ARTICLES OF FOOTWEAR WITH KNITTED COMPONENTS AND METHODS OF MANUFACTURING THE SAME

FIELD

This disclosure is directed to methods of manufacturing articles of footwear and the resulting articles and, in particular, to methods of forming uppers and the resulting articles of footwear.

BACKGROUND

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the footwear for comfortably and securely receiving a foot. Improvements in the construction of the upper are always desirable. For example, such improvements can include performance enhancement for the wearer and/or more efficient manufacturing methods.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side view of an exemplary article of footwear formed with a knitted component.

FIG. 2 illustrates a front perspective view of the exemplary article of footwear shown in FIG. 1.

FIG. 3 illustrates a schematic view of a method of positioning an inlaid strand within a knitted component.

FIG. 4 illustrates an exemplary knitted component with an inlaid strand.

FIG. 5 illustrates a schematic view of an exemplary knitted component with an inlaid strand.

FIG. 6 illustrates a schematic view of another exemplary knitted component with an inlaid strand.

FIG. 7 illustrates a schematic view of another exemplary knitted component with an inlaid strand.

FIG. 8 illustrates a schematic view of another exemplary knitted component with an inlaid strand.

FIG. 9 illustrates a schematic view of another exemplary knitted component with an inlaid strand.

FIG. 10 illustrates a schematic view of another exemplary knitted component with an inlaid strand.

FIG. 11 illustrates a schematic view of another exemplary knitted component with an inlaid strand.

DETAILED DESCRIPTION

General Considerations

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 assembly.

The systems and methods described herein, and individual components thereof, should not be construed as being limited to the particular uses or systems described herein in any way. Instead, this disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed embodiments, alone and in various combinations and subcombinations with one another. For example, any features or aspects of the disclosed embodiments can be used in various combinations and subcombinations with one another, as will be recognized by an ordinarily skilled artisan in the relevant field(s) in view of the information disclosed herein. In addition, the disclosed systems, methods, and components thereof are not limited to any specific aspect or feature or combinations thereof, nor do the disclosed things and methods require that any one or more specific advantages be present or problems be solved.

As used in this application the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” or “secured” encompasses mechanical and chemical couplings, as well as other practical ways of coupling or linking items together, and does not exclude the presence of intermediate elements between the coupled items unless otherwise indicated, such as by referring to elements, or surfaces thereof, being “directly” coupled or secured. Furthermore, as used herein, the term “and/or” means any one item or combination of items in the phrase.

As used herein, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As used herein, the terms “e.g.,” and “for example,” introduce a list of one or more non-limiting embodiments, examples, instances, and/or illustrations.

Unless otherwise stated, the recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within the respective ranges, as well as the recited endpoints. For example, within three inches includes three inches as well as any distance less than three inches. Similarly, a ratio between 2:1 and 5:1 includes both endpoints.

Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed things and methods can be used in conjunction with other things and methods. Additionally, the description sometimes uses terms like “provide” and “produce” to describe the disclosed methods. These terms are high-level descriptions of the actual operations that are performed. The actual operations that correspond to these terms will vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art having the benefit of this disclosure.

As used herein, the directional terms (e.g., “upper” and “lower”) generally correspond to the orientation of an article of footwear or sole structure as it is configured to be worn by a wearer. For example, an “upwardly-facing surface” and/or an “upper surface” of a sole structure refers to the surface oriented in the “superior” anatomical direction (i.e., toward the head of a wearer) when the article of footwear is being worn by the wearer. Similarly, the directional terms “downwardly” and/or “lower” refer to the anatomical direction “inferior” (i.e., toward the ground and away from the head of the wearer). “Front” means “anterior” (e.g., towards the toes), and “rear” means “posterior” (e.g., towards the heel). “Medial” means “toward the midline of the body,” and “lateral” means “away from the midline of the body.” “Longitudinal axis” refers to a centerline of the article from the heel to toe. Similarly, a “longitudinal length” refers to a length of the article along the longitudinal axis and a “longitudinal direction” refers to a direction along the longitudinal axis. As used herein, the term “perimeter” (sometimes referred to as the “outer perimeter”) refers to an area forming the boundary of the object referred to. For example, a perimeter of a knitted component is the area that extends along the boundary of that structure.

As used herein, the term “sole structure” refers to any combination of materials that provides support for a wearer's foot and bears the surface that is in direct contact with the ground or playing surface, such as, for example, a single sole; a combination of an outsole and an inner sole; a combination of an outsole, a midsole, and an inner sole; and a combination of an outer covering, an outsole, a midsole and an inner sole.

As used herein, the term “fixedly attached” refers to two components joined in a manner such that the components may not be readily separated from one another without destroying and/or damaging one or both of the components. Exemplary modalities of fixed attachment may include joining with permanent adhesive, stitches, welding, or other thermal bonding, and/or other joining techniques. In addition, two components may be “fixedly attached” by virtue of being integrally formed, for example, in a molding process.

Although the figures may illustrate an article of footwear intended for use on only one foot (e.g., a right foot) of a wearer. One skilled in the art will recognize that a corresponding article of footwear for the other foot (e.g., a left foot) would be a mirror image of the right article of footwear.

The present disclosure relates to uppers configured for use in articles of footwear. When referring to articles of footwear, it should be understood that the structures are not limited to any particular type of footwear. For example, the structures disclosed herein can be suitable for use with various types of footwear, including, basketball shoes, running shoes, biking shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, soccer shoes, tennis shoes, and/or walking shoes, as well as footwear styles generally considered non-athletic.

Introduction to the Disclosed Technology

The articles of footwear disclosed herein utilized textile elements that include knitted components. The knitted components can form the entire upper, or a part of the upper. As used herein, the term “knitted component” refers to a structure that is formed as a unitary knit construction, which is a process of forming a one-piece element through a knitting process. The knitting process can form all or substantially all of the various features and structures of the knitted component without the need for significant additional manufacturing steps or processes.

The knitted components described herein can be formed by various knitting techniques. Knitting may generally be classified as either weft knitting or warp knitting. In both weft knitting and warp knitting, one or more yarns are manipulated to form a plurality of intermeshed loops that define a variety of courses and wales. In weft knitting in particular, the courses and wales are perpendicular to each other and may be formed from a single yarn or multiple yarns. While knitting may be performed by hand, commercial manufacture of knit textiles is generally performed by knitting machines.

Although portions of the knitted component may be joined to each other following the knitting process (e.g., edges of knitted component being joined together to form the shape of an upper), a knitted component has a unitary knit construction if it is formed as a one-piece knit element.

The knitted components disclosed herein utilize one or more inlaid strands that can impart enhanced support, stability, and/or structure to the article of footwear. As described in more detail below, inlaid strand(s) can extend through the knitted component and pass between various loops within the knitted component. Inlaid strand(s) generally extend along courses within the knitted component. However, in some embodiments, if desired, the inlaid strand may additionally extend along wales within the knitted component, or at least a portion thereof.

The configuration of the inlaid strand(s) can vary. As used herein, “inlaid strand” refers to any elongated structure that can be inlaid into the knitted component through the knitting process. For example, the inlaid strand can comprise a cable, yarn, filament (e.g., a monofilament), thread, rope, webbing, cable, chain, and/or any combination of these structures. The knitted component can comprise a textile element and, in some embodiments, the inlaid strand can have a thickness that is greater than the material primarily forming the knitted component (e.g., yarn). The cross-sectional shape of the inlaid strand can vary. In some embodiments, the inlaid strand can have a round cross section. In others, the shape can be triangular, square, rectangular, elliptical, irregular, and/or some combination of these shapes.

The materials forming the inlaid strand can vary. For example, the inlaid strand can be formed from materials such as cotton, elastane, polyester, rayon, wool, and nylon. Inlaid strands may also be formed from a variety of engineering filaments that are utilized for higher tensile strength applications, including glass, aramids (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene, and liquid crystal polymer.

The knitted components disclosed herein are formed by a radial knit process. As used herein, the term “radial knit process” or the like refers to a knitting process which the medial and lateral sides of the knitted component are formed sequentially, rather than simultaneously. For example, instead of forming medial and lateral sides simultaneously, all (or substantially all, i.e., within 5% by length) of the medial side can be formed, then all (or substantially all, i.e., within 5% by length) of the lateral side can be formed next. Alternatively, the lateral side can be formed first and the medial side can be formed next. In some embodiments, a portion of a first side (either the medial or lateral) can be formed first and then the second side (e.g., the other side), before completing the knitted component by knitting the remaining portion of the first side.

The radial knit processes disclosed herein allow the inlaid strand(s) to be inlaid along courses of the knitted component so that the inlaid strand extends from a perimeter of the knitted component towards an opposing side of the knitted component. As used herein, the term “radial inlaid strand” or “radially extending strand” refers to an inlaid strand that extends, when the upper is formed into an article of footwear, from a perimeter of the knitted component toward a common area of the article of footwear that is spaced apart from the perimeter, such as a throat region of the article of footwear. In this manner, the strands radiate inward from the perimeter toward the common area, and do not, for example, extend across the body of the knitted component from a lateral side to a medial side edge of the perimeter.

As used herein, the term “throat region” refers to an opening formed between a lateral and medial side of the upper when formed into the shape of the article of footwear. In some embodiments the common area can extend beyond the throat region and include, for example, at least a portion of a “collar region,” which is the region of the upper that defines the opening to the foot-receiving cavity.

Examples of the Disclosed Technology

FIGS. 1 and 2 depict an article of footwear 100 and its components, according to one example. The article of footwear 100 can also be referred to as “the article 100,” “the footwear 100,” or “the shoe 100.” FIG. 1 depicts a side view of the article of footwear 100, and FIG. 2 depicts a front view of the article of footwear 100 (e.g., configured to be worn on a right foot of a wearer).

Referring to FIG. 1, the article of footwear 100 comprises a sole structure 102 and an upper 104. The upper 104 is coupled to and extends from the sole structure 102 and forms a foot-receiving cavity 106 between the sole structure 102 and the upper 104. The article of footwear can also include a closure system in a throat region to adjust the foot-receiving cavity 106. In this manner, the closure system can be used, for example, to secure/release the article of footwear 100 to/from a wearer's foot. Exemplary closure systems include laces (FIGS. 1 and 2), straps, bands, cables, cords, ratcheting mechanisms, hook-and-loop, etc.

The article of footwear 100 can be divided into one or more regions (which can also be referred to as “zones,” “portions,” or “sections”). For example, in an anterior posterior direction, the article of footwear 100 (and/or its components) can be divided into (and/or include) a forefoot region 108, a midfoot region 110, and a heel region 112. The forefoot region 108 of the article of footwear 100 can correspond to anterior portions of a foot, including toes and joints connecting metatarsal bones with phalanx bones of the foot. The midfoot region 110 of the article of footwear 100 can correspond with an arch area of the foot. The heel region 112 of the article of footwear 100 can correspond with posterior portions of the foot, including a calcaneus bone.

Referring to FIG. 2, in a medial/lateral direction, the article of footwear 100 (and/or its components) can be divided into a lateral side portion 114 and a medial side portion 116, both of which extend through the forefoot region 108, the midfoot region 110, and the heel region 112. The lateral side portion 114 and the medial side portion 116 are separated by a longitudinal axis 118.

Referring to FIG. 1, the upper 104 of the footwear 100 is a knitted component that is formed as a single, unitary component by knitting. The upper 104 can be fixedly coupled to the sole structure 102 in various ways, including for example, through adhesive, stitching, and/or other means for coupling. The article of footwear 100 can, in some instances, further comprise a sockliner (which may also be referred to as “an insole”). The sockliner can be configured to be positioned directly underfoot and is configured to cushion and/or support the wearer's foot. The sockliner can comprise various materials including textile, leather, foam, and/or other types of materials.

An outsole 120 of the sole structure 102 is configured to be the primary ground-contacting surface of the article of footwear 100. As such, the outsole 120 can include structures that help provide traction and/or to protect the other components of the sole structure 102 and/or the upper 104. In some examples, the outsole can comprise various traction elements (e.g., nubs, ribs, cleats, lugs, patterns, etc.) configured for engaging one or more types of ground surfaces.

As shown in FIGS. 1 and 2, the knitted component can comprise one or more inlaid strands that define a plurality of strand segments 122 that extend radially between an outer perimeter 124 of the knitted component (e.g., as shown in FIG. 3) and a common region or area. For example, the common region or area shown in FIGS. 1 and 2 is throat region 126, which is defined by an opening formed between the lateral side portion 114 and medial side portion 116. As shown in FIG. 1, the throat region 126 can extend through at least a portion of the midfoot region 110 between an area of the forefoot region 108 to an area of the heel region 112 (e.g., collar opening 128).

As shown in FIGS. 1 and 2, in a portion of the heel region 112, the strand segments 122 extend from the perimeter 124 of the knitted component (e.g., at a joined region between two ends of the knitted component) to the common region of the throat region 126. Thus, ends (e.g., edges) of the knitted component can be joined together with a seam that runs, for example, vertically from the sole structure to a top portion of the knitted component at the collar region of the heel region.

In the midfoot region 110, the strand segments 122 extend from the 124 perimeter of knitted component to the common region of the throat region 126. Similarly, in the forefoot region 108, the strand segments 122 extend from the perimeter 124 of knitted component to the common region of the throat region 126. In this manner, the inlaid strand forms a plurality of strand segments 122 that radially “fan” out from a common region (i.e., the throat region 126 as shown in FIG. 2).

For convenience, strand segments in the heel region, midfoot region, and forefoot region can also be referred to as heel strand segments, midfoot strand segments, and forefoot strand segments, respectively.

The dimensions of the throat region 126 can vary to change the width and length of the opening. A tongue 130 can be disposed within the opening of the throat region 126. In some embodiments, the tongue can be attached at its forward end and can substantially fill the throat opening. A closure system (e.g., laces 132 and lace-receiving members 134) can be provided to reduce the width of the opening in the throat region 126. Lace-receiving members 134 can comprise eyelets, loops, tunnels, and/or other structures that can moveably receive the tensioning member (e.g., laces 132). For example, by tensioning laces 132, the lateral side 114 and medial side 116 can be pulled toward each other to tighten the article 100 on the wearer's foot. Similarly, by reducing tension in the laces 132, the article 100 can be loosened, making it easier to put on or remove from the wearer's foot.

FIG. 3 illustrates a schematic view of a radial knit process in which the lateral and medial sides 114, 116 of the knitted component are formed sequentially and in which a single continuous inlaid strand is integrated into a knitted component 140, which is subsequently formed into an upper (either as the entirety of the upper or as a part of the upper).

As shown in FIG. 3, the knitted component 140 is formed by a knitting machine 142 by starting at a heel region 112 of the medial side 116 of the knitted component 140, knitting in a knit direction 144 from the heel region 112 to the forefoot region 108, and then knitting the lateral side 114 of the knitted component starting at the forefoot region 108 and finishing at the heel region 112 as shown by knit direction 144.

During the knitting process, the inlaid strand can be integrated with the knitted component 140 by inlaying the strand as the knitting process moves in the knit direction 144 thereby forming a plurality of strand segments 122 that extend between a lower portion of the upper to an upper portion of the upper. In FIG. 3, the inlaid strand is schematically depicted by the direction of its travel (i.e., away from perimeter 124, towards perimeter 124) in a discontinuous manner. However, as shown in more detail in other embodiments, it should be understood that the inlaid strand is a continuous, single elongate member that forms a plurality of strand segments.

In some embodiments, the strand can be a discontinuous strand. For example, the inlaid strand can comprise a first strand that forms a plurality of medial side strands and a second strand that forms a plurality of lateral side strands. In this embodiment, the continuous strands shown herein can be illustrated by simply cutting the strand along a portion of its length. For example, FIG. 3 can be understood to schematically show both a continuous strand as well as any strand that is discontinuous at any change of direction shown in FIG. 3.

Referring again to FIG. 3, the strand segments 122 extend from the perimeter 124 of the knitted component 140 towards a common region, which, in this embodiment, is the opposing side of the knitted component 140 that forms the throat region 126 of an upper.

During the radial knit process, the inlaid strand is inlaid along rows (e.g., courses) of the knitted component during knitting with the inlaid strand moving back and forth between the perimeter 124 of the knitted component and the opposing side 146 of the knitted component to provide a plurality of strand segments 122. In this embodiment, the area of the opposing side 146 is the throat region 126 of the upper.

FIG. 4 illustrates another schematic view of an exemplary knitted 140, with the knit direction 144 reversed. In this embodiment, knit direction 144 begins on a lateral side 114 and ends on a medial side 116. Inlaid strand is a continuous strand that extends from a first end 148 to a second end 150. As the strand is inlaid into the knitted component 140 during the radial knit process, the strand is integrated in the knitted component 140 in a back and forth direction between the perimeter 124 of the knitted component and an opposing side 146, within rows of the knitted component, to provide a plurality of strand segments 122.

In some embodiments, one or more strand segments 122 can define loops 152. Loops 152 can provide a structure, such as a lace-receiving structure, for other components of the article, such as laces, to engage with.

In some embodiments, the strand segments 122 can have portions 154 that extend beyond the perimeter 124. In this case, the portion of the inlaid strand extending beyond the perimeter can be secured to sole structure when the sole structure is attached. For example, the portion extending beyond the perimeter can be positioned between the upper and the sole structure and secured thereto (e.g., at the biteline of the article) by adhesive and/or other securing members.

FIG. 5 illustrates a schematic view of a radial knitted component 140. As discussed above, an inlaid strand is integrated with the knitted component 140 during the radial knit process so that the strand segments 122 extend between the perimeter 124 of the knitted component and an opposing side 146 of the knitted component.

The knitted component 140 is formed in a knit direction 144 that starts at the heel region 112 of a first side (e.g., lateral side 114) and continues with the midfoot region 110 of the first side, the forefoot region 108 of the first side, the forefoot region 108 of the second side (e.g., medial side 116), the midfoot region 110 of the second side, and finishes with the heel region 112 of the second side. From this construction, an upper (or portion thereof) can be formed by joining the edges of the two sides of the heel regions together. As discussed above, however, in some embodiments, the start and finish areas of the knitted component 140 can vary. For example, the knit direction can begin with in an area of the heel region of one side and end in an adjacent area on the same side. This structure would look similar to that shown in FIG. 5, but a portion of one of the two sides would be shifted to the other side of the radial knitted component 140. As such, although the start and finish locations of the knitted component can vary (and the joining regions of the completed knitted component can vary), the continuity of the knit process can be maintained.

The number of strand segments that extend between the perimeter and common area of the knitted component can vary. In some embodiments, the number of strand segments on at least one of the medial or lateral sides can range from 2 to 35, or from 2 to 30, or from 5 to 25, or from 10 to 25 strand segments. In some embodiments, the number of strand segments can be the same on both sides (e.g., FIG. 5). In other embodiments, as discussed in more detail below, the number of strand segments on a lateral side can be different from the number of strand segments on the medial side.

Referring to FIG. 5, the spacing of adjacent strand segments 122 of the inlaid strand (i.e., the strand portions that extend between the perimeter and common area of the knitted component) can vary along the length of the knitted component 140. For example, in the embodiment shown in FIG. 5, the strand segments 122 are closer together in the forefoot region 108, further apart in midfoot region 110, and yet further apart in the heel region 112.

The spacing between strand segments 122 can be defined by a distance 156 between adjacent strand segments along the perimeter of the knitted component 140. In some embodiments, the distance between strand segments can vary between 0.5 cm and 5 cm. As shown in FIG. 5, the distance can vary based on the location of the strand segment in the knitted component. In addition, the spacing can be generally constant within a region (e.g., within 5% of each other), or the spacing can vary within a region (e.g., increase or decrease by more than 5%). In the embodiment shown in FIG. 5, the spacing increase from the forefoot region to the midfoot region and from the midfoot region to the heel region. However, as described in more detail below, the spacing can vary in other manners depending on the desired responsiveness (e.g., lockout, stretch-resistance, deformation) of the article of footwear. Spacing in a particular region can also be described as average spacing in a region, which is calculated by measuring a distance between adjacent strands and dividing by the number of spacing areas between strand segments in that region.

Table 1 below illustrates exemplary spacing of strand segments based on the location of the strand segment in the knitted component for articles of footwear that increase in spacing from the forefoot to the heel regions, as shown in FIG. 5 for example.

TABLE 1

Forefoot
Midfoot
Heel

Example
region (cm)
region (cm)
region (cm)

Example 1
0.5-1.5
1.5-2.0
2.0-5.0

Example 2
0.2-1.0
1.0-2.5
2.5-4.0

Example 3
1.0
2.0
3.5-4.0

Example 4
1.0
1.0-2.5
3.0

Example 5
0.5-2.0
2.0-3.0
4.0

In some embodiments, ratio of the average spacing in the heel region to the average spacing in the forefoot region can be greater than 1.5:1 (e.g., an average spacing of 3.0 cm to 2.0) cm) and less than 10:1 (e.g., an average spacing of 5.0 cm to 0.5 cm), or in some embodiments the ratio can be between 2:1 and 5:1, or in other embodiments between 3:1 and 5:1.

Spacing can also be defined by the number of rows of the knitted component between strand segments. For example, in some embodiments, the inlaid strand can be positioned at a spacing of every fourth row of the knitted component. In this embodiment, there would be three rows of knitted component without the inlaid strand between rows with the inlaid strand. Table 2 below provides exemplary spacing based on the number of rows of the knitted component without the inlaid strand between rows that have the inlaid strand.

TABLE 2

Forefoot region
Midfoot region
Heel region

(Rows
(Rows
(Rows

Example
between strands)
between strands)
between strands)

Example 6
2-6
3-10
3-20

Example 7
3
5
10

Example 8
2-10
5-15
5-20

Example 9
4
7
10

In some embodiments, ratio of the average spacing based on the number of rows between strand segments in the heel region to average number of rows between strand segments in the forefoot region can be greater than 1.5:1 (e.g., 3 rows between strand segments to 2 rows between strand segments) and less than 10:1 (e.g., 20 rows between strand segments to 2 rows between strand segments), or in some embodiments the ratio can be between 2:1 and 5:1, or in other embodiments between 3:1 and 5:1.

As discussed above, the location and number of strand segments formed by the radial knit process can vary. FIGS. 6-11 illustrate additional exemplary embodiments in which a knitted component is formed with an inlaid strand that extends from a perimeter of the knitted component to a common area on another side of the knitted component.

FIG. 6 illustrates an exemplary radial knitted component 240 in which the strand segments 222 of the inlaid strand extend between the perimeter 224 of the knitted component 240 to a common area of another side 246 of the knitted component 240. In this embodiment, the common area of the other side includes a portion of the knitted component 240 that defines the throat region 226 and a portion of the knitted component that defines a collar region 260.

The knitted component can be formed by inlaying the strand during the radial knit process at a first region of one side of the knitted component (e.g., a heel region of the medial or lateral side) and completing the knitted component by moving a knit direction until the knitted component is fully constructed as described elsewhere herein. As in the previous embodiments, the strand segments 222 extend throughout the forefoot region 208, the midfoot region 210, and the heel region 212.

As shown in FIG. 6, the spacing of the radial inlaid strand segments 222 in this embodiment is more uniform throughout the longitudinal length of the upper than in the previous embodiment. For example, the smallest distance between adjacent strand segments 222 in all regions (forefoot region 208, midfoot region 210, heel region 212) can be within 50% of the largest distance, within 40% of the largest distance, or within 25% of the largest distance. Thus, for example, in one embodiment, the largest spacing (e.g., in the heel region) can be 4 cm and the smallest spacing of adjacent strand segments (e.g., in either the midfoot or forefoot) can be equal to or greater than 3 cm (i.e., within 25% of 4 cm).

Similarly, the spacing of the strand segments 222 of the inlaid strand by rows based on the number of rows of the knitted component without an inlaid strand between rows that have an inlaid strand can be more uniform than in previous embodiments. For example, the smallest number of rows between adjacent strand segments can be within 50% of the largest number of rows between adjacent strand segments, within in 40% of the largest number of rows between adjacent strand segments, or within 25% of the largest number of rows between adjacent strand segments. Thus, for example, in one embodiment, the largest spacing (e.g., in the heel region) could be 10 rows between adjacent strand segments and the smallest spacing (e.g., in either the midfoot or forefoot) can be between 5 and 10 rows (e.g., within 50%).

FIG. 7 illustrates another embodiment of a knitted component 340 formed by a radial knit process. The strand segments 322 of the inlaid strand extend between the perimeter 324 of the knitted component 340 to a common area of another side 346 of the knitted component 340. In this embodiment, the common area is smaller and includes only a forward portion of the throat region 326. Thus, in some embodiments, the common area can be within a smaller area of the throat region 326, such as within two inches, or in some embodiments, within one inch or within ½ inch, (i.e., in a longitudinal direction) of the forward-most portion of the throat region 326. As used herein, the forward-most portion of the throat region 326 is defined by the forward-most edge of the knitted component that forms the throat region of an upper.

As in other embodiments, the knitted component can be formed from a radial knit process in which the inlaid strand is integrated with the knitted component 340 along a knitted direction that includes knitting one side of the knitted component at a time. In this embodiment, the strand segments 322 of the inlaid strand extend throughout the forefoot region 308, the midfoot region 310, and the heel region 312, but the placement of the strand segments 322 on the lateral side 314 and medial side 316 is asymmetric.

For asymmetrical embodiments such as this one, it should be understood that the lateral and medial sides can be reversed. Thus, for example, either the medial or lateral side can have the greater number of strand segments.

The lateral side 314 of the knitted component 340 is similar to other embodiments described herein. Thus, the spacing described above in other embodiments can be used to describe the spacing on the lateral side 314 of this embodiment. For example, the spacing of strand segments 322 for one side of the knitted component (e.g., a lateral or medial side) can meet the ratios described above, including those described in Tables 1 and 2.

FIG. 7 illustrates inlaid strands being positioned differently on the lateral and medial sides. For example, FIG. 7 illustrates 5 strand segments on the medial side, 13 strand segments on the lateral side, and 1 strand segment extending along the longitudinal axis. Thus, in this embodiment, the number of strand segments positioned on one side (e.g., the lateral side) can be greater than the number of strand segments positioned on the other side (e.g., the medial side). In some embodiments, the number of strand segments on one side can be equal to or less than ½ of the number of strand segments on the other side. In other embodiments, the number of strand segments on one side can be equal to or less than ⅓ of the number of strand segments on the other side.

FIG. 8 illustrates another embodiment of a knitted component 440 formed by a radial knit process. The strand segments 422 of inlaid strand extend between the perimeter 424 of the knitted component 440 to a common area of another side 446 of the knitted component 440. Like the common area of FIG. 7, the common area of FIG. 8 includes only a forward portion (e.g., a forward half) of the throat region 426. In some embodiments, the common area of FIG. 8 can be within two inches, or in some embodiments, within one inch or within ½ inch, (i.e., in a longitudinal direction) of the forward-most portion of the throat region 426.

As in other embodiments, the knitted component can be formed from a radial knit process in which the inlaid strand is integrated with the knitted component 440 along a knitted direction that includes knitting one side of the knitted component at a time. In this embodiment, the strand segments 422 of the inlaid strand extend through portions of the forefoot region 408 and midfoot region 410, but not in the heel region 412. An equal number of strand segments (in this case, five) can be provided on each side (lateral side 414 and medial side 416).

FIG. 9 illustrates another embodiment of a knitted component 540 formed by a radial knit process. The strand segments 522 of inlaid strand extend between the perimeter 524 of the knitted component 540 to a common area of another side 546 of the knitted component 540. Like the common areas of FIGS. 7 and 8, the common area of FIG. 9 includes only a forward portion of the throat region 526, and the common area of FIG. 8 can be within two inches, or in some embodiments, within one inch or within ½ inch, (i.e., in a longitudinal direction) of the forward-most portion of the throat region 526.

As in other embodiments, the knitted component can be formed from a radial knit process in which the inlaid strand is integrated with the knitted component 540 along a knitted direction that includes knitting one side of the knitted component at a time. In this embodiment, the strand segments 522 of inlaid strand extend through portions of the forefoot region 508, midfoot region 510, and heel region 512. The placement of strand segments is asymmetrical, with the medial side having a greater number of strand segments in the forefoot region 508 and the lateral side having a greater number of strand segments in the midfoot region 510.

At least some of the strand segments on the medial side 516 are offset (relative to the longitudinal axis 518) from those on the lateral side 514. The offset strand segments can result in a configuration where the lateral and medial sides have the same number of strand segments, or a different number of strand segments.

As shown in FIG. 9, at least some of the strand segments one side can be offset from those on the other side along an offset axis 570 that passes through longitudinal axis 518. Thus, at least some of the strand segments can be aligned along an offset axis (axis 570) to provide support to the article of footwear along the offset axis.

FIGS. 10 and 11 illustrates additional embodiment of a knitted component 640, 740 formed by a radial knit process. The strand segments 622, 722 of the inlaid strands extend between the perimeters 624, 724, respectively, of the knitted components to a common area of another side 646, 746 of the knitted components.

FIG. 10 illustrates an embodiment in which the common area of the strand segments is a forward area of the throat region 626 (e.g., a forward half, or within two inches, one inch or 1/2 inch of the forward-most portion of the throat region 626).

FIG. 11 illustrates an embodiment in which the common area of the strand segments is a rear area of the throat region 726 (e.g., a rear half). In this embodiment, the common area of the strand segments can be in the rear half, or within two inches, within one inch, or within ½ inch of the rearward-most portion of the throat region 726. As used herein, the rearward-most portion of the throat region 726 is defined by the rearward-most edges of the knitted component that forms the throat region of an upper (i.e., the area of the upper directly adjacent the collar region of the upper).

As in other embodiments, the knitted components 640, 740 can be formed from a radial knit process in which the inlaid strands are integrated with the respective knitted components 640, 740 along a knitted direction that includes knitting one side of the knitted component at a time. In both embodiments, the strand segments 622, 722 of the inlaid strands extend through portions of the forefoot region 608, 708, midfoot region 610, 710 and heel region 612, 712.

FIG. 10 illustrates an embodiment in which all of the strand segments 622 of the inlaid strand are placed on a lateral side 614 of the knitted component 640, while FIG. 11 illustrates an embodiment in which all of the strand segments 722 of the inlaid strand are placed on a lateral side 716 of the knitted component 740.

In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.

ARTICLES OF FOOTWEAR WITH KNITTED COMPONENTS AND METHODS OF MANUFACTURING THE SAME

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