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

BACKGROUND

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the footwear for comfortably and securely receiving a foot. Uppers may be formed by a variety of materials, including knitted textiles. When an athlete moves their foot within a knitted upper, a force may be exerted on the athlete's foot that pushes the foot partially off the sole structure. Performance and comfort may be improved by keeping the foot contained over the sole structure during movement. Various components, e.g., synthetic leather textiles, laminate film layers, or the like, may be added and secured, e.g., glued, stitched, bonded, or the like, to a knitted upper through post-knitting processes to keep the foot contained and/or increase durability of the upper. However, such components added through post-knitting processes may increase the weight of the upper, increase production time, reduce recyclability of the upper and impact performance in unintentional and possibly negative ways.

BRIEF DESCRIPTION OF THE DRAWINGS

The articles of footwear and methods of manufacturing the same described herein are discussed in detail in connection with the attached drawing figures, wherein:

FIG. 1A depicts a lateral side perspective view of an article of footwear, in accordance with aspects hereof;

FIG. 1B depicts a medial side view of the article of footwear of FIG. 1A, in accordance with aspects hereof;

FIG. 2 depicts a top-down view of a knitted component of the article of footwear of FIG. 1A in a generally planar configuration, in accordance with aspects hereof;

FIG. 3 depicts a schematic view of tensile elements 150 in a portion of the knitted component of FIG. 2, in accordance with aspects hereof;

FIG. 4 depicts an example stitch diagram for a portion of the knitted component of FIG. 2, in accordance with aspects hereof; and

FIG. 5 depicts a block diagram of a method of manufacturing an upper for an article of footwear, in accordance with aspects hereof.

DETAILED DESCRIPTION

This detailed description is related to knitted components for articles of footwear and methods of manufacturing thereof that provide support and containment while maintaining a light weight of the upper, reducing production time, and improving recyclability, among other benefits. In at least some examples, an article of footwear with an upper includes a knitted component with courses formed with a tensile element. The tensile element has a higher tenacity than other yarn forming the knitted component. Further, the tensile element may be knit with a repeating sequence of knitted loop stitches (e.g., knitted loops) and float stitches along the courses. Such a knit sequence provides containment and strength through the floats due to less elongation while maintaining integrity to the knit structure by keeping the tensile element integrated into the knitted structure with the knitted loop stitches. Each float extends over a quantity of wales in the knitted structure. Generally, examples of the knit sequence of the tensile element have a greater quantity of wales in each float than the quantity of knitted loop stitches, which results in less elongation and stretch of the knitted component. For instance, the tensile element may be knit with a sequence of one knitted loop stitch and five-needle float (resulting in a float extending five wales in the knitted component), where the sequence is repeated multiple times along the length of the course.

Examples of the article of footwear may include one or more first zones with courses of the tensile element following a repeating knit-float sequence while also having one or more second zones lacking the tensile element with the repeating knit-float sequence. For example, in some aspects, the upper includes courses of the tensile element with the knit-float sequence throughout the midfoot region on a lateral and/or medial side. In particular, the courses of the tensile element in the midfoot region extend from an outer perimeter of the knitted component to a throat area. Courses of the tensile element located within the midfoot region and extending to the throat area help to redistribute tension forces applied through the laces or other tensioning devices in the throat area. Further examples include such courses of the tensile element with the repeating sequence extending through the midfoot region and the heel region. Such courses may also be included in at least part of the forefoot region of the upper. Inclusion of the tensile element courses in these areas further provide containment, due to less elongation, around a wearer's foot when the upper is worn. Inclusion of the tensile courses through a majority of the upper may be beneficial in providing necessary support when the knitted component is otherwise knit with lightweight materials and/or is formed without additional support structures. In some aspects, courses of the tensile element with the repeating sequence may be absent from a central portion of the forefoot region, which could reduce knit time and rely on structure and containment from the tensile element courses in the other areas of the upper.

Generally, various components, such as synthetic leather textiles and/or laminate film layers, have been added and secured, e.g., glued, stitched, heat-bonded, or the like, to the upper to provide supporting structures to the footwear and containment around the wearer's foot. However, these components are typically heavier than tensile elements that are capable of being knitted into the knitted component. Additionally, such components may not be recyclable or require adhesives that reduce recyclability. Further, these components are added through a post-knitting process and, therefore, increase production time. Another alternative to provide support is inlaying a cable or other type of tensile element, often through a knitted tunnel. However, such cables are often heavy and bulky and require inlaying with a specialized feeder (a combination feeder), and forming a knitted tunnel for such cable may increase the knit time. Aspects of the disclosure seek to provide strength to a knitted structure and containment around the wearer's foot while decreasing the weight of the upper, decreasing production time, and improving recyclability of the upper.

As described herein, certain aspects of the present disclosure relate to articles of footwear or aspects thereof that are at least partially formed from knit textiles. In an illustrative example, aspects are directed to an upper formed at least partially of a knitted component. As used herein, the term “upper” refers to a footwear component that 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 to form a void for receiving a wearer's foot. Illustrative, non-limiting examples of uppers may include uppers incorporated into 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. Further, in other aspects, the upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal. Accordingly, the concepts disclosed herein with respect to articles of footwear apply to a wide variety of footwear types. Although the figures may illustrate an article of footwear intended for use on only one foot (e.g., a left foot) of a wearer, one skilled in the art will recognize that a corresponding article of footwear for the other foot (e.g., a right foot) would be a mirror image of the right article of footwear.

Positional terms used when describing articles of footwear or aspects thereof, such as top, bottom, front, sides, back, superior, inferior, lateral, medial, right, left, interior, exterior, interior-facing, exterior-facing, and the like, are used with respect to the article of footwear or upper being worn as intended with the wearer standing upright such that the wearer's foot is in the foot-receiving void and the wearer's ankle or leg extends through the ankle opening. For example, an “upwardly-facing surface” and/or an “upper surface” of an upper refers to the surface oriented in the “superior” anatomical direction (e.g., 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” (e.g., toward the ground and away from the head of the wearer). “Front” or “forward” means “anterior” (e.g., towards the toes), and “rear” means “posterior” (e.g., toward 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 extending between the heel region and the forefoot region. 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. It should be understood, however, that use of positional terms do not depend on the actual presence of a human being for interpretative purposes.

The term “knitted component” refers to a textile piece that 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 courses and wales. The term “course,” as used herein, refers to a predominantly horizontal row of knit loops (in an upright textile as it is knit on the knitting machine) that is produced by adjacent needles during the same knitting cycle. The course may comprise one or more stitch types, such as a knit stitch (also referred to herein as a knitted loop stitch), a missed stitch, a tuck stitch, a transfer stitch, a rib stitch, and the like, as these terms are known in the art of knitting. The term “wale,” as used herein, is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles.

The term “integrally knit,” as used herein, may mean a knitted component having a yarn from one or more knitted courses in a first area or region being interlooped with one or more knitted courses of another area or region. The interlooping may be through a simple knit stitch, a tuck stitch, a held stitch, a float or miss stitch, and the like. In this way, areas that are integrally knit together have a seamless transition.

The term “radially extending,” as used herein, refers to an orientation of a knit course that radiates out from a common portion of the knitted component. Specifically, the knit course may be radially extending if it extends between an outer perimeter of the knitted component and the common portion. In this manner, the courses may radiate inwards from the outer perimeter towards the common portion and do not, for example, extend continuously across the body of the knitted component from a lateral side edge to a medial side edge of the outer perimeter. The structures of the knitted component may be radially extending from the common portion when the knitted component is laid out in a flat configuration after knitting, but it is also contemplated that determining whether structures are radially extending may be based on the orientation of the structures towards the common portion after the knitted component is folded into the shape of an upper or a portion of an upper.

The term “common portion,” as used herein, refers to an area of the knitted component towards which multiple similar structures (e.g., multiple courses) extend. As such, courses may extend from an outer perimeter to a single common portion rather than extending generally parallel from the outer perimeter towards the other side. The common portion is spaced-apart from the outer perimeter and, in various aspects, may be relatively centrally located within the knitted component. In this way, the common portion may encompass and/or be directly adjacent to the longitudinal axis of the knitted component. In some examples disclosed herein, the common portion may include a throat region or a portion thereof.

As used herein, the term “throat region” refers to an area on a top (upward-facing) side of an upper generally extending between an ankle opening and a forefoot region. The throat region may include an opening formed between a lateral side and medial side of the upper when formed into the shape of the article of footwear, and in some aspects, the throat region may include a tongue extending across the opening in the throat region. In some aspects, the throat region does not have an opening but, rather, includes a continuous integrally knit area of a knit component extending between the medial and lateral sides, e.g., one that can be formed of elastic yarns, material, and/or other components that include a degree of stretchability.

As used herein, the term “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. The “outer perimeter” may refer to portions of a perimeter of a knitted component that, once formed into an article of footwear, are secured to the sole structure or form a seam between two ends of the outer perimeter (such that they may at least partially extend under the foot of the wearer when the article of footwear is worn. In contrast, an “inner perimeter” may refer to portions of the perimeter of a knitted component that, once formed into an article of footwear, define openings, such as an opening in a throat region and/or the ankle opening. The perimeter (outer perimeter or inner perimeter) may refer to an edge of the knitted component or to a peripheral area adjacent to the edge.

Different 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. Additionally, there are various measurements provided herein. Unless indicated otherwise, the term “about” or “approximately” with respect to a measurement means within +10% of the indicated value.

FIGS. 1A and 1B depict a lateral side perspective view and a medial side view, respectively, of an article of footwear 100 and its components, according to aspects hereof. 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 between the sole structure 102 and the upper 104. The area of the article of footwear 100 where the sole structure 102 joins the upper 104 may be referred to as the biteline 106. The upper 104 may be joined to the sole structure 102 in a fixed manner using any suitable technique, such as through the use of an adhesive, sewing, or the like. It is contemplated that the upper 104 may extend partially or completely around the foot of a wearer, may extend under the foot of a wearer, and/or may be integral with the sole. A sockliner, which may be referred to as a strobel, may or may not be used. The sockliner can comprise various materials including textile, leather, foam, and/or other types of materials.

The article of footwear 100 (and/or its components) can be divided into one or more regions (which can also be referred to as ‘areas” or “portions”). For example, in an anterior-to-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. In a medial-to-lateral direction, the article of footwear 100 (and/or its components) can be divided into a lateral side 114 and a medial side 116, both of which extend through the forefoot region 108, the midfoot region 110, and the heel region 112. More particularly, the lateral side 114 corresponds with an outside area of the foot (e.g., a side that faces away from the other foot) when the article of footwear 100 is worn, while the medial side 116 corresponds with an inside area of the foot (e.g., a side that faces towards the other foot) when the article of footwear 100 is worn. The lateral side 114 and the medial side 116 are separated by a longitudinal axis 118. These regions 108, 110, and 112 and sides 114 and 116 are not intended to demarcate precise areas of the article of footwear 100 but, rather, are intended to represent general areas of the article of footwear 100 to aid in understanding the various descriptions provided herein.

The sole structure 102 generally extends between the foot and the ground when the article of footwear 100 is worn. The sole structure 102 may include multiple components, such as an outsole, a midsole, and an insole or sockliner. Various materials may be used to form the sole structure 102, such as rubber, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), thermoplastic elastomer (e.g., polyether block amide), and the like. The sole structure 102 may also include various other elements, such as a heel counter and a toe cap. The sole structure 102 may include various other features to attenuate forces, enhance stability, and/or provide traction, such as treads or cleats, as understood by one skilled in the art.

The upper 104 defines a void within the article of footwear 100 for receiving and securing a foot relative to the sole structure 102. Access to the void is provided by an ankle opening 125 located in at least the heel region 112. The upper 104 includes a throat area 126 disposed in the midfoot region 110 between the ankle opening 125 and the forefoot region 108. The throat area 126 may be configured to cover a top side of the wearer's foot and, therefore, form part of a top side (or overfoot region) of the upper 104 between the lateral side 114 and the medial side 116. The article of footwear 100 can also include a closure system in the throat area 126 to adjust the foot-receiving cavity. In this manner, the closure system can be used, for example, to secure and/or release the article of footwear 100 to and/or from a wearer's foot. Example closure systems include laces 132 (as shown in FIGS. 1A and 1B), straps, bands, cables, cords, ratcheting mechanisms, hook-and-loop connections, and the like. Laces 132 may extend through openings in eye-stays, e.g., which may be integrally knit, or through other post-knitted components, e.g., in the throat area 126.

At least a portion of the upper 104 may include at least one knitted component 140 formed by a knitting process, such as by a weft-knitting process on a flat knitting machine, for example. In some aspects, the entire or substantially the entire upper 104 may be formed of the knitted component 140. FIG. 2 depicts another view of the knitted component 140 prior to being shaped into the upper 104 shown in FIGS. 1A and 1B.

The knitted component 140 may incorporate various types of yarn that impart different properties to separate areas of the upper 104. That is, one area of the knitted component 140 may be formed from a first type of yarn that imparts a first set of properties, and another area of the knitted component 140 may be formed from a second type of yarn that imparts a second set of properties. With this configuration, properties may vary throughout the upper 104 by selecting specific yarns for different areas of the knitted component 140. The properties that a particular type of yarn will impart to an area of the knitted component 140 partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester, which may be a recycled polyester, is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the yarns selected for the knitted component 140 may affect the properties of the upper 104. For example, a yarn forming the knitted component 140 may be a mono-filament yarn or a multi-filament yarn. As such, unless otherwise specified, the term “yarn” as used herein, does not require multiple filaments or fibers. 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 the upper 104. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of the upper 104. Additional properties of yarn(s) used in various aspects of this disclosure are described in further detail below.

The knitted component 140 may be formed as a single integral one-piece element during a knitting process, e.g., such as weft-knitting, warp-knitting, or another suitable knitting process. Additional elements, such as an underfoot portion and/or a heel element may be integrally formed with the upper 104 as a one-piece unitary structure, e.g., in a single knitting process performed on a knitting machine. Alternatively, one or more such additional elements may be formed separately from the upper 104 and then later attached, secured, or otherwise assembled and/or integrated as needed. Forming the upper 104 with the knitted component may provide the upper 104 with advantageous characteristics including, but not limited to, a particular degree of elasticity, breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination of such properties. Further, forming the upper 104 from an integrally-knit knitted component may form various features and structures of the upper 104 without the need for significant additional manufacturing steps or processes, thereby increasing production efficiency.

Looking at FIGS. 1A and 1B and FIG. 2, the knitted component 140 includes courses of tensile elements 150. The tensile elements 150 may each have the configuration of a multi-filament yarn or a filament (e.g., a mono-filament yarn), for example. The tensile elements 150 may comprise a material having a physical property for increasing the strength of the knitted component 140 in areas with the tensile elements 150. For example, the tensile elements 150 may comprise a yarn having a high tenacity, such as a tenacity greater than 5 grams/denier. In some embodiments, the tenacity of the tensile elements 150 may be greater than other yarn(s) of the knitted component 140. In one example, the tensile elements 150 are formed from a high tenacity polyester yarn, such as Gral, produced by the Coats Group PLC. In another example, the tensile elements 150 are formed by a high-tenacity nylon yarn. In some aspects, the yarn forming the tensile elements 150 have a greater diameter or denier than other yarns, including a first yarn, forming the rest of the knitted component 140. As used herein, “tenacity” refers to a property of a fiber or yarn, and may be determined according to the test method detailed in EN ISO 2062 with the pre-load set to 5 grams. Elongation is recorded at the maximum tensile force value applied prior to breaking. Tenacity can be calculated as the ratio of load required to break the specimen to the linear density of the specimen.

The increased tenacity, diameter, or denier of the tensile elements 150 may increase stretch resistance (reduce elongation) in the direction of the tensile elements 150 compared to areas of the knitted component 140 without the tensile elements 150. Further, the tensile elements 150 may provide strength to the knitted component 140 to disperse tensile forces applied to the upper 104. Such forces may occur when the upper 104 is being donned or doffed, including during tensioning of the laces 132, and during movement (including side-to-side and forward-to-back movements) when the upper 104 is worn.

The tensile elements 150 are incorporated into the knitted structure of the knitted component 140 through knitting. Particularly, the tensile elements 150 may be knit into the knitted structure of the knitted component 140 using a sequence of repeating float stitches and knitted loop stitches as the tensile element 150 extends from an outer perimeter 136, which may be adjacent the biteline 106 when the upper 104 is secured to the sole structure 102, toward an inner perimeter 134, which may define the ankle opening 125 and/or an opening in the throat area 126. The incorporation of several float stitches along each course of a tensile element 150 provides strength and stretch-resistance. The knitted loop stitches, where the tensile element 150 in one course is interlooped with a yarn (of either the tensile element 150 or a different yarn) in an adjacent course, helps anchor the tensile elements 150 in place. In this way, incorporating knitted loop stitches in the knit sequence helps keep the tensile elements 150 extending in straighter or cleaner lines along a course and reduce the risk of something snagging particularly on a longer float stitch.

Incorporating the tensile elements 150 through the knitted loop-float sequence provides a desired stretch resistance and stretch to the upper 104 that may have previously been achieved through inlaying tensile elements and has an additional benefit of utilizing a lighter-weight yarn for the tensile elements 150 compared to traditional inlaying. Particularly, knitting tensile elements 150 through a knitted loop-float sequence generally requires yarn with a smaller denier or diameter compared to what is often used for inlaying. As such, the tensile elements 150 may be knit with a smaller and lighter-weight yarn, thereby decreasing the overall weight of the upper 104. Additionally, incorporating the tensile elements 150 with knitted loop stitches and floats instead of inlays may be performed with a regular feeder or a combination feeder on a knitting machine, whereas inlaying requires a combination feeder. In this way, this knitting technique provides more flexibility in which knitting machines may be used to form the knitted component 140 and/or how a particular knitting machine is used.

FIG. 3 provides a schematic depiction of a portion of the example knitted component 140 with tensile elements 150 using a knitted loop-float sequence. Particularly, each course of the tensile element 150 includes a sequence of knitted loop stitches 152 and float stitches 154, where the sequence is repeated along the length of the course. In example aspects, the sequence includes one knit stitch and one float stitch extending across a plurality of wales. The number of wales that a single float stitch extends across corresponds to the number of needles along a needle bed along which the tensile element 150 is floated in between two knitted loop stitches. The number of wales that each float stitch extends may be no greater than 8. In some aspects, the number of wales that each float stitch extends is within a range of 3 to 8. In some aspects, the number of wale is within a range is of 3 to 5. Particularly, in one example, each float may extend 5 wales. In another example, each float may extend 4 wales. In another example, each float may extend 3 wales.

Each float stitch 154 may be separated from an adjacent float stitch by one knitted loop stitch. As such, in some examples, the knit sequence of the tensile elements 150 is one knitted loop stitch followed by a 5-needle (or 5-wale) float stitch, which may then be repeated. In another example, the knit sequence of the tensile elements is one knitted loop stitch followed by a 4-needle (or 4-wale) float stitch. In yet another example, the knit sequence of the tensile elements is one knitted loop stitch followed by a 3-needle (or 3-wale) float stitch. The knitted loop-float sequence may be repeated through all of or at least a majority of the length of each course of a tensile element 150. In some examples, one or both ends of a course of the tensile element 150 may not follow the same knit sequence and the tensile element 150 may have more knitted loop stitches and, in some aspects, may have no float stitches at one or more ends of a course. For example, in a portion of the knitted component 140 adjacent the outer perimeter 136, the tensile elements 150 may not have a float stitch. In some aspects, the knitted component 140 may also lack float stitches of the tensile elements 150 adjacent the inner perimeter 134. Generally, at least approximately 75% of the length of each course of the tensile element 150 includes the repeated knitted loop-float sequence. In some examples, at least approximately 85% of the length of each courses of the tensile element 150 includes the repeated knitted loop-float sequence. In at least some courses, the tensile element 150 may repeat the sequence at least 5 times within a single course. In some aspects, the tensile element 150 repeats the sequence at least 10 times within a single course.

In some aspects, the location of the knit stitch in adjacent courses of the tensile elements 150 may be offset such that they occur at different needle positions. For example, where the knitted loop stitches in the first course of a tensile element 150 are at needle positions 2, 8, 14, the knitted loop stitches in the adjacent course of a tensile element 150 may be at needle positions 3, 9, 15.

For simplicity, only the tensile elements 150 following the knitted loop-float sequence are schematically depicted in FIG. 3, but it should be understood that the knitted component 140 may include courses of additional yarns knit with the tensile elements 150. For example, the tensile elements 150 may be knit with one or more other yarns knit within the same course using the same or different needle bed. These other yarn(s) have a different physical property as the tensile element 150, such as a lower tenacity. These other yarns are knit with a different knit sequence as the tensile element 150, for example using knitted loop stitches or a combination of knit stitches and tuck stitches. Example knit sequences are described below with respect to FIG. 4. Further, in some aspects, each tensile element 150 may represent multiple ends, of a yarn having a greater tenacity than another yarn forming the knitted component 140, where the multiple ends are knit to overlap within a single course of the knitted component 140. An example of such a feature is described further with respect to FIG. 4.

Further, some aspects of the knitted component 140 are radially knit such that the knitted component 140 includes knit courses, including courses of the tensile elements 150, extending from an outer perimeter 136 of the knitted component toward a common portion or region. Particularly, the courses of the knitted component 140 may extend from the outer perimeter 136 (visible in FIG. 2) to the throat area 126, which may be referred to as the common portion. In this way, knit courses of the knitted component 140 may extend diagonally to each other, rather than parallel. Further, radially-extending courses within the knitted component 140 may divide the knitted component 140 into wedge-shaped portions. For example, looking at the close-up view of the knitted component 140 in FIG. 3, a wedge-shaped portion 121 is marked by dashed boundary lines, and similar wedge-shaped portions can be seen throughout the knitted component 140. In some aspects, the courses forming the wedge-shaped portion 121 between may be formed by knitting full-length, radially-extending courses and partial-length, radially-extending courses. The wedge-shaped portion 121 includes two full-length knit courses with partial-length knit courses in between. A full-length knit course, such as course 142a, may extend from one edge of the knitted component 140 (e.g., at the outer perimeter 136) to another edge of the knitted component 140 (e.g., at the inner perimeter 134 in a throat area 126). Partial-length knit courses, such as course 142b, may not fully extend between two edges of the knitted component 140. One or both ends of a partial-length knit course may end before the edge of the knitted component 140. However, the partial-length knit courses, such as course 142b, may still be considered radially-extending as they extend in a direction from the outer perimeter 136 toward the common portion (e.g., the throat area 126). For simplicity, the partial-length knit courses are only depicted in FIG. 3 within the wedge-shaped portion 121, but it should be understood that the knitted component 140 would include additional partial-length courses forming other wedge-shaped portions not illustrated. Forming partial-length knit courses distributed between full-length knit courses may create shape and dimension in the knitted component 140 while also enabling the courses to extend radially.

In example aspects, the courses of the knitted component 140 extending radially from an outer perimeter to a common portion, such as the throat area 126, include courses of the tensile element 150 as well as courses of one or more additional yarns knit with a different knit sequence. As previously described, the tensile elements 150 help to disperse tension applied through laces 132, which prevents wear and tear in the throat area 126. Extending the tensile elements 150 radially along the knitted component 140 creates additional angles through which tension can be distributed around the upper 104 and, thereby, result in more effective re-distribution of tension forces. The tensile elements 150 may also help provide strength and stretch-resistance to the upper 104, which provides containment around a wearer's foot when the upper 104 is worn. Extending the tensile elements 150 radially creates additional angles of containment around a wearer's foot compared to tensile elements extending generally parallel to each other.

Although FIG. 3 depicts tensile elements 150 extending radially from the outer perimeter 136 to a common portion, it should be understood that aspects of the tensile elements formed with a knitted loop-float sequence may be present in a knitted component that is not radially knit, such as where the courses of the tensile elements 150 extend parallel to one another, e.g., such as extending parallel along a medial-to-lateral axis, without converging towards a common portion.

Tensile elements 150 knit with a repeated knitted loop-float sequence may be selectively arranged in various places around the upper 104 to provide desired strength, stretch-resistance, and containment. As such, the upper 104 may include one or more first zones with the tensile elements 150 knit with the disclosed repeated stitch sequence and also having one or more first zones without the tensile elements 150 knit with the disclosed repeated stitch sequence. For example, the courses of tensile elements 150 extend through at least the midfoot region 110 on the lateral and/or medial sides 114 and 116. In the example of illustrated in FIGS. 1A-2, the courses of tensile elements 150 extend through the heel region 112, the midfoot region 110, and medial and lateral portions 107 and 109 of the forefoot region 108, where tensile elements with the knit sequence are absent from a central portion 111 of the forefoot region 108. The central portion 111 of the forefoot region 108 without tensile elements 150 may extend through a longitudinal midline portion of the knitted component 140 from an anterior-most aspect of the forefoot region 108 to the throat area 126. The central portion 111 of the forefoot region 108 may be configured to extend over the top of a wearer's toes (and similarly be referred to as a toebox) when the article of footwear 100 is worn. The medial portion 107 of the forefoot region 108 generally extends medially of the central portion 111, and the lateral portion 109 of the forefoot region 108 generally extends laterally of the central portion 111.

As illustrated, in some aspects, tensile elements 150 are present throughout the length of the knitted component 140 except in the central portion 111 of the forefoot region 108. In some aspects, the article of footwear 100 is intended to be worn while running. Having tensile elements 150 present throughout the length of the knitted component 140 except in the central portion 111 of the forefoot region 108 may provide strength to the footwear 100 along with containment around the wearer's foot, while providing sufficient flexibility in the forefoot region 108. In alternative aspects, the tensile elements 150 may be present throughout the length of the knitted component 140, including in the central portion 111 of the forefoot region 108, or the tensile elements 150 may be present throughout the length of the knitted component 140 except in the entire forefoot region 108. Other arrangements of the tensile elements 150 throughout the knitted component 140 are contemplated herein. As such, certain percentages of the length of the outer perimeter 136 may include courses with the tensile elements 150. For example, approximately 75%-95% of the length of the outer perimeter 136 includes courses of tensile elements 150 in some aspects. In other aspects, approximately 80%-90% of the length of the outer perimeter 136 includes courses of tensile elements 150 in some aspects. Other aspects may include more or less of the outer perimeter 136 having courses of tensile elements 150.

Further, for simplicity, only select courses of the tensile elements 150 are depicted in FIGS. 1A-2. In various aspects, however, the tensile elements 150 are knit, in accordance with a specified knit sequence, in adjacent courses within the midfoot region 110 and the heel region 112. The tensile elements 150 may further be knit in adjacent courses in at least the medial and lateral portions 107 and 109 of the forefoot region 108.

Turning to FIG. 4, an example stitch diagram 400 is provided. The stitch diagram includes rows 402, 404, 406, and 408, each including representations of needles on front and back needle beds of a knitting machine. Each of these rows 402, 404, 406 and 408 may represent a pass of a feeder of a knitting machine and may be knit together before any of the stitches are released by the needles such that rows 402, 404, 406, and 408 of the stitch diagram 400 may collectively represent a portion of one course of a knitted component, such as the knitted component 140. It should be understood that such a course may be knit with additional ends of yarn not shown in stitch diagram 400.

Rows 402, 404, 406, and 408 depict knit sequences of a first strand 412, a second strand 414, a third strand 416, and a fourth strand 418, respectively. The second strand 414 and the third strand 416 may be yarns (e.g., either multi-filament or mono-filament) having a higher tenacity than yarns of the first and fourth strands 412 and 418. As such, the second and third strands 414 and 416 may represent tensile elements 150, and in aspects, the second and third strands 414 and 416 may have any of the characteristics described above with respect to tensile elements 150. The second and third strands 414 and 416 may be the same yarn type or may be different yarn types. Further, the first and fourth strands 412 and 418 may be the same yarn type as each other or different yarn types. In one example, each of the first and fourth strands 412 and 418 are a polyester yarn having a lower tenacity than yarn of the second and third strands 414 and 416.

In row 404, the second strand 414 (e.g., that can be tensile element 150) has a knit sequence 420 marked by dashed lines. The knit sequence 420 includes one knitted loop stitch on a back needle bed, and a float stitch 422 extending across five needle positions on each bed. It will be understood that while there are needles on each bed, a needle on the front bed and a needle on the back bed form a needle position corresponding to a wale on one surface of a knitted component, such that the float stitch 422 is a five-needle float. The knit sequence 420 is repeated in row 404 once more in the stitch diagram 400, but it should be understood that the sequence may be repeated additional times within the same course.

In row 406, the third strand 416 generally follows the same knit sequence 420, but it starts at a different needle position so that the knitted loop stitches of the third strand 416 are offset by 3 needle positions from the knitted loop stitches of the second strand 414. In other aspects, the knit sequence 420 in the third row 406 is offset from the knit sequence 420 in the second row 404 by a different number of needle positions. In other aspects, the knit sequence 420 in the third row 406 aligns with the knit sequence 420 in the second row 404.

In some aspects, the knitted loop stitches of strands 414 and/or 416 may be knit on the front needle bed in addition to or alternatively to being knit on the back needle bed. Further, in other aspects, the knit sequence 420 may include a different length of the float stitch, including any of those described with respect to the tensile element 150.

In row 402, the first strand 412 follows a different knit sequence 430 than the knit sequence of the first and second strands 414 and 416 having a greater tenacity. This knit sequence includes one knitted loop stitch on a back needle bed, one knitted loop stitch on a front needle bed, and a float stitch over one needle positon. This knit sequence 430 is repeated multiple times through row 402. In row 404, the fourth strand 418 follows yet another knit sequence 440 that includes two knitted loop stitches on the back needle bed followed by a float stitch over one needle position. Although the stitch diagram 400 includes different knit sequences for the first strand 412 and the fourth strand 418, the first and fourth strands 412 and 418 may follow the same knit sequence as each other in other examples. Additionally, other knit sequences may be used by the first strand 412 and/or the fourth strand 418, including knit sequences with different numbers of knitted loop stitches, no float stitches, different lengths of float stitches that are shorter than the length of the float stitch in the knit sequence 420, tuck stitches, and/or transfers, for example.

Additional aspects of this disclosure include processes for manufacturing an article of footwear, an upper, and/or a knitted component for an upper. Particularly, some aspects include steps in manufacturing that integrally knit tensile elements 150 without inlaying the tensile elements. FIG. 5, for example, illustrates a flow diagram depicting an example method 500 of manufacturing an article of footwear, which may include the footwear 100 or components thereof. The steps provided in method 500 are merely illustrative, and method 500 may include additional steps that are not illustrated.

At step 510, a knitted component is knit on a knitting machine. Step 510 may be performed by an automated knitting machine and as such, may be performed and/or controlled using a control unit having a processor or computer communicatively coupled with or integrated into the knitting machine. In example aspects, the knitting machine used to knit the knitted component is a V-bed flat knitting machine having two needle beds—a front needle bed and a back needle bed—that are angled relative to each other to form a V-bed. The front and back needle beds may each include a plurality of individual needles extending across a common plane. A carriage may move feeders, such as standard and/or combination feeders, along the front and back needle beds to supply yarns to needles. Generally, standard feeders and combination feeders both supply yarn for needles to knit, tuck, and/or float, while combination feeders may also supply yarn to inlay through or between knitted structures. Although the machine used to knit the knitted component at step 510 may include a combination feeder, it should be understood that a combination may not be needed as courses described herein formed at step 510 may be knit on either a standard feeder or a combination feeder. Although a flat V-bed knitting machine is described herein, it should be understood that this is one example and that other knitting machines may be used to form the knitted component or a portion thereof.

Step 510 includes knitting the knitted component to form courses with a first yarn and a tensile element having a greater tenacity compared to the first yarn. The tensile element may be aspects described of tensile element 150, the second strand 414 and/or the third strand 416. For example, the tensile element may have a tenacity of at least 5 grams per denier. The first yarn may have a tenacity less than 5 grams per denier or a tenacity of or greater than 5 grams per denier if it is still less than that of the tensile element. As stated, the first yarn may have a lower tenacity than the tensile element and, in some aspects, may have a smaller diameter or denier than the tensile element. In some aspects, the first yarn is a polyester yarn. The first yarn may be aspects of the first strand 412 and/or the fourth strand 418 described above.

The tensile element may be knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales, where the quantity of wales is greater than the quantity of knitted loop stitches within the sequence. For example, the sequence may be one knitted loop stitches and a float stitch extending at least one wale. In some aspects, the number of wales over which a float stitch extends may be at least 3 wales and no greater than 8 wales. In one example, the knit sequence is one knitted loop stitch and a 5-needle float (e.g., a float stitch extending over five wales). In another example, the knit sequence is one knitted loop stitch and a 4-needle float (e.g., a float stitch extending over four wales). In yet another example, the knit sequence is one knitted loop stitch and a 3-needle float (e.g., a float stitch extending over three wales). The sequence is repeated by the tensile element multiple times along each course within the plurality of courses. Other examples of the knit sequence knit at step 510 may be as described with respect to the knitted component 140. In various aspects, the first yarn knit within the knitted component may follow a different knit sequence, including a knit sequence without float stitches or with float stitches extending over a quantity of wales less than the quantity in the knit sequence of the tensile elements, such as one wale or two wales for example.

The courses of the tensile element and first yarn may be knit at step 510 to form at least the midfoot region on lateral and medial sides of the upper. In other aspects, such courses also form a heel region of the upper. Additionally or alternatively, such courses may form at least part of the forefoot region of the upper, such as lateral and medial portions of the forefoot region, where a central portion of the forefoot region (e.g., central portion 111) may lack the tensile element 150 knit with the knitted loop-float sequence. Examples of the arrangement of the tensile elements 150 within the upper may apply to various aspects of the tensile element knit at step 510.

Step 520 of method 500 includes forming an upper with the knitted component 140. This step may include at least securing together one or more perimeter edges of the knitted component. Further method 500 may include securing the knitted component 140 to one or more sole structures, such as an insole or sockliner, a midsole, and/or an outsole. Examples of such components that may be incorporated at step 520 are described herein with respect to footwear 100. The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting.

Clause 1: An article of footwear having an upper comprising: a knitted component comprising: one or more first zones with a plurality of courses knit with a first yarn and a tensile element having a greater tenacity compared to the first yarn, wherein within the one or more first zones, the tensile element is knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence, wherein the sequence is repeated multiple times along each course within the plurality of courses, one or more second zones lacking tensile elements knit with the sequence.

Clause 2: The article of footwear of clause 1, wherein the tensile element has a greater diameter than the first yarn.

Clause 3: The article of footwear of clause 1, wherein the one or more first zones form midfoot regions on a lateral side and/or a medial side of the upper.

Clause 4: The article of footwear of any of clauses 1-3, wherein the one or more first zones form a heel region of the upper.

Clause 5: The article of footwear of any of clauses 1-4, wherein each course within the one or more first zones includes the tensile element knit with the sequence.

Clause 6: The article of footwear of any of clauses 1-5, wherein the one or more first zones are integrally knit with the one or more second zones so as to have a seamless transition between at least a first zone and a second zone.

Clause 7: The article of footwear of any of clauses 1-6, wherein the one or more second zones form a central portion of a forefoot region of the upper.

Clause 8: The article of footwear of any of clauses 1-7, wherein the one or more first zones form lateral and medial portions of the forefoot region.

Clause 9: The article of footwear of any of clauses 1-8, wherein the plurality of courses each extend from an outer perimeter of the knitted component to a throat area of the upper.

Clause 10: The article of footwear of any of clauses 1-9, wherein courses within the plurality of courses are adjacent courses.

Clause 11: An article of footwear having an upper comprising: a knitted component having a plurality of courses knit with a first yarn and a tensile element having a greater tenacity than the first yarn, wherein, within the plurality of courses, the tensile element is knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence, the quantity of wales being at least 3 wales and no greater than 8 wales, wherein the sequence is repeated multiple times along each course within the plurality of courses.

Clause 12: The article of footwear of clause 11, wherein the quantity of wales is 5 and the quantity of knitted loop stitches is 1.

Clause 13: The article of footwear of clause 11, wherein the quantity of wales is 4 and the quantity of knitted loop stitches is 1.

Clause 14: The article of footwear of any of clauses 11-13, wherein the tensile element is knit with the sequence in courses in a heel region of the upper and a midfoot region of the upper on a lateral side and a medial side.

Clause 15: The article of footwear of any of clauses 11-14, wherein the tensile element is knit with the sequence in each course within the heel region and the midfoot region.

Clause 16: The article of footwear of any of clauses 11-15, wherein the sequence is repeated at least 5 times within at least one course within the plurality of courses.

Clause 17: The article of footwear of any of clauses 11-16, wherein the tensile element is knit without floats in an area adjacent an outer perimeter of the knitted component and in an area adjacent the inner perimeter of the knitted component.

Clause 18: A method of manufacturing an article of footwear comprising: knitting a plurality of courses with a first yarn and a tensile element having at least one of a greater diameter and greater tenacity compared to the first yarn, the plurality of courses forming midfoot regions on a lateral side and/or a medial side of the upper, wherein knitting the plurality of courses includes knitting the tensile element with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence and repeating the sequence multiple times along each course within the plurality of courses.

Clause 19: The method of manufacturing an article of footwear of clause 18, wherein the plurality of courses also form a heel region of the upper.

Clause 20: The method of manufacturing an article of footwear of any of clauses 18-19, where the quantity of wales is at least 3 wales and no greater than 8 wales.

Clause 21: An article of footwear having an upper comprising: a knitted component comprising radially-extending courses extending from an outer perimeter towards a throat area; the radially-extending courses forming: one or more first zones with radially-extending courses knit with a first yarn and a tensile element having a greater tenacity compared to the first yarn, wherein within the one or more first zones, the tensile element is knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence, wherein the sequence is repeated multiple times along each course within the plurality of courses, one or more second zones with radially-extending courses and lacking tensile elements knit with the sequence.

Clause 22: The article of footwear of clause 21, wherein the tensile element has a greater diameter than the first yarn.

Clause 23: The article of footwear of any of clauses 21-22, wherein the one or more first zones form midfoot regions on a lateral side and/or a medial side of the upper.

Clause 24: The article of footwear of any of clauses 21-23, wherein the one or more first zones form a heel region of the upper.

Clause 25: The article of footwear of any of clauses 21-24, wherein each course within the one or more first zones includes the tensile element knit with the sequence.

Clause 26: The article of footwear of any of clauses 21-25, wherein the one or more first zones are integrally knit with the one or more second zones so as to have a seamless transition between at least a first zone and a second zone.

Clause 27: The article of footwear of any of clauses 21-26, wherein the one or more second zones form a central portion of a forefoot region of the upper.

Clause 28: The article of footwear of any of clauses 21-27, wherein the one or more first zones form lateral and medial portions of the forefoot region.

Clause 29: The article of footwear of any of clauses 21-28, wherein the one or more first zones extend along the entire lengths of a heel region and a midfoot region.

Clause 30: The article of footwear of any of clauses 21-29, wherein radially-extending courses form a plurality of wedged-shaped portions in at least a forefoot region and a midfoot region.

Clause 31: The article of footwear of any of clauses 21-30, wherein radially-extending courses of the one or more first zones knit with at least the tensile element in the sequence are consecutive with one another.

In accordance with use herein, a recitation of “and/or” with respect to two or more elements should be interpreted to mean only one element, or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

This detailed description is provided in order to meet statutory requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways, to include different steps, different combinations of steps, different elements, and/or different combinations of elements, similar or equivalent to those described in this disclosure, and in conjunction with other present or future technologies. The examples herein are intended in all respects to be illustrative rather than restrictive. In this sense, alternative examples or implementations can become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof.

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

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM

Provisional Applications (1)