Patent Application
20180177260
A variety of articles are formed from textiles. As examples, articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats) are often at least partially formed from textiles. These textiles are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines. One particular object that may be formed from a textile is an upper for an article of footwear.
Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. In some articles of athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. The outsole may be secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material.
The upper of the article of footwear generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel area of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.
One general aspect of the present disclosure includes an article having a first zone, the first including a first region of a knitted base layer and a knitted second layer, where the second layer is disposed primarily on one side of the base layer. The article may further include a second zone that may include a second region of the base layer, where the second region of the base layer and the first region of the base layer have a common yarn, and where the second region of the base layer and the second layer have a common yarn. The first zone may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone may have a second degree of elasticity such that it has a second elongation when subjected to the tensile load. The first elongation may be at least 5% greater than the second elongation.
Another general aspect of the present disclosure includes an article with a first zone, the first zone include a knitted base layer and a first region of a knitted second layer disposed primarily on one side of the base layer. The article may further include a second zone including the base layer and a second region of the second layer disposed primarily on one side of the base layer, where the first zone has a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and where the second zone has a second degree of elasticity such that it has a second elongation when subjected to the tensile load. The first elongation may be at least 5% greater than the second elongation.
Another general aspect of the present disclosure includes a method, where the method may include the knitting a pass of a base layer with a first yarn on a knitting machine, the knitting machine having a first needle bed and a second needle bed, where the base layer is at least partially formed on the second needle bed. The method may further include knitting at least one pass of a second layer with a second yarn at least partially on the first needle bed of the knitting machine, and transferring the second yarn from the first needle bed to the second needle bed.
Various aspects are described below with reference to the drawings in which like elements generally are identified by like numerals. The relationship and functioning of the various elements of the aspects may better be understood by reference to the following detailed description. However, aspects are not limited to those illustrated in the drawings or explicitly described below. It also should be understood that the drawings are not necessarily to scale, and in certain instances details may have been omitted that are not necessary for an understanding of aspects disclosed herein, such as conventional fabrication and assembly.
Certain aspects of the present disclosure relate to articles at least partially formed from textiles. One example of an article is an article of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear, or the like). The article may be an upper configured for use in an article of footwear. The upper may be used in connection with any type of footwear. Illustrative, non-limiting examples of articles of footwear include a basketball shoe, a biking shoe, a cross-training shoe, a global football (soccer) shoe, an American football shoe, a bowling shoe, a golf shoe, a hiking shoe, a ski or snowboarding boot, a tennis shoe, a running shoe, and a walking shoe. The upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal.
Referring to
In some embodiments, the sole 110 includes a midsole (not shown) and an outsole. The article of footwear 100 may additionally comprise a throat 126 and an ankle opening 128, which may be surrounded by a collar 130 and may lead to a void 132. The void 132 of the article of footwear 100 may be configured to accommodate a foot of a person. The throat 126 is generally disposed in the mid-foot area 102 of the upper 120. The mid-foot area 102 is generally an area of the upper 120 located between a heel area 101 and a toe area 103.
In some embodiments, a tongue may be disposed in the throat 126 of the shoe, but a tongue is an optional component. The tongue may be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included, the lateral and medial sides of the throat 126 may be joined together. Although not shown, in some embodiments, the article of footwear 100 may include an optional fastening element, such as a lace (which may be associated with the lace apertures 136). Any suitable type of fastening element may be used.
As depicted in
In some embodiments, the upper 120 may include a second layer 150. While not limited to including a net, the second layer 150 is depicted as a net layer. Herein, a “net layer” may include, but is not limited to, an open-meshed fabric or layer formed of yarns that are interlooped, twisted, knotted, or woven together at certain intervals, and may have a relatively low stitch density (i.e., the number of loops per measured area) with respect to typical knitted fabric and/or the base layer 140. In some exemplary embodiments, the second layer 150 is formed on a knitting machine. As depicted, the second layer 150 may have one or more regions (e.g., a first region 152, a second region 154, a third region 156, and a fourth region 158, shown in
The second layer 150 is depicted as being located on an outer surface of the upper 120, but it is contemplated that the second layer 150 could be at least partially located on another surface (e.g., the inner surface). Further, the second layer 150 may have substantially the same boundary dimensions as the base layer 140 such that substantially all of at least one surface of the base layer 140 is covered by the second layer 150. Alternatively, and as depicted by
The upper 120 is shown having four zones including the second layer 150, where each zone is associated with one of the four regions 152, 154, 156, and 158 of the second layer 150. The first region 152 of the second layer 150 may include a relatively large structure (e.g., relatively large cells 160 as described in more detail below). This structure may provide the upper 120 with a desirable level of support and elasticity, for example. The second region 154 of the second layer 150 may have a relatively dense structure (e.g., relatively small cells 160). This structure may be relatively rigid and/or inelastic (at least with respect to the first region 152), which may be advantageous in areas of the upper 120 where support, strength, durability, and/or other particular properties associated with a dense structure are desired. In some embodiments, the first region 152 may have a first elasticity, and the second region 154 may have a second elasticity, such that when the same tensile load is applied to both regions, a zone with the first region 152 elongates at least 5% more, at least 10% more, at least 20% more, at least 50% more, or even at least 100% more (or greater) than a zone with the second region 154. As shown, it may be advantageous for the second region 154 of the second layer 150 to extend from the biteline 116 to the throat 126 and/or to a throat area 127 adjacent to the throat 126, which may provide durability and structural integrity to an area that commonly experiences a high degree and frequency of stress during typical use of an article of footwear. Further, the second region 154 may interact with a fastening element, such as a lace, to ensure a snug and comfortable fit of the upper 120. For example, tightening the lace may tighten the second region 154 (and its associated zone) around the foot. Similarly, the third region 156, which is depicted as including an area of the second layer 150 with two structures (described in more detail below), may exhibit increased strength and durability and a decreased amount of elasticity with respect to other areas and/or may provide a desirable visual effect. The fourth region 158 may have another structure (or a structure substantially the same a structure from another region) to achieve characteristics desired in that zone of the upper 120. While four regions of the second layer 150 have been illustrated for purposes of this explanation, the second layer 150 may have more or less than four regions.
A fifth region 142 of the base layer 140 may include a portion of the base layer 140 that is isolated from and uncovered by the second layer 150. In this embodiment, the second layer 150 terminates at the edge of the fifth region 142, but it is contemplated that the structure of the second layer 150 could fade or otherwise slowly transition from the fourth region 158 into the fifth region 142 in a transition zone. The fifth region 142 may elongate at least 20% more, at least 50% more, at least 100% more, at least 200% more, or even at least 300% more (or greater) than at least one of the zones incorporating a region of the second layer 150. It may be advantageous to include the fifth region 142 and/or other uncovered, isolated regions of the base layer 140 where flexibility, elasticity, and certain other characteristics that may be primarily associated with the base layer 140 in isolation are desired.
The structure of the second layer 350 may form any suitable number of cells 360. The cells 360 are depicted in
The base layer 340 and the second layer 350 may have different functional and/or visual characteristics. For example, the base layer 340 may be more elastic than the second layer 350. The difference in elasticity may be achieved by using yarns formed of different materials and/or having different dimensions, by varying the way the yarns interact (for example, by selecting a particular knit structure that exhibits a particular degree of elasticity), or a combination thereof. In some embodiments, the base layer 340 and the second layer 350 may additionally or alternatively have different degrees of strength, durability, thermal resistance, fluid (e.g., water or air) permeability, weight, flexibility, or the like. Further, the second layer 350 may have different visual properties (e.g., a different color) than the base layer 340 such that the combination of the second layer 350 and the base layer 340 is aesthetically pleasing. It is contemplated that when the article 300 is in use (for example as an upper of an article of footwear), its movement may cause the second layer 350 to visibly move with respect to the underlying base layer 340, which may create a desirable visual effect.
The yarns of the second layer 350 and the base layer 340 may be formed of any suitable material. For example, in some embodiments, the yarns forming the second layer 350 may be formed of a material that is relatively inelastic when compared to the yarns that form the underlying base layer 340. To illustrate, the yarns forming the base layer 340 may elongate at least 5% more, at least 50% more, at least 100% more, or even at least 500% more (and potentially greater than 500% more) than the yarns forming the second layer 350 when subjected to the same tensile load. The combination of the base layer 340 and the second layer 350 may be advantageous for achieving a desirable combination of characteristics of the article 300. For example, the base layer 340 may be relatively soft and anti-abrasive, which are characteristics that may be desirable for an inner surface of an upper or other article configured to contact a wearer. The base layer 340 may also be relatively elastic, which when used in an upper, for example, may facilitate a snug and comfortable fit around the foot of the wearer. The second layer 350, which may be located on an outer surface of the base layer 340, may be relatively inelastic to provide the upper with structural integrity and durability either throughout the entirety of the upper or at select locations.
As shown in
The tie-down yarns 642 and/or 644 may be yarns that form the base layer 640. For example, as described in more detail below with reference to
Referring to
This sequence may be substantially repeated in Steps G-K of
In
Referring to Step I, the second yarn 852 may again be knitted on one needle of each of the first needle bed 862 and the second needle bed 864. However, the second yarn 852 may be offset with respect to its previous pass. For example, it may be offset by six (6) needles with respect to its previous pass, which may correspond with one dimension of the cells of the second layer. The cell size of the second layer may also correlate with the number of passes of the base layer alone (e.g., the single jersey passes from Steps C-F and Steps K-N) between knitting the second yarn 852 and/or the third yarn 854. Step J similarly involves knitting the third yarn 854 in a manner offset from its previous pass in Step B. Steps K-N involve again knitting the first yarn 842 of the base layer to form a single jersey structure. This knitting process may be substantially repeated to form a multi-structure (e.g., a two structure) region.
The inventors have found that varying the structure of the second layer as described herein can achieve particular advantageous characteristics. For example, in one test, an article with five zones was formed in accordance with the present disclosure. Herein, each zone of the article may be associated with a region of a second layer. One zone (e.g., the Control Zone) included only a knitted base layer without (i.e., isolated from) a second layer. The 1st Zone included the base layer and a second layer with relatively large cells. The 2nd, 3rd, and 4th Zones included a base layer with second layers having decreasing cell size such that the 4th Zone included the smallest cells. Each of the zones was formed into an approximately 1 inch by 6 inch strip. The zones were then separately tested with a testing machine (i.e., an Instron 5965 Testing System) that applied a particular load and then measured the elongation of each of the zones at a loading speed of 50 millimeters per minute and at a gage length of 75 millimeters. Table 1 includes the data recovered from these tests.
As shown in Table 1, the elongation correlates with cell size, where a smaller cell size reduces the elongation. Advantageously, the cell size of a second layer as described herein can be selected to achieve particular elongation properties.
In a second test, the zones were tested to determine their recovery characteristics. In this test, a testing machine (i.e., the Instron 5965 Testing System) pulled each of the zones with a 100 Newton load for 100 cycles. The gauge length was set at 100 millimeters. Displacement measurements were taken initially at approximately 9.8 Newtons (P0) and then again after the 100 cycles (P1). Table 2 includes the data recovered from this test. The Stretch-Recovery Index was determined by dividing the difference between the initial measured length (P0) and the final measured length (P1) by the difference between the gauge length and the initial length.
As indicated by the data, the cell size of the second layer is correlated with a lower Stretch Recovery Index. Advantageously, the structure of the second layer as described herein can therefore be configured to achieve particular recovery properties. For example, the second layer may provide a particular zone with a desirable lock-out effect in certain regions of an article of footwear, for example, while other zones may be configured to have a relatively high elasticity where a high degree of freedom of movement is desirable.
In the embodiments above, zones with a second layer (e.g., a net layer) are generally described as having a relatively low elasticity and high stretch resistance when compared to zones without the second layer. However, it is also contemplated that zones with the net layer may be relatively elastic when compared to other zones.
For example, referring to
The second zone 954 of the article 900 may include a second region 944 of the base layer 940. The second layer 950 may terminate adjacent to the second region 944 of the base layer 940 such that it does not cover a surface of the second region 944. The second region of the base layer 940 may share at least one common yarn (e.g., the first yarn) and/or at least one common course with the first region of the base layer 940, and it is contemplated that the knit structure forming the first region 942 and the second region 944 may be different. The second region 944 of the base layer 940 may also share at least one common yarn (e.g., the second yarn) and/or at least one common course with the second layer 950 located in the first region 942. In other words, the second region 944 of the base layer 940 may be at least partially formed by the yarns forming the first region 942 of the base layer 940 and the yarns forming the second layer 950. This may, in some embodiments, result in the second region 944 of the base layer 940 having a higher stitch density (i.e., the total number of knit loops in a measured area of fabric) with respect to the first region 942 of the base layer 940. Additionally, or alternatively, the second region 944 of the base layer 940 may incorporate the second yarn (e.g., the yarn at least partially forming the second layer 950), which may result in the second region 944 of the base layer 940 having a different elasticity than the first region 942 of the base layer 940.
As a result, the first zone 952 of the article 900 may include a relatively high elasticity when compared to the second zone 954 of the article in some embodiments. In other words, the first zone 952 may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone 954 may have a second degree of elasticity such that it has a second elongation when subjected to the tensile load. The first elongation may be being at least 5% more, at least 10% more, at least 20% more, at least 50% more, or even at least 100% more (or greater) than the second elongation, for example.
The yarns of the second region 944 of the base layer 940 may be distributed such that the first yarns forming the first region 942 of the base layer 940 are primarily associated with an outer surface of the second region 944 and/or such that the second yarns forming the second region 944 of the base layer 940 are primarily associated with an inner surface of the second region 944 of the base layer 940 (or vice versa). Advantageously, from an external visual perspective, the second yarns may be hidden such that the first region 942 and the second region 944 of the base layer 940 may have a uniform appearance, which may be desirable aesthetically, while still exhibiting the functional characteristics described above. Alternatively, the second yarns may be exposed (when associated with the outer surface) to produce a contrast in appearance between the first region 942 and the second region 944 of the base layer 940. Alternatively, both the first and second yarns may be associated with both surfaces.
While not required, the article 900 may also include a third zone 956 with a third region 946 of the base layer that is similar in knit structure and/or yarn composition to the first region 942 of the base layer 940. The second layer 950 may terminate adjacent to the third region 946 of the base layer 940 such that the third region 946 of the base layer 940 is isolated from other layers in the third zone 956. As a result, the third zone 956 may have a relatively high elasticity when compared to the first zone 952 and the second zone 954, and accordingly may elongate at least 5% more, at least 10% more, at least 20% more, at least 50% more, or even at least 100% more (or greater) than the elongation of the first zone 952 and second zone 954 when subjected to a certain tensile load. Also, while not shown, it is contemplated that the second layer 950 may have multiple regions (similar to as described with reference to the article 500 of
Referring to
In the present disclosure, the ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present embodiments are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges (including all fractional and whole values) subsumed therein.
Furthermore, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
This application claims the benefit of U.S. Provisional Application No. 62/359,108, filed Jul. 6, 2016, which is herein incorporated by reference in its entirety. This application also claims the benefit of U.S. Provisional Application No. 62/503,704, filed May 9, 2017, which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62359108 | Jul 2016 | US | |
| 62503704 | May 2017 | US |
