Patent Application
20250098810
Conventional articles of footwear generally include two primary elements, an upper and a sole structure. The upper, which may be made of one or more knit elements, is secured to the sole structure and forms a void on the interior of the footwear for securely receiving a foot.
The present disclosure describes an upper for a shoe that includes a knit element and an inlaid yarn. The knit element defines an edge of the tongue opening of the upper. The inlaid yarn is inlaid within a first course of the knit element that runs parallel to the edge of the tongue opening. In examples, the first course runs parallel to the medial edge of the tongue opening of the upper, so that it is substantially parallel to the heel-toe axis of the shoe. In other words, the machine direction of the knitting process is in the medial-lateral direction, and not the heel-toe direction. This is perpendicular to the conventional machine direction and allows for a designer to take advantage of the different aesthetic possibilities that this disclosure enables.
In examples, the inlaid yarn has both ends exiting the course through the same course opening. The inlaid yarn is bent within the course so that it is doubled over within the course. In some examples, the course opening is near the toe of the shoe. This allows both ends of the inlaid yarn to be anchored to the sole structure to provide tension resistance to forces experienced by the shoe when a wearer tightens the laces of the shoe, while minimizing the number of points along the perimeter of the knitted element of the upper that need to reach the biteline of the shoe. This allows for greater flexibility in the design of the shoe and the knitted element. For example, the knit element can be combined with other components to form the upper, with portions of the other components defining the perimeter of the upper along the biteline instead of the knitted element. In examples, a first and second knitted element, each with an inlaid yarn, are used on either side (medial and lateral) of the upper and attached to additional knitted components that collectively define the void of the shoe.
In examples, the inlaid yarn can exit and reenter the course of the knitted element along one or more points along the length of the first course. The inlaid yarn can be formed into one or more loops through which a lace or laces can be passed through. Using the loops to provide anchor points for the laces instead of separate eyelets reduces the number of parts needed to assemble the shoe and allows the inlaid yarn to provide direct tensile support in response to the tension caused by the laces, and further provides a different visual aesthetic to the shoe. Using the loops as lace apertures can also be used in combination with conventional eyelets and eyestays, with each loop capable of being positioned on either the interior or exterior side of the eyestay.
In another example, an embroidering strand can be embroidered along the course encasing the inlaid yarn. The embroidering strand further anchors the inlaid yarn into place, preventing distortion of the length of the loops.
This disclosure is related to a knitted component of an upper for a shoe. In at least some examples, the knitted component includes an inlaid strand that runs through a course of the knitted component that runs in a toe-heel direction. Along at least one portion of the course, a segment of the inlaid strand is exposed, and may extend out of the course in the form of a loop through which the laces of the shoe's lacing system can be threaded. The inlaid strand has sufficient tensile strength to allow the laces to be tightened without damaging the strand or other parts of the knitted component.
Conventional articles of footwear generally include two primary elements, an upper and a sole structure. The upper, which may be formed using one or more knit elements, is secured to the sole structure and forms a void on the interior of the footwear for securely receiving a foot. The knit element or elements of the upper typically include a yarn that is knitted to form a plurality of loops defining courses and wales.
The present disclosure further advances sustainability by using the inlaid strand itself as the lace apertures through which the laces can be threaded. The inlaid strand may be formed of a strong and durable material, and can optionally be treated to provide additional strength, durability, or other desired features (e.g., waterproofing, abrasion resistance, etc.). This simplifies manufacturing and reduces costs. A conventional eyelet or eyelets can still be used in combination with the loops. The inlaid strand loops can also offer a different aesthetic to the shoe with respect to their appearance (e.g., color, texture, etc.) and positioning (on the interior or exterior of the knitted component).
In examples, the inlaid yarn has both ends exiting the course through the same course opening. The inlaid yarn is bent within the course so that it is doubled over within the course. In examples, the course opening is near the toe of the shoe. This allows both ends of the inlaid yarn to be anchored to the sole structure to provide tension resistance to forces experienced by the shoe when a wearer tightens the laces of the shoe, while minimizing the number of points along the perimeter of the knitted element of the upper that need to reach the biteline of the shoe. This allows for greater flexibility in the design of the shoe and the knitted element. For example, the knit element can be combined with other components to form the upper, with portions of the other components defining at least part of the perimeter of the upper along the biteline instead of the knitted element. In examples, a first and second knitted element, each with an inlaid yarn, are used on either side (medial and lateral) of the upper and attached to additional knitted components that collectively define the void of the shoe.
In examples, the inlaid yarn can exit and reenter the course of the knitted element along one or more points along the length of the first course. The inlaid yarn can be formed into one or more loops through which a lace or laces can be passed through. Using the loops to provide anchor points for the laces instead of separate eyelets reduces the number of parts needed to assemble the shoe and allows the inlaid yarn to provide direct tensile support in response to the tension caused by the laces, and further provides a different visual aesthetic to the shoe.
In another example, an embroidering strand can be embroidered along the course encasing the inlaid yarn. The embroidering strand further anchors the inlaid yarn into place, preventing distortion of the length of the loops.
By using the inlaid strand to form the loops that are then locked by the embroidering strand, the tension applied by the laces is “absorbed” through the inlaid strand that is anchored near the toe. This reduces the stresses experienced by the rest of the upper, which in turn reduces the minimum strength/resilience/flexibility requirements of one or more other sections of the upper, allowing for more flexibility in selecting the materials, configurations, and knit structures for the rest of the upper.
In at least some examples, the knit element is knit with a yarn formed from recycled leather, which may be referred to herein as scrap leather yarn (SLY), which increases sustainability of the upper. The inlaid yarns described herein may help to provide strength to compensate for any decrease in tensile strength associated with recycled materials such as SLY.
The term “outer-facing surface” as used herein means a surface of the knitted upper or article of footwear that faces the external environment. In some examples, the outer-facing surface may mean the outermost-facing surface of the knitted upper or article of footwear. The term “inner-facing surface” as used herein means a surface of the knitted upper or article of footwear that faces a void for receiving the wearer's foot. In some examples, the inner-facing surface may mean the innermost-facing surface of the knitted upper or article of footwear.
The term “knit” such as is used herein to describe the 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 (also known as interlooping) 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, 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 “course-wise direction” refers to a direction that is parallel to the knit courses of the textile piece. 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 “wale-wise direction” refers to a direction that is parallel to the knit wales of the textile piece.
The term “integrally knit,” as used herein, may mean a knit textile having a yarn from one or more knit courses in a first area being interlooped with one or more knit courses of another area. 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 such that they seamlessly extend from one another. In some cases, the term is used to describe two layers covering the same area, where those two layers are interconnected through a common yarn forming at least part of a course on one layer and moving to form part of a course on the other layer, a yarn extending between and forming at least some of each of the two layers, and/or yarns from each layer being formed using overlapping sets of needles on a needle bed at the same time such that the yarns of each layer may be intertwined even if they do not interloop one another. In these cases, the two layers are integrally knit in that they are connected at one or more locations through the knitted process and not through stitches, adhesive, or other bonding.
As used herein, the term “eyelet” means a hole in the upper that a lace extends through. The eyelet may be formed integrally with the upper or may be part of a separate component embedded or attached to the upper. The term “eyestay” as used herein means the material of the shoe upper that holds the lace apertures, such as eyelets or loops, in place.
As utilized herein, a knitted component is defined as being formed of a “unitary knit construction” when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures of the knitted component without the need for significant additional manufacturing steps or processes. Although portions of a knitted component may be joined to each other following the knitting process, a knitted component remains formed of a unitary knit construction because it is formed as a one-piece knit element. Moreover, a knitted component remains formed of a unitary knit construction when other elements (e.g., lace or other trim, a tongue, logos, trademarks, placards with care instructions, and material information) are added following the knitting process (or the “post-knitting processing”). In examples, one or more sections of the knitted component can include a plush construction. In other examples, the knitted component can be further shaped after knitting is completed, such as by cutting away one or more portions from a section of the knitted component. As used herein, an “inlaid strand” is a strand that is inlaid within the structure of a knitted component such that the inlaid strand generally extends in an unlooped state along a course formed by knitted loops of one or more other yarns.
Examples of the knitted components described herein may be weft knit on a weft-knitting machine, such as a flat v-bed knitting machine, with inlay feeders capable of inlaying yarns within the knitted component during the knitting process.
As used herein, “about” includes +/−10% of a given value.
An article of footwear 100 in accordance with examples of the disclosure herein is depicted in
For reference purposes, footwear 100 may be divided into three general regions: a forefoot region 101, a midfoot region 102, and a heel region 103. Forefoot region 101 generally includes portions of footwear 100 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 102 generally includes portions of footwear 100 corresponding with an arch area of the foot. Heel region 103 generally corresponds with rear portions of the foot, including the calcaneus bone. Footwear 100 also includes a lateral side 104 and a medial side 105, which extend through each of regions 101-103 and correspond with opposite sides of footwear 100. More particularly, lateral side 104 corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot), and medial side 105 corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Regions 101-103 and sides 104-105 are not intended to demarcate precise areas of footwear 100. Rather, regions 101-103 and sides 104-105 are intended to represent general areas of footwear 100 to aid in the following discussion. In addition to footwear 100, regions 101-103 and sides 104-105 may also be applied to sole structure 110, upper 120, and individual elements thereof.
Sole structure 110 is secured to upper 120 and extends between the foot and the ground when footwear 100 is worn. The primary elements of sole structure 110 are a midsole 111, an outsole 112, and a sockliner 113. Midsole 111 is secured to a lower surface of upper 120 and may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate (EVA) foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further configurations, midsole 111 may incorporate plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motions of the foot. Outsole 112 is secured to a lower surface of midsole 111 and may be formed from a wear-resistant rubber material that is textured to impart traction. Sockliner 113 is located within upper 120 and is positioned to extend under a lower surface of the foot to enhance the comfort of footwear 100. Although this configuration for sole structure 110 provides an example of a sole structure that may be used in connection with upper 120, a variety of other conventional or nonconventional configurations for sole structure 110 may also be utilized. Accordingly, the features of sole structure 110 or any sole structure utilized with upper 120 may vary considerably.
Upper 120 defines a void within footwear 100 for receiving and securing a foot relative to sole structure 110. The void is shaped to accommodate the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Access to the void is provided by an ankle opening 121 located in at least heel region 103. A lace 122 extends through various lace apertures 123 and permits the wearer to modify dimensions of upper 120 to accommodate proportions of the foot. More particularly, lace 122 permits the wearer to tighten upper 120 around the foot, and lace 122 permits the wearer to loosen upper 120 to facilitate entry and removal of the foot from the void (i.e., through ankle opening 121). In addition, upper 120 includes a tongue 124 within a throat opening 131 that extends under lace 122 and lace apertures 123 to enhance the comfort of footwear 100. In some examples, such as the one shown in
Many conventional footwear uppers are formed from multiple material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) that are joined through stitching or bonding, for example. In contrast, a majority of upper 120 is formed from a plurality of knitted components, including medial knitted component 140, lateral knitted component 160, and inner knitted component 400. Inner knitted component 400 may be at least partially covered by the medial knitted component 140 and lateral knitted component 160. In some examples, inner knitted component 400 forms the tongue 124. The upper 120 formed from these knitted components extends through each of regions 101-103, along both lateral side 104 and medial side 105, over forefoot region 101, and around heel region 103. In addition, the knitted components 140, 160, and 400 collectively form portions of both an exterior surface and an opposite interior surface of upper 120. As such, knitted components 140, 160, and 400 define at least a portion of the void within upper 120. In some configurations, one or more of the knitted components 140, 160, and 180 may also extend under the foot. In some examples, a strobel sock (not shown) is secured to one or more of knitted components 140, 160, and 400 and an upper surface of midsole 111, thereby forming a portion of upper 120 that extends under sockliner 113.
Forming an article, such as upper 120, using a combination of knitted components may provide advantages including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. These characteristics may be accomplished by selecting a particular combination of knit structures, by varying the size and tension of the knit structures, by using one or more yarns formed of a particular material (e.g., a polyester material, which is a relatively inelastic material, or a thermoplastic material, which is a relatively elastic material and may be used to form elasticated or elastomeric yarns), by selecting yarns of a particular size (e.g., denier), and/or a combination thereof. Using a multi-part construction of knitted components may also provide desirable aesthetic characteristics by incorporating yarns having different colors, textures, or other visual properties arranged in a particular pattern. The yarns themselves and/or the knit structure formed by one or more of the yarns may be varied at different locations such that the completed upper from the different knitted components may have different properties, as described herein.
Looking again at
Medial knitted component 140 comprises a toe section 511 in the forefoot region 101 and a heel section 513 in the heel region 103. Medial knitted component 140 further comprises a first edge 142 in the forefoot region 101 and midfoot region 102 along the medial side of the throat opening 131 for the tongue 124. In the examples of
A first course 200 runs along the edge of the medial eyestay 141 opposite the first edge 142. In examples, the first course 200 runs in a generally toe-heel direction. Loop sets 310, 320, 330, 340, and 350, formed from exposed portions of an inlaid strand 300, extend out from the first course 200; loop set 350 extends out from the outer-facing surface of the medial knitted component 140, and loop sets 310, 320, 330, and 340 extend out from the inner-facing surface of the medial knitted component 140. A similar set of loop sets 360, 370, 380, and 390 extending out of the lateral knitted component 160 may be seen in
In the example shown in
In some examples, embroidery 250 with an embroidering strand 252 is stitched along the first course 200 on both the inner-facing surface and outer-facing surface of medial knitted component 140. Embroidery 250 may generally run parallel to the first course 200 and/or first edge 142, such that the longitudinal axis of embroidery 250 may extend from adjacent the ankle opening 121 to the forefoot region 101. In some examples, embroidery 250 may include a plurality of longer stitches 251 stitched with the embroidering strand 252 and spaced apart along the length of the embroidery 250 to further prevent slipping of the inlaid strand 300 and loops.
While the example shown in
Medial knitted component 140 further comprises biteline edges 144 and 146, which run along the biteline 130 between the upper 120 and the sole structure 110. In between biteline edges 144 and 146 is a cutout edge 152 that is spaced apart from the biteline 130, exposing the medial wing outer surface 412 of inner knitted component 400. In examples, a trim 153 may be attached to the cutout edge 152. Medial knitted component 140 also comprises a heel counter edge 147 that runs along the heel counter 126 in the heel region 103.
As seen in
A medial knit blank 500 for forming medial knitted component 140 is shown in
The medial knit blank 500 also includes a collar edge 150, a heel edge 148, and a heel counter edge 147, which all correspond with the collar edge 150, heel edge 148, and heel counter edge 147 of the medial knitted component 140. The medial knit blank 500 further includes a lower perimeter edge 502 in between the heel counter edge 147 and the first edge 142. In post-knitting processing, cutout portion 154 may be removed from the knitted component along a portion of the lower perimeter edge 502, resulting in the cutout edge 152 of the medial knitted component 140 being formed. In some examples, when incorporated into the article of footwear 100, the remaining sections of the lower perimeter edge 502 (edges 503 and 504), may be positioned against the upper surface of the sole structure 110 and may be joined to a strobel.
A first course 200 runs along at least a portion of the medial knit blank 500. In some examples, the first course 200 is generally parallel to the first edge 142 and offset from the first edge 142 by a quantity of courses of the medial knit blank 500. In other examples, the first course 200 may run along the first edge 142 or be immediately adjacent to the first edge. In the example shown in
During the knitting of the first course 200, inlaid strand 300 is inlaid into the first course 200. In some examples, a feeder (e.g., a combination feeder) makes a first pass to inlay a first segment of the inlaid strand 300 starting from the end of the first course 200 in the forefoot region 101 of the medial knit blank 500. The feeder then makes a second pass along the same first course 200 to lay a second length of the inlaid strand into the first course 200. In some examples, after the feeder finishes the first inlaying pass but before starting the second, an anchoring stitch is made to secure the inlaid strand into the first course at a bend point 305, so that the first inlaid strand segment remains in place while the feeder makes its second run to inlay the second segment of the inlaid strand. During both inlaying passes, the feeder may feed additional lengths of strand when at certain needle positions, corresponding to the openings in the first course 200 for loop sets 310, 320, 330, 340, and 350, where these additional lengths will be formed into loop sets 310, 320, 330, 340, and 350. At the end of the inlaying, ends 301 and 302 of the inlaid strand 300 extend out of the end of the first course 200 near the forefoot region 101.
After the first course 200 is knit, the remaining portion of the medial knit blank 500 is knit. As described herein above, the medial knit blank 500 may comprise a combination of edges that will be finished edges, while other edges may undergo post-processing steps to form finished edges.
The size of the loop sets 310, 320, 330, 340, and 350 may also be adjusted after the knitting of the medial knit blank 500 is completed. In some examples, the pins of a jig may be inserted into each of the loops, and then each loop is tightened (i.e., shortened) by pulling on one or more other segments of the inlaid strand 300 (e.g., a segment forming an adjacent loop set or one or both of the ends 301 and 302 extending out from the end of the first course 200). An advantage to this method of manufacture is that each loop set may be independently tensioned, loosened, or otherwise adjusted during the manufacturing process of footwear 100. That is, prior to securing the inlaid strand 300 in place within the first course 200, the loop sets may be independently adjusted to the proper size. Once the loop sets 310, 320, 330, 340, and 350 are adjusted to be the correct size, embroidering strand 252 can be stitched along the first course 200 on both the outer-facing surface and inner-facing surface, securing the inlaid strand 300 and loop sets 310, 320, 330, 340, and 350 into place.
As shown in
Although this example includes two loops within each loop set, other examples may include different quantities. For example, each loop set 310, 320, 330, 340, and 350 may include one loop of the inlaid strand 300, such as where the inlaid strand 300 is inlaid only once in the first course 200. In other examples, there may be more than two loops within each loop set 310, 320, 330, 340, and 350, such as through additional passes of the feeder of the inlaid yarn and/or through additional ends of an inlaid yarn.
Lateral knitted component 160 may be formed from a lateral knit blank that may have all the features described with respect to the medial knit blank 500.
The inner knitted component 400 is shown in
Medial knitted component 140, lateral knitted component 160, and inner knitted component 400 are assembled together to form the upper 120. The heel edges 148 and 149 of the medial knitted component 140 and the lateral knitted component 160 are joined to each other. In examples, such as seen in
The multi-piece construction of the upper 120 described herein creates a layered look and construction for upper 120. The multi-piece construction also allows for a combination of material properties to be manifested in the upper 120 of the footwear 100. Accordingly, different materials and knit structures may be chosen for the different portions and layers of the upper based on different factors. For example, materials for the inner layers (e.g., inner knitted component 400) of the upper 120 can be chosen for comfort and breathability, while materials for the outer layers (e.g., medial and lateral knitted components 140 and 160) may be selected based on factors such as appearance and durability.
Knitted components 140, 160, and 400 may incorporate various types of yarn that impart different properties to separate areas of upper 120. That is, one area of a knitted component may be formed from a first type of yarn that imparts a first set of properties, and another area of a knitted component may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout upper 120 by selecting specific yarns for different areas of the knitted components 140, 160, and 200. The properties that a particular type of yarn will impart to an area of a knitted component partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability.
In some examples, a yarn comprising recycled leather, which may be referred to herein as scrap leather yarn (“SLY”), may be used to knit at least the outer-facing surface of medial and lateral knitted components 140 and 160. In some examples, the recycled leather yarn comprises a combination of leather scraps and PET, which may be in the form of recycled PET. In one example, the recycled leather yarn is formed from about 50% leather scraps and about 50% PET (e.g., by weight). In other examples, the recycled leather yarn is formed from about 25% leather scraps and about 75% PET; about 35% leather scraps and about 65% PET; or about 70% leather scraps and about 30% PET. Other ratios of leather scraps and PET (or another material, including another recyclable material) are also contemplated. The leather scraps and the PET can be mixed together before carding and spinning into the recycled leather yarn. The leather scraps can imbue the recycled leather yarn with a soft hand feel and a relatively greater resistance to abrasion compared to a PET yarn without the recycled leather scraps. Moreover, the recycled leather yarn is sustainable since it can be formed from recycled materials (i.e., the leather scraps and, in some examples, the recycled PET). Furthermore, as previously discussed above, one or more of the yarns used to form the upper may comprise a thermoplastic polymer that may be at least partially melted and cooled to fuse different yarns together.
In addition to materials, other examples of the yarns selected for the knitted component 140, 160, and 400 may affect the properties of upper 120. For example, a yarn forming any of knitted components 140, 160, and 400 may be a monofilament yarn or a multifilament yarn. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of upper 120. Accordingly, both the materials forming the yarn and other examples of the yarn may be selected to impart a variety of properties to separate areas of upper 120.
In comparison with the yarn or yarns used to knit the knitted components of upper 120, the inlaid strands, such as inlaid strand 300, may exhibit greater stretch resistance. That is, inlaid strand 300 may stretch less than the rest of upper 120. The inlaid strand 300 may also exhibit greater resistance to breaking under tension than the yarn or yarns used in the rest of the upper 120. The loops and loop sets formed by the inlaid strands thus can be suitable for use as lace apertures 123, which are subject to increased tension during the tightening of lace 122, and once the lace 122 is secured in a tightened state (e.g., by tying the two ends into a knot or securing the ends to the upper 120 or other shoe components). Placing tension upon the lace 122 may impart tension to the inlaid strands, thereby inducing the portions of upper 120 between the throat area and the biteline 130 to lay against the foot more closely. As such, the inlaid strands operate in connection with the lace 122 to enhance the fit of footwear 100.
As with the yarns forming the knitted components 140, 160, and 400, the configuration of the inlaid strands may also vary significantly. In addition to yarn, the inlaid strands may have the configurations of a filament (e.g., a monofilament), thread, rope, webbing, cable, or chain, for example. In comparison with the yarns forming the knitted components, the thickness of inlaid strand 300 may be greater. In some configurations, the inlaid strands may have a significantly greater thickness than the yarns of the knitted components. Although the cross-sectional shape of the inlaid strands may be round, triangular, square, rectangular, elliptical, or irregular shapes may also be utilized. Moreover, the materials forming the inlaid strands may include any of the materials for the yarn within the knitted components, such as cotton, elastane, polyester, rayon, wool, and nylon. As noted above, the inlaid strands may exhibit greater stretch resistance than the knitted components that form upper 120. As such, suitable materials for the inlaid strands may include a variety of engineering filaments that are utilized for high tensile strength applications, including glass, aramids (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene, and liquid crystal polymer. In some examples, a high-tenacity cable comprising polyester and having a tensile strength greater than 5 grams/denier may be used, with the cable having a diameter greater than the yarns used to form the knitted components of the upper 120. As another example, a braided polyester thread may also be utilized as an inlaid strand.
While the non-limiting examples discussed above may include a single strand being inlaid into a knitted component (e.g., a medial or lateral side of an upper), the aspects described herein are not limited to a single strand inlaid within a single course. For example, an upper formed with a knitted component may have a first strand inlaid within a first course, and a second strand inlaid within a second course, and so on, in aspects. The loops of the second inlaid strand may be configured to be used in combination with loops of the first inlaid strand (e.g., a loop of the first strand and a loop of the second strand may overlap or interact to thereby form a common lace aperture), or they may be configured to be used separately (e.g., the loops of the first inlaid strand and the second strand act as separate lace apertures from each other). In some aspects, a second strand may be inlaid within the same course as the first strand, in which the second strand may have a different property (e.g., a different color, diameter, denier, elasticity, texture) and/or can be formed of a different material than the first strand. In some aspects, a loop of the first inlaid strand may extend from one side of the upper around an eyelet or eyestay, and a loop of the second inlaid strand may extend from the other side of the upper around the same eyelet or eyestay. These aspects are provided as examples and other configurations of uppers with knitted components that include multiple strands in common or separate courses are also possible and contemplated herein.
Looking at
The following clauses represent examples 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 examples contemplated herein. The following clauses are examples and are not limiting.
Clause 1. An upper for an article of footwear, the upper comprising: a knitted component comprising a first course and a first edge that at least partially defines a medial side or a lateral side of a throat opening of the upper, and an inlaid strand comprising: an inlaid segment that is inlaid within at least a portion of the first course of the knitted component, and an exposed segment where the inlaid strand exits and reenters the knitted component at least once along the first course.
Clause 2. The upper according to clause 1, wherein the exposed segment is a first exposed segment configured into a first loop extending out from the knitted component.
Clause 3. The upper according to clause 2, wherein the inlaid strand includes a second exposed segment configured into a second loop extending out from the knitted component.
Clause 4. The upper according to clause 3, wherein the knitted component further comprises an edge portion between the first edge and the first course, and the first loop and the second loop are positioned on opposite sides of the edge portion.
Clause 5. The upper according to any of clauses 1 through 4, wherein the inlaid segment is secured within the first course.
Clause 6. The upper according to clause 4, wherein the inlaid strand is secured within the first course via an embroidering strand.
Clause 7. The upper according to any of clauses 1 through 6, wherein the inlaid strand further comprises a bend between the first end and the second end, and the bend is located within the first course.
Clause 8. The upper according to any of clauses 1 through 7, wherein the at least a portion of the first course is substantially parallel to the first edge of the knitted component.
Clause 9. An article of footwear comprising an upper and a sole structure attached to the upper along a biteline, the upper comprising: a knitted component having a first edge that at least partially defines a medial side or a lateral side of a throat opening of the upper, the knitted component having a first course extending in a toe-heel direction, and an inlaid strand comprising an inlaid segment that is inlaid within at least a portion of the first course of the knitted component, the inlaid strand further comprising an exposed segment where the inlaid strand exits and reenters the knitted component at least once along the first course.
Clause 10. The article of footwear according to clause 9, wherein the inlaid strand has a first end and a second end, wherein the first course has a first end opening along the perimeter edge of the knitted element, and the first end and the second end of the inlaid strand exit the first course through the first end opening.
Clause 11. The article of footwear according to clause 10, wherein the first end and the second end of the inlaid strand extend to the biteline.
Clause 12. The article of footwear according to clause 11, wherein the first end and the second end of the inlaid strand are secured to the sole structure.
Clause 13. The article of footwear according to any of clauses 9 through 12, wherein the knitted component is a first knitted component and the upper further comprises a tongue comprising a second knitted component attached to the first knitted component.
Clause 14. The article of footwear according to clause 13, further comprising a third knitted component attached to the second knitted component, wherein the first edge of the first knitted component defines the medial side of the throat opening and the third knitted component comprises a second edge that defines the lateral side of the throat opening, the third knitted component further comprising a second course and a second inlaid strand inlaid within at least a portion of the second course.
Clause 15. A method of forming a knitted component of an upper for an article of footwear, comprising the steps of: knitting a plurality of courses together to form at least part of the knitted component that defines at least one of a medial edge or a lateral edge of a tongue opening of the upper, including at least a first course; and during the knitting step, inlaying a first inlaid segment of an inlaid strand within the first course so that the inlaid strand further comprises a first exposed segment where the inlaid strand exits and reenters the knitted component at least once along the first course.
Clause 16. The method according to clause 15, wherein the inlaying step further comprises the step of inlaying a second inlaid segment of the inlaid strand alongside the first inlaid segment within the first course.
Clause 17. The method according to clause 15 or 16, further comprising the step of arranging the first exposed portion of the inlaid strand into a first loop positioned outside the first course.
Clause 18. The method according to clause 17, further comprising the step of shrinking the first loop by pulling on the inlaid strand after knitting.
Clause 19. The method according to clause 18, further comprising the step of arranging a second exposed segment of the inlaid strand into a second loop positioned outside the first course.
Clause 20. The method according to any of clauses 15 through 19, further comprising the step of stitching an embroidery strand along an exterior of the first course to secure the first inlaid segment within the first course.
The subject matter of the present disclosure is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.
This non-provisional patent application claims priority to co-pending U.S. provisional patent app. No. 63/540,810, filed on Sep. 27, 2023, and titled “Footwear Upper With Inlaid Strand Lace Apertures,” the contents of which is incorporated herein by reference in the entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63540810 | Sep 2023 | US |
