodiment of welt 1700 that does not include a tensile element which extends through the welt. As shown, monofilament course 1802 and monofilament course 1804 are knit using monofilament strand 1408 on a back needle bed in a configuration utilizing every other needle of the back needle bed. In an exemplary embodiment, each of monofilament course 1802 and monofilament course 1804 may interact with alternating every other needles. Monofilament course 1802 may be formed from a single pass, and monofilament course 1804 may be formed during another pass. Monofilament course 1804 is also knit using monofilament strand. As such, in some embodiments, monofilament course 1802 and monofilament course 1804 may not interloop with one another. Rather, in some embodiments, monofilament course 1802 may interact with other passes that were previously formed.

Multiple multifilament courses may be formed during a single pass. For example, multifilament course 1806, as well as multifilament course 1808, are both formed during the same single pass of a feeder. Multifilament course 1806 is knit using multifilament yarn 1406 on back needles and multifilament course 1808 is knit using multifilament yarn 1406 on front needles. In some embodiments, multifilament course 1806 may be considered the beginning of interior portion 1704 of welt 1700. As shown, multifilament course 1806 and multifilament course 1808 are formed using the same multifilament yarn 1406, but are not interlooped with one another; rather each is formed on a different set of needle beds. Because multifilament course 1806 is formed on the back needle bed, multifilament course 1806 may interact and interloop with monofilament course 1804. Multifilament course 1806 may therefore clear the monofilament strand away such that monofilament course 1804 interloops with a multifilament course.

In some embodiments, multifilament course 1808 may be considered the beginning of exterior portion 1702 of welt 1700. Multifilament course 1810 is knit using multifilament yarn 1406 on the front needle bed and interloops with multifilament course 1808. In some embodiments, multiple multifilament courses may be formed on the front needle bed after the formation of multifilament pass 1810. Additional courses on the front needle bed may be formed in order to adjust the shape and size of exterior portion 1702 of welt 1700. For example, an embodiment which includes four additional courses on the front needle bed after multifilament course 1810 may produce a larger exterior portion than exterior portion 1702 in FIG. 17.

In some embodiments, an additional course, multifilament course 1812 may be knit using multifilament yarn 1406 on the back bed. In some embodiments, additional courses may be formed on the back bed that interact and interloop with multifilament course 1812. By increasing the number of courses formed on the back bed after multifilament course 1812, the size of interior portion 1704 may increase.

In some embodiments, the course remaining on the back bed may be transferred the front bed after the preferred number of courses are formed on the back bed and the front bed. After such an action, the final course on the back bed may interact and interloop with the course on the front bed. This action may complete the formation of a welt such as welt 1700. Welt 1700 may therefore be largely constructed of multifilament yarn while thereby diminishing the likelihood that monofilament strands may experience abrasion or other forces.

While various embodiments 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 embodiments and implementations are possible that are within the scope of the embodiments. Accordingly, the embodiments 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.

Claims

1-15. (canceled)

16. A method of manufacturing an article of footwear comprising: knitting a knitted component including at least one monofilament area comprised of a monofilament strand, the at least one monofilament area having a shape;knitting a first multifilament area adjacent to the at least one monofilament area, the first multifilament area comprising at least two overlapping knit layers of multifilament yarn, wherein the at least two overlapping knit layers form a first unsecured area there between;knitting a second multifilament area adjacent to the at least one monofilament area;wherein the first multifilament area and the second multifilament area define at least a portion of the shape of the at least one monofilament area.

17. The method according to claim 16, wherein the at least one monofilament area comprises a width and wherein the width of the at least one monofilament area is at least two courses.

18. The method according to claim 16, wherein knitting the first unsecured area comprises knitting an interior layer and an exterior layer, and connecting at least a portion of the interior layer with at least a portion of the exterior layer to form a central unsecured area.

19. The method according to claim 18, wherein knitting the exterior layer includes knitting a first number of courses and knitting the interior layer includes knitting a second number of courses, the first number of courses being greater than the second number of courses.

20. The method according to claim 16, further comprising extending at least a portion of a tensile element through at least a portion of the first unsecured area.

21. The method according to claim 16 wherein knitting the second multifilament area comprises knitting at least two overlapping layers of multifilament yarn, wherein the at least two overlapping knit layers form a second unsecured area there between.

22. The method according to claim 21 further comprising extending at least a portion of a second tensile element through at least a portion of the second unsecured area.

23. The method according to claim 18 wherein the method further comprises knitting the at least one monofilament area in a first plane of the article of footwear and knitting the exterior layer of the first multifilament area in a second plane of the article of footwear, the second plane being located radially outwardly of the first plane.

24. The method according to claim 23 wherein at least a portion of the at least one monofilament area underlies at least a portion of the exterior layer of the first multifilament area.

25. A method of manufacturing an article of footwear comprising: knitting a knitted component comprising a plurality of monofilament areas comprising a monofilament strand, the plurality of monofilament areas comprising a shape;knitting a plurality of multifilament areas comprising at least two overlapping knit layers of multifilament yarn, wherein the at least two overlapping knit layers comprise an interior layer and an exterior layer and wherein the plurality of multifilament areas define at least a portion of the shape of the plurality of monofilament areas;wherein the plurality of monofilament areas are located in a first plane of the article of footwear and wherein at least the exterior layer of the plurality of multifilament areas is located in a second plane of the article of footwear.

26. The method according to claim 25 wherein the second plane is located radially outwardly of the first plane.