Patent Application
20150223552
This application is related to and claims priority benefits from German Patent Application No. DE 10 2014 202 432.3, filed on Feb. 11, 2014, entitled IMPROVED SOCCER SHOE (“the '432 application”). The '432 application is hereby incorporated herein in its entirety by this reference.
The present invention relates to a shoe, in particular a soccer shoe.
A number of requirements are imposed on a soccer shoe, such as that the soccer shoe should be light, adjust to a wearer's foot in an optimal manner, and provide good control of the ball for the soccer player. While a lower-weight soccer shoe is of particularly great importance during fast sprints, a heavy soccer shoe is also impedimental and detrimental to precision when shooting a soccer ball. A soccer shoe that is well-adjusted to the shape of the foot provides the soccer player with the necessary support on the one hand and enables precise transmission of force to the ball during shooting on the other hand. Good control of the ball is especially important during technically ambitious play, such as e.g. dribbling. Soccer players for whom precisely guiding the ball has priority, such as midfielders, prefer soccer shoes that allow the most direct and immediate contact possible with the ball.
These varied requirements imposed on a soccer shoe can be difficult to realize simultaneously. For example, reduction of a soccer shoe's weight usually results in the soccer shoe providing the soccer player with less support since the lighter weight is typically achieved by dispensing with material that would otherwise support the foot and ensure a firm coupling of the soccer shoe to the foot. In addition, allowing the most direct and immediate contact with the ball possible for the soccer player is typically realized by a correspondingly thin material of the shoe upper, which is detrimental to stability and a firm fit. Thus, there is tension between the various requirements imposed on a soccer shoe, which means that the known solutions to date typically meet certain requirements, but tend to disregard other requirements.
For example, a cleat shoe described in US 2011/0308108 A1 comprises an inner layer and an outer layer. Fasteners in the form of ribbons are mounted between the inner layer and the outer layer in order to fix the shoe to the foot. The shoe provides sufficient support to the foot of a wearer, but it is cumbersome to handle, heavy and, due to the inner layer, outer layer, and the fasteners being arranged on top of each other, it does not allow a good feel for the ball.
Similar disadvantages can be found in the soccer shoe described in DE 10 2010 037 585 A1, which consists of an inner section and an outer section. The inner section meets the essential requirements, such as stability for the foot, protection for vulnerable areas of the foot, cushioning of the footbed, as well as contact properties with the ball, and the outer section ensures the carrying function for the sole portion and the cleat connection. However, shoe is heavy and cumbersome to handle.
The present invention therefore has the aim of providing a soccer shoe which is light, provides sufficient support to a wearer, and allows good control of the ball.
The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.
According to certain embodiments of the present invention, a soccer shoe comprises an upper comprising knitwear, and a sole comprising cleats, wherein the sole is connected to the knitwear, and the knitwear is configured to couple the sole to a foot of a wearer when the soccer shoe is worn. In some embodiments, the sole is a rigid sole.
The knitwear may be configured to extend above an ankle of the wearer when the soccer shoe is worn. In certain embodiments, the knitwear comprises more than one weft-knitted or warp-knitted sections. The knitwear may also be formed as one-piece knitwear. In some embodiments, the knitwear substantially encloses the foot of the wearer when the soccer shoe is worn. The knitwear may be weft-knitted and/or may be warp-knitted.
In some embodiments, the soccer shoe does not comprise a separate tongue in an area of an instep and/or the soccer shoe does not comprise laces.
According to certain embodiments of the present invention, a soccer shoe comprises an upper comprising knitwear, wherein the knitwear comprises a first and a second weft-knitted or warp-knitted layers, and a sole comprising cleats, wherein the sole is connected to the knitwear, and the knitwear is configured to couple the sole to a foot of a wearer when the soccer shoe is worn.
In some embodiments, a reinforcement is arranged between the first and the second weft-knitted or warp-knitted layers. The reinforcement may be made from plastic and/or may be arranged in at least one of a lateral area and a medial area of the upper.
In certain embodiments, the knitwear is coated, such that friction between a soccer ball and the coated knitwear is increased compared to friction between the soccer ball and uncoated knitwear.
According to some embodiments, the upper does not comprise a securing element. The upper may be configured to overlap a section of a shin guard when the soccer shoe is worn.
In some embodiments, the knitwear is made on a flat weft-knitting or warp-knitting machine. In additional embodiments, the knitwear is made on a circular weft-knitting or warp-knitting machine. The knitwear may be reinforced with a polymer reinforcement.
In certain embodiments, the upper is configured to connect to a shin guard or a soccer sock.
According to certain embodiments, a method of manufacturing a soccer shoe comprises providing the sole, weft-knitting or warp-knitting the knitwear for the upper, such that the knitwear is configured to couple the sole to a foot of a wearer when the soccer shoe is worn, and connecting the sole to the upper.
In certain embodiments, the sole is a rigid sole. The knitwear may be weft-knitted or warp-knitted and configured to extend above an ankle of the wearer when the soccer shoe is worn.
In some embodiments, the weft-knitting or warp-knitting of the knitwear further comprises weft-knitting or warp-knitting multiple weft-knitted or warp-knitted sections, and joining the multiple weft-knitted or warp-knitted section to form the knitwear.
In the following detailed description, embodiments of the invention are described referring to the following figures:
a is a schematic representation of textile structures, according to certain embodiments of the present invention.
b is a schematic representation of a weft-knitted fabric with a filler yarn, according to certain embodiments of the present invention.
a is a side view of a shoe upper with two connected textile areas, according to certain embodiments of the present invention.
b is a side view of a shoe upper with two connected textile areas, according to certain embodiments of the present invention.
a-6c are cross-sectional views of an upper connected to a shoe sole via adhesive tape, according to certain embodiments of the present invention.
a is a medial view of a soccer shoe, according to certain embodiments of the present invention.
b is a lateral view of the soccer shoe of
a-14b are lateral and medial views, respectively, of a soccer shoe, according to certain embodiments of the present invention.
a-15f are views of a soccer shoe, according to certain embodiments of the present invention.
a-16d are views of a soccer shoe, according to certain embodiments of the present invention.
a-17b are views of a soccer shoe, according to certain embodiments of the present invention.
a-18b are views of a soccer shoe, according to certain embodiments of the present invention.
a-19c are views of a soccer shoe, according to certain embodiments of the present invention.
According to a first aspect of the present invention, this aim is achieved by a soccer shoe which comprises a shoe upper comprising knitwear and a rigid sole which comprises cleats and is connected to the knitwear, wherein the knitwear is capable of coupling the sole to a foot of a wearer of the soccer shoe while the soccer shoe is being worn.
By the soccer shoe according to the invention comprising a shoe upper which comprises knitwear, the material of the shoe upper is sufficiently thin for providing direct and immediate contact to a soccer ball. The wearer of the soccer shoe in accordance with the invention thus has good control of the ball, which may be beneficial when dribbling or shooting, for example. Moreover, knitwear comprises a certain level of stretchability so that the shoe upper may optimally adjust to the shape of the foot and provides the wearer with the necessary support.
The knitwear of the shoe upper is furthermore suitable for coupling the sole of the soccer shoe to the foot of a wearer of the soccer shoe while it is being worn. In this way, the sole is tightly connected to the foot so that twisting of the foot is avoided or at least reduced. The knitwear essentially, i.e. more than 50% of the required forces, causes the sole to be fixed under the foot of the wearer and to hold it in its position.
Thus, by knitwear being used in the shoe upper for coupling the sole to the foot, the soccer shoe is very light on the one hand while providing the foot with the necessary stability due to an optimal fit on the other hand. The knitwear may generally also be arranged only on the outside of the shoe upper, only on the inside of the shoe upper, or both on the inside and on the outside. The inside is the side of the shoe upper facing the foot. The outside is the side of the shoe upper facing away from the foot.
The sole of the shoe according to certain embodiments of the invention comprises sufficient rigidity to transmit forces between the foot and the ground, which occur during playing soccer on grass, artificial turf, or indoor.
Cleats are understood as any type of bump on the sole that is capable of increasing the traction of the sole with the ground, for example grass or artificial turf. The cleats comprise such a hardness that they press into the ground, e.g. grass or artificial turf, to some degree under the weight of a soccer player.
In certain embodiments of the invention, the sole is a rigid sole. A rigid sole provides a soccer player sufficient support and provides good transmission of forces between a foot of the player and the ground, especially on grass and artificial turf.
In additional embodiments of the invention, the knitwear is capable of extending above an ankle of the foot while the soccer shoe is being worn. Due to this, the sole of the soccer shoe may be coupled to the foot very tightly, since the contact area of the knitwear with the foot is correspondingly large. Moreover, the “taping” necessary among soccer players, i.e. wrapping the ankle area in ribbons, may not be necessary. This is because the knitwear extending above the ankle protects the ankle from injuries, while also ensuring a smooth transition from the soccer shoe to a shin guard and/or soccer socks on the other hand. The knitwear may be suitable for extending all the way to a knee while the soccer shoe is being worn.
In further embodiments of the invention, the knitwear consists of several weft-knitted or warp-knitted sections. This enables use of knitwear only in areas that are necessary for safely coupling the sole of the soccer shoe to the foot. Other materials may be used in other areas. Moreover, individual knitwear sections may be manufactured on a flat weft-knitting machine or a flat warp-knitting machine and then connected in order to obtain a three-dimensional shape.
In alternative embodiments of the invention, the knitwear may be formed as one-piece knitwear. One-piece knitwear may simply and cost-effectively be weft-knitted or warp-knitted on a corresponding machine. Since seams can be omitted, pressure sores may be reduced or avoided.
In further embodiments of the invention, the sole of the soccer shoe comprises knitwear. In additional embodiments, the sole and the knitwear are formed as one-piece knitwear. In this case, the soccer shoe may be produced in one piece on a corresponding weft-knitting or warp-knitting machine.
In some embodiments, knitwear encloses a foot of a wearer of the soccer shoe substantially completely. This ensures a firm coupling of the sole of the soccer shoe to the foot by the knitwear. The soccer shoe provides the foot with a high degree of stability.
In further embodiments of the invention, the knitwear is weft-knitted. Weft-knitted knitwear may be simply and specifically provided with functional properties. Weft-knitted knitwear may, for example, be weft-knitted in a more open-meshed manner in places where the most humidity occurs on the foot so as to specifically better air the foot in these places. The knitwear may be flat weft-knitted or circular weft-knitted.
In additional embodiments of the invention, the knitwear is warp-knitted. By machine warp-knitting, the knitwear may be produced relatively rapidly and cost-effectively. The knitwear may be either flat warp-knitted or circular warp-knitted.
The knitwear may be formed to fulfil the function of a tongue in the area of the instep. In this manner, separately forming the tongue may be omitted so that the manufacture of the soccer shoe is simplified. Moreover, pressure sores are reduced or prevented since the otherwise common discontinuous transition between the tongue and the shoe upper is omitted.
In certain embodiments, the knitwear is formed to fulfil the function of laces. Thus, laces may be omitted, which simplifies the handling of the soccer shoe, as well as its manufacture.
The sole may be injection molded to the shoe upper. This enables a simple manufacture of the soccer shoe, since the work step of connecting the sole to the shoe upper is omitted. In further embodiments, the sole is injection molded directly to the knitwear. This ensures a firm coupling of the sole to a foot of a wearer of the soccer shoe. In certain embodiments, polyurethane (“PU”), thermoplastic polyurethane (“TPU”) or polyamides (“PA”) are used for injection molding the sole to the shoe upper.
In alternative embodiments of the invention, the sole is glued to the shoe upper. For example, the sole may be manufactured by injection molding and may be subsequently glued to the shoe upper. Suitable materials for manufacturing the sole are rubber, ethylene vinyl acetate (“EVA”), or expanded thermoplastic polyurethane (“eTPU”).
In certain embodiments of the invention, the knitwear of the upper comprises a first and a second weft-knitted or warp-knitted layer. In this way, the material thickness of the shoe upper may be specifically varied.
A reinforcement may be arranged between the first and the second weft-knit or warp-knit layer. The reinforcement may simply be placed between the first and the second layer. In this manner, the soccer shoe may be cost-effectively reinforced in specific places, for example in the toe region or the heel region or in both areas. The reinforcement may be generally manufactured from any desired material which is suitable for structural reinforcement like e.g. a fibrous web or a textile. The reinforcement may also be arranged in a shin area of the shoe upper. In this way, a separate shin guard may be omitted.
The reinforcement may be made from plastic. Reinforcements made from plastic are simple and cost-effective to manufacture by corresponding methods, such as injection molding. Suitable plastics are PU, polyethylene, polypropylene, and EVA, for example. These may be used e.g. as a sheet for reinforcement. Alternatively, the reinforcement is a non-woven made from the mentioned plastics. The sheet or the non-woven may be applied to an inner side or an outer side of the soccer shoe.
The reinforcement may be arranged in a lateral area or in a medial area or in a lateral and a medial area of the upper. In this way, the soccer shoe may specifically be reinforced in areas in which it comes into contact with the ball. At the same time, however, the reinforcement may be formed in a sufficiently thin manner, e.g. as a plastic sheet, so as not to considerably restrict the feel for the ball.
In certain embodiments of the invention, the shoe upper does not comprise a securing element. Dispensing with a securing element, such as laces, for example, enables a more cost-effective manufacture of the soccer shoe. In general, using knitwear allows for such an accurately fitting manufacture that a securing element may be omitted.
The knitwear may be coated, such that the friction between a soccer ball and the knitwear is increased compared to uncoated knitwear. This allows for the ball to be played precisely. Moreover, the soccer player is able to provide the ball with a spin, which is referred to as swerve, so as to cause a bent trajectory.
The upper may comprise such a height that the upper edge of the upper overlaps a section of a shin guard while the soccer shoe is being worn. A smooth transition may thus be created between the shin guard and the soccer shoe. “Taping” the ankle area, as was mentioned before, may be omitted.
In certain embodiments of the invention, the knitwear is made on a flat weft-knitting machine or a flat warp-knitting machine. The knitwear may be manufactured simply and cost-effectively on a flat weft-knitting machine or a flat warp-knitting machine.
In alternative embodiments of the invention, the knitwear is made on a circular weft-knitting machine or a circular warp-knitting machine. Knitwear manufactured on circular weft-knitting machines or circular warp-knitting machines already has a tube-like shape and is therefore easier to adjust to the shape of a cobbler's last and thus to the shape of the foot.
In certain embodiments of the invention, the upper comprises a coupling mechanism to connect the upper to a shin guard or a soccer sock. This further increases the coupling of the sole of the soccer shoe to the foot.
The coupling mechanism may be a hook-and-loop fastener. A hook-and-loop fastener is easy to attach to the shoe upper or the soccer sock, e.g. by sewing, and it is very easy to handle.
The knitwear may be reinforced with a polymer reinforcement. The knitwear may be provided with a polymer reinforcement, e.g. by the latter being applied as a coating.
Further aspects of the present invention relate to a method of manufacturing a soccer shoe as described above, the method comprising: providing the sole; weft-knitting or warp-knitting the knitwear for the upper, such that the knitwear is capable of coupling the sole to a foot of a wearer of the soccer shoe during wearing the soccer shoe; and connecting the sole to the upper.
In certain embodiments, the sole provided is a rigid sole. A rigid sole provides a soccer player sufficient support and provides good transmission of forces between a foot of the player and the ground, especially on grass and artificial turf.
The knitwear may be weft-knitted or warp-knitted such that the knitwear is capable of extending above an ankle of a foot while the soccer shoe is being worn. Due to this, the sole of the soccer shoe may be coupled to the foot very tightly, since the contact area of the knitwear with the foot is correspondingly large. Moreover, the aforementioned “taping” may be omitted. This is because on the one hand, the knitwear extending above the ankle protects the ankle from injuries on the one hand while ensuring a smooth transition from the soccer shoe to a shin guard and/or soccer socks on the other hand.
The weft-knitting or warp-knitting of the knitwear may further comprise: weft-knitting or warp-knitting multiple weft-knitted or warp-knitted sections; and joining the multiple weft-knitted or warp-knitted sections to form the knitwear. This enables use of knitwear only in areas that are necessary for safely coupling the sole of the soccer shoe to the foot. Other materials may be used in other areas. Moreover, individual knitwear sections may be manufactured on a flat weft-knitting machine or a flat warp-knitting machine and connected then in order to obtain a three-dimensional shape.
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
Embodiments and variations of the present invention will be described in more detail below.
The use of knitwear allows products such as a shoe upper or a sole of a shoe, such as an insole, strobel sole, midsole and/or outer sole to be equipped with areas having different characteristics and providing different functions with low production effort. The properties include bendability, stretchability (expressed as Young's modulus, for example), permeability to air and water, thermoconductivity, thermal capacity, moisture absorption, static friction, abrasion resistance, hardness, and thickness, for example.
Various techniques are applied in order to achieve such characteristics or functions, which will be described in the following. Such suitable techniques in manufacturing knitwear include knitting techniques, the selection of fibers and yarns, coating the fibers, yarns or knitwear with polymer or other materials, the use of monofilaments, the combination of monofilaments and polymer coating, the application of fused/melted yarns, and multi-layer textile material. In general, the yarns used for the manufacture of knitwear may be equipped, i.e. coated accordingly. In addition or alternatively, the finished knitwear may be equipped accordingly.
Another aspect of providing functions concerns the specific use of knitwear for certain areas of a product, for example of a shoe upper or a sole, and the connection of different parts by suitable connection techniques. The mentioned aspects and techniques as well as other aspects and techniques will be explained in the following.
The described techniques may be used individually or may be combined in any manner.
Knitwear used in the present invention is divided into weft-knitted fabrics and single-thread warp-knitted fabrics on the one hand and warp-knitted fabrics on the other hand. The distinctive characteristic of knitwear is that it is formed of interlocking yarn or thread loops. These thread loops are also referred to as stitches and may be formed of one or several yarns or threads.
Yarn or thread are terms for a structure of one or several fibers which is long in relation to its diameter. A fiber is a flexible structure which is rather thin in relation to its length. Very long fibers, of virtually unlimited length with regard to their use, are referred to as filaments. Monofilaments are yarns formed of one single filament, that is, one single fiber.
In weft-knitted fabrics and single-thread warp-knitted fabrics, the stitch formation requires at least one thread or yarn, with the thread running in longitudinal direction of the product, i.e. substantially at a right angle to the direction in which the product is made during the manufacturing process. In warp-knitted fabrics, the stitch formation requires at least one warp sheet, i.e. a plurality of so-called warps. These stitch-forming threads run in longitudinal direction, i.e. substantially in the direction in which the product is made during the manufacturing process.
a shows the basic difference between woven fabrics 10, weft-knitted fabrics 11 and 12, and warp-knitted fabrics 13. A woven fabric 10 has at least two thread sheets that are usually arranged at a right angle to one another. In this regard, the threads are placed above or underneath each other and do not form stitches. Weft-knitted fabrics 11 and 12 are created by knitting with one thread from the left to the right by interlocking stitches. View 11 shows a front view (also referred to as the front loop fabric side) and view 12 a back view (also referred to as the back loop fabric side) of a weft-knitted fabric 11, 12. The front loop and back loop product sides differ in the run of the legs 14. On the back loop fabric side 12, the legs 14 are covered in contrast to the front loop fabric side 11.
Certain embodiments of a weft-knitted fabric that may be used for the present invention with a filler yarn 15 is shown in
Warp-knitted fabric 13 is created by warp-knitting with many threads from top down, as shown in
By way of example, the interlaces tricot 21, 2×1 plain 22, and atlas 23 are shown in
Stitches arranged above each other with joint binding sites are referred to as wales.
Three basic weft-knitted structures are known in weft-knitted fabrics, which may be recognized by the run of the stitches along a wale. With plain, single Jersey, only back loops may be recognized along a wale on one side of the fabric and only back loops may be recognized along the other side of the product. This structure is created on one row of needles of a knitting machine, i.e. an arrangement of neighboring knitting needles, and also referred to as single Jersey. With rib fabric, front and back loops alternate within a course, i.e. either only front or back loops may be found along a wale, depending on the side of the product from which the wale is considered. This structure is created on two rows of needles with needles offset opposite each other. With purl fabric, front and back loops alternate in one wale. Both sides of the product look the same. This structure is manufactured using latch needles as illustrated in
In many embodiments, a variety of structures and surfaces that may be created with knitwear, which may or may not also be possible with weaving. It is possible to manufacture both very heavy and/or stiff knitwear and very soft, transparent and/or stretchable knitwear with substantially the same manufacturing technique. The parameters by which the properties of the material may be influenced substantially are the pattern of weft-knitting or warp-knitting, respectively, the used yarn, the needle size or the needle distance, and the tensile strain subject to which the yarn is placed on the needles.
In certain embodiments of weft-knitting, yarns may be weft-knitted in at freely selectable places. In this manner, selected zones may be provided with certain properties. For example, the shoe upper for the soccer shoe according to certain embodiments of the invention may be provided with zones made from rubberized yarn in order to achieve higher static friction and thus enable the player to better control the ball. By certain yarns being weft-knitted in at selected places, no additional elements have to be applied.
Knitted fabrics are manufactured on machines in the industrial context. These machines usually comprise a plurality of needles. In weft-knitting, latch needles 41 are usually used, which may comprise a moveable latch 42, as illustrated in
A differentiation is made between flat-knitting and circular-knitting machines. In flat-knitting machines, a thread feeder feeds the thread back and forth along a row of needles. In a circular-knitting machine, the needles are arranged in a circular manner and the thread feeding correspondingly takes place in a circular movement along one or more round rows of needles.
Instead of a single row of needles, it is also possible for a knitting machine to comprise two parallel rows of needles. When looked at from the side, the needles of the two rows of needles may, for example, be opposite each other at a right angle. This enables the manufacture of more elaborate structures or weaves. The use of two rows of needles allows the manufacture of a one-layered or two-layered weft-knitted fabric. A one-layered weft-knitted fabric is created when the stitches generated on the first row of needles are enmeshed with the stitches generated on the second row of needles. Accordingly, a two-layered weft-knitted fabric is created when the stitches generate on the first row of needles are not or only selectively enmeshed with the stitches generated on the second row of needles and/or if they are merely enmeshed at the end of the weft-knitted fabric. If the stitches generated on the first row of needles are loosely enmeshed only selectively with the stitches generated on the second row of needles by an additional yarn, this is also referred to as spacer weft-knitted fabric. The additional yarn, for example a monofilament, is thus guided back and forth between two layers, so that a distance between the two layers is created. The two layers may e.g. be connected to each other via so-called handles.
Generally, the following weft-knitted fabrics may thus be manufactured on a weft-knitting machine: If only one row of needles is used, a one-layered weft-knitted fabric may be created. When two rows of needles are used, the stitches of both rows of needles may consistently be connected to each other so that the resulting knitwear comprises a single layer. If the stitches of both rows of needles are not connected or only connected at the edge when two rows of needles are used or are only selectively connected in certain locations, two layers are created. If the stitches of both rows of needles are connected selectively in turns by an additional thread, a spacer weft-knitted fabric is created. The additional thread is also referred to as spacer thread and it may be fed via a separate yarn feeder.
In certain embodiments, single-thread warp-knitted fabrics may be manufactured by jointly moved needles. In other embodiments, single-thread warp-knitted fabrics needles may be manufactured by fixing the needles and moving the fabric to create the relative motion between the needles and the fabric. In contrast to weft-knitting, the needles are typically not moved individually. Similar to weft-knitting, there are flat single thread warp-knitting and circular single thread warp-knitting machines.
In warp-knitting, one or several coiled threads, which are next to one another, are used. In stitch formation, the individual warps are placed around the needles and the needles are moved jointly.
The techniques described herein as well as further aspects of the manufacture of knitwear may be found in “Fachwissen Bekleidung”, 6th ed. by H. Eberle et al. (published with the title “Clothing Technology” in English), in “Textil- and Modelexikon”, 6th ed. by Alfons Hofer and in “Maschenlexikon”, 11th ed. by Walter Holthaus, for example.
Three-dimensional (3D) knitwear may also be manufactured on weft-knitting machines and warp-knitting machines. This is knitwear comprises a spatial structure although it is weft-knitted or warp-knitted in a single process. A three-dimensional weft-knitting or warp-knitting technique allows for spatial knitwear to be manufactured without seams, cut or manufacture in one piece and in a single process.
Three-dimensional knitwear may, for example, be manufactured by varying the number of stitches in the direction of the wales by partial courses being formed. The corresponding mechanical process is referred to as “needle parking”. Depending on the requirement, this technique may be combined with structural variations and/or variations of the number of stitches in the direction of the course. When partial courses are formed, stitch formation temporarily occurs only along a partial width of the weft-knitted fabric or warp-knitted fabric. The needles which are not involved in the stitch formation keep the half stitches (“needle parking”) until weft-knitting occurs again at this position. In this way, it is possible to form bulges, for example.
By three-dimensional weft-knitting or warp-knitting, a shoe upper may be adjusted to the cobbler's last or the foot and a sole may be profiled, for example. The tongue of a shoe may e.g. be weft-knitted into the right shape. Contours, structures, knobs, curvatures, notches, openings, fasteners, loops and pockets may be integrated into the knitwear in a single process.
Three-dimensional knitwear may be used for the present invention in an advantageous manner.
According to certain embodiments of the present invention, knitwear and particularly weft-knitted fabric may be provided with a range of functional properties and used in the present invention.
It is possible using a weft-knitting technique to manufacture knitwear having different functional areas and simultaneously maintaining its contours. The structures of knitwear may be adjusted to functional requirements in certain areas, by the stitch pattern, the yarn, the needle size, the needle distance or the tensile strain subject to which the yarn is placed on the needles being selected accordingly.
It is possible, for example, to include structures with large stitches or openings within the knitwear in areas in which airing is desired. In contrast, in areas in which support and stability are desired, fine-meshed stitch patterns, stiffer yarns or even multi-layered weft-knitting structures may be used, which will be described in the following. In the same manner, the thickness of the knitwear is variable.
Knitwear having more than one layer provides numerous possible constructions for the knitwear, which provide many advantages. Knitwear with more than one layer, e.g. two, may be weft-knitted or warp-knitted on a weft-knitting machine or a warp-knitting machine with several rows of needles, e.g. two, in a single stage, as described in the section “knitwear” above. Alternatively, several layers, e.g. two, may be weft-knitted or warp-knitted in separate stages and then placed above each other and connected to each other if applicable, e.g. by sewing, gluing, welding or linking.
Several layers fundamentally increase solidness and stability of the knitwear. In this regard, the resulting solidness depends on the extent to which and the techniques by which the layers are connected to each other. The same yarn or different yarns may be used for the individual layers. For example, it is possible for one layer to be weft-knitted from multi-fiber yarn and one layer to be weft-knitted from monofilament, whose stitches are enmeshed in a weft-knitted fabric. In particular, stretchability of the weft-knitted layer is reduced due to this combination of different yarns. In this construction, a layer made from monofilament may be arranged between two layers made from multi-fiber yarn in order to reduce stretchability and increase solidness of the knitwear. This results in a pleasant surface made from multi-fiber yarn on both sides of the knitwear.
An alternative of two-layered knitwear is referred to as spacer weft-knitted fabric or spacer warp-knitted fabric, as explained in the section “knitwear”. In this regard, a spacer yarn is weft-knitted or warp-knitted more or less loosely between two weft-knitted or warp-knitted layers, interconnecting the two layers and simultaneously serving as a filler. The spacer yarn may comprise the same material as the layers themselves, e.g. polyester or another material. The spacer yarn may also be a monofilament which provides the spacer weft-knitted fabric or spacer warp-knitted fabric with stability.
Such spacer weft-knitted fabrics or spacer warp-knitted fabrics, respectively, which are also referred to as three-dimensional weft-knitted fabrics, which are differentiated from the formative 3D weft-knitted fabrics or 3D warp-knitted fabrics mentioned in the section “three-dimensional knitwear” above, may be used wherever additional cushioning or protection is desired, e.g. at the shoe upper or the tongue of a shoe upper or in certain areas of a sole. Three-dimensional structures may also serve to create spaces between neighboring textile layers or also between a textile layer and the foot and thus ensuring airing. Moreover, the layers of a spacer weft-knitted fabric or a spacer warp-knitted fabric may comprise different yarns depending on the position of the spacer weft-knitted fabric on the foot.
The thickness of a spacer weft-knitted fabric or a spacer warp-knitted fabric may be set in different areas depending on the function or the wearer. Various degrees of cushioning may be achieved with areas of various thicknesses, for example. Thin areas may increase bendability, for example, thus fulfilling the function of joints or flex lines.
Multi-layered constructions also provide opportunities for color design, by different colors being used for different layers. In this way, knitwear may be provided with two different colors for the front and the back, for example. A shoe upper made from such knitwear may then comprise a different color on the outside than on the inside.
Other multi-layered constructions may include pockets or tunnels, in which two textile layers or knitwear weft-knitted or warp-knitted on two rows of needles are connected to each other only in certain areas so that a hollow space is created. Alternatively, items of knitwear weft-knitted or warp-knitted in two separate processes are connected to each other such that a void is created, e.g. by sewing, gluing, welding or linking. It is then possible to introduce a cushioning material such as a foam material, eTPU (expanded thermoplastic urethane), ePP (expanded polypropylene), expanded EVA (ethylene vinyl acetate) or particle foam, an air or gel cushion for example, through an opening, e.g. at the tongue, the shoe upper, the heel, the sole or in other areas. Alternatively or additionally, the pocket may also be filled with a filler thread or a spacer knitwear. It is furthermore possible for threads to be pulled through tunnels, for example as reinforcement in case of tension loads in certain areas of a shoe upper. Moreover, it is also possible for the laces to be guided through such tunnels. Moreover, loose threads may be placed into tunnels or pockets for padding, for example in the area of the ankle. However, it is also possible for stiffer reinforcing elements, such as caps, flaps or bones to be inserted into tunnels or pockets. These may be manufactured from plastic such as polyethylene, TPU, polyethylene or polypropylene, for example.
A further possibility for a functional design of knitwear is the use of certain variations of the basic weaves. In weft-knitting, it is possible for bulges, ribs or waves to be weft-knitted in certain areas, for example, in order to achieve reinforcement in these places. A wave may, for example, be created by stitch accumulation on a layer of knitwear. This means that more stitches are weft-knitted or warp-knitted on one layer than on another layer. Alternatively, different stitches are weft-knitted fabric on the one layer than on the other layer, e.g. by being weft-knitted fabric tighter, wider or using a different yarn. Thickening is caused in both alternatives.
Ribs, waves, or similar patterns may, for example, also be used at the bottom of a weft-knitted outer sole of a shoe in order to provide a tread and provide the shoe with better non-slip properties. In order to obtain a rather thick weft-knitted fabric, for example, it is possible to use the weft-knitting techniques “tuck” or “half cardigan”, which are described in “Fachwissen Bekleidung”, 6th ed. by H. Eberle et al., for example.
Waves may be weft-knitted or warp-knitted such that a connection is created between two layers of a two-layered knitwear or such that no connection is created between the two layers. A wave may also be weft-knitted as a right-left wave on both sides with or without a connection of the two layers. A structure in the knitwear may be achieved by an uneven ration of stitches on the front or the back of the knitwear.
Ribs, waves or similar patterns, for example, may be included in the knitwear of the soccer shoe according to certain embodiments of the invention in order to increase friction with a soccer ball, for example, and/or in order to generally allow for a soccer player to have better control of the ball.
A further possibility of functionally designing knitwear within the framework of the present invention is providing openings in the knitwear already during weft-knitting or warp-knitting. In this manner, airing of the soccer shoe according to the invention may be provided in specific places in a simple manner.
In certain embodiments, functionally designing knitwear within the framework may include forming laces integrally with the knitwear of the shoe upper. In these embodiments, the laces are warp-knitted or weft-knitted integrally with the knitwear already when the knitwear of the shoe upper is weft-knitted or warp-knitted. In this regard, a first end of a lace is connected to the knitwear, while a second end is free.
In some embodiments, the first end is connected to the knitwear of the shoe upper in the area of the transition from the tongue to the area of the forefoot of the shoe upper. In these embodiments, a first end of a first lace may be connected to the knitwear of the shoe upper at the medial side of the tongue and a first end of a second lace is connected to the knitwear of the shoe upper at the lateral side of the tongue. The respective second ends of the two laces may then be pulled through lace eyelets for tying the shoe.
A possibility of speeding up the integral weft-knitting or warp-knitting of laces is having all yarns used for weft-knitting or warp-knitting knitwear end in the area of the transition from the tongue to the area of the forefoot of the shoe upper. In some embodiments, the yarns may end in the medial side of the shoe upper on the medial side of the tongue and form the lace connected on the medial side of the tongue. In certain embodiments, the yarns may end in the lateral side of the shoe upper on the lateral side of the tongue and form the lace connected to the lateral side of the tongue. The yarns may then be cut off at a length that is sufficiently long for forming laces. The yarns may be twisted or intertwined, for example. The respective second end of the laces may be provided with a lace clip. Alternatively, the second ends are fused or provided with a coating.
The knitwear is particularly stretchable in the direction of the stitches (longitudinal direction) due to its construction. This stretching may be reduced e.g. by subsequent polymer coating of the knitwear. The stretching may also be reduced during manufacture of the knitwear itself. One possibility is reducing the mesh openings, that is, using a smaller needle size. Smaller stitches generally result in less stretching of the knitwear. Moreover, the stretching of the knitwear may be reduced by knitted reinforcement, e.g. three-dimensional structures. In various embodiments, such structures may be arranged on the inside or the outside of the knitwear of the shoe upper. Furthermore, non-stretchable yarn, e.g. made from nylon, may be laid in a tunnel along the knitwear in order to limit stretching to the length of the non-stretchable yarn.
Colored areas with several colors may be created by using a different thread and/or by additional layers. In transitional areas, smaller mesh openings (smaller needle sizes) are used in order to achieve a fluent passage of colors.
Further effects may be achieved by weft-knitted insets (inlaid works) or Jacquard knitting. Inlaid works are areas which only provide a certain yarn, e.g. in a certain color. Neighboring areas which may comprise a different yarn, for example in a different color, are then connected to each other by a so-called handle.
During Jacquard knitting, two rows of needles are used and two different yarns run through all areas, for example. However, in certain areas only one yarn appears on the visible side of the knitwear and the respective other yarn runs invisibly on the other side of the knitwear.
A product manufactured from knitwear may be manufactured in one piece on a weft-knitting machine or a warp-knitting machine. Functional areas may then already be manufactured during weft-knitting or warp-knitting by corresponding techniques as described here.
Alternatively, the product may be combined from several parts of knitwear and it may also comprise parts that are not manufactured from knitwear. In this regard, the parts of knitwear may each be designed separately with different functions, for example regarding thickness, isolation, transport of moisture, stability, protection, abrasion resistance, durability, cooling, stretching, rigidity, compression, etc.
In certain embodiments, the shoe upper of the soccer shoe and/or its sole may, for example, be generally manufactured from knitwear as a whole or it may be put together from different parts of knitted goods. A whole shoe upper or parts of that may, for example, be separated, e.g. punched, from a larger piece of knitwear. The larger piece of knitwear may, for example, be a circular weft-knitted fabric or a circular warp-knitted fabric or a flat weft-knitted fabric or a flat warp-knitted fabric.
For example, a tongue may be manufactured as a continuous piece and connected with the shoe upper subsequently, or it may be manufactured in one piece with the shoe upper. With regard to their functional designs, ridges on the inside may e.g. improve flexibility of the tongue and ensure that a distance is created between the tongue and the foot, which provides additional airing. Laces may be guided through one or several weft-knitted tunnels of the tongue. The tongue may also be reinforced with polymer in order to achieve stabilization of the tongue and e.g. prevent a very thin tongue from convolving. Moreover, the tongue may then also be fitted to the shape of the cobbler's last or the foot.
Applications such as PU prints, TPU ribbons, textile reinforcements, leather, rubber, etc., may be subsequently applied to the knitwear of the soccer shoe. Thus, it is possible, for example, to apply a plastic heel or toe cap as reinforcement or logos and eyelets for laces on the shoe upper, for example by sewing, gluing or welding, as described below.
Sewing, gluing or welding, for example, constitute suitable connection techniques for connecting individual parts of knitwear with other textiles or with other parts of knitwear. Linking is another possibility for connecting two parts of knitwear. Therein, two edges of knitwear are connected to each other according to the stitches (usually stitch by stitch).
A possibility for welding textiles, particularly ones made from plastic yarns or threads, is ultrasonic welding. Therein, mechanical oscillations in the ultrasonic frequency range are transferred to a tool referred to as a sonotrode. The oscillations are transferred to the textiles to be connected by the sonotrode under pressure. Due to the resulting friction, the textiles are heated up, softened and ultimately connected in the area of the place of contact with the sonotrode. Ultrasonic welding allows rapidly and cost-effectively connecting particularly textiles with plastic yarns or threads. It is possible for a ribbon to be attached, for example glued, to the weld seam, which additionally reinforces the weld seam and is optically more appealing. Moreover, wear comfort is increased since skin irritations—especially at the transition to the tongue—are avoided.
Connecting various textile areas, such as parts of knitwear, may occur at quite different locations. For example, the seams for connecting various textile areas of the shoe upper of the soccer shoe may be arranged at various positions, as shown in
The seam 54 which connects the two textile areas 52 and 53 runs diagonally from an instep area of the shoe upper to an area of the sole in the transition area from the midfoot to the heel. In
In certain embodiments, adhesive tape may be used to connect textile areas. This feature may also be used in addition to an existing connection, e.g. over a sewn seam or a welded seam. An adhesive tape may fulfill further functions in addition to the function of connecting, such as e.g. protection against dirt or water. An adhesive tape may comprise properties which change over its length.
Embodiments of a shoe upper 51 connected to a shoe sole 61 using adhesive tape are shown in
The shoe sole 61 may be an outsole or a midsole. The shoe upper 51 and the shoe sole 61 are connected to each other by a surrounding adhesive tape 62. The adhesive tape 62 may be of varying flexibility along its length. For example, the adhesive tape 62 might be particularly rigid and not very flexible in the shoe's heel region in order to provide the shoe with the necessary stability in the heel region. This may be achieved by varying the width and/or the thickness of the adhesive tape 62, for example. The adhesive tape 62 may generally be constructed such that it is able to receive certain forces in certain areas along the tape.
In this way, the adhesive tape 62 does not only connect the shoe upper to the sole but simultaneously fulfills the function of structural reinforcement.
The yarns or threads, respectively, used for the knitwear of the present invention usually comprise fibers. As was explained above, a flexible structure which is rather thin in relation to its length is referred to as a fiber. Very long fibers, of virtually unlimited length with regard to their use, are referred to as filaments. Fibers are spun or twisted into threads or yarns. Fibers may also be long, however, and twirled into a yarn. Fibers may include natural or synthetic materials. Natural fibers are environmentally friendly, since they are compostable. Natural fibers include cotton, wool, alpaca, hemp, coconut fibers or silk, for example. Among the synthetic fibers are polymer-based fibers such as nylon, polyester, elastane, or spandex, respectively, or Kevlar® or other para-aramid synthetic fiber, which may be produced as classic fibers or as high-performance fibers or technical fibers.
In certain embodiments, a soccer shoe may be assembled from various parts, with a weft-knitted or a warp-knitted part comprising natural yarn made from natural fibers and a removable part, e.g. the insole, comprising plastic, for example. In this manner, both parts may be disposed of separately. In this example, the weft-knitted part could be directed to compostable waste, whereas the insole could be directed to recycling of reusable materials, for example.
The mechanical and physical properties of a fiber and the yarn manufactured therefrom are also determined by the fiber's cross-section, as illustrated in
A fiber having the circular cross-section 710 may either be solid or hollow. A solid fiber is the most frequent type, it allows easy bending and is soft to the touch. A fiber as a hollow circle with the same weight/length ratio as the solid fiber has a larger cross-section and is more resistant to bending. Examples of fibers with a circular cross-section are nylon, polyester, and Lyocell.
A fiber having the bone-shaped cross-section 730 has the property of wicking moisture. Examples of such fibers are acrylic or spandex. The concave areas in the middle of the fiber support moisture being passed on in the longitudinal direction, with moisture being rapidly wicked from a certain place and distributed.
The following further cross-sections are illustrated in
Individual fibers with their properties which are relevant for the manufacture of knitwear for the present invention will be described in the following:
A plurality of different yarns may be used for the manufacture of knitwear according to certain embodiments in the present invention. As was already defined, a structure of one or several fibers which is long in relation to its diameter is referred to as a yarn.
Functional yarns are capable of transporting moisture and thus of absorbing sweat and moisture. They may be electrically conducting, self-cleaning, thermally regulating and insulating, flame resistant, and UV-absorbing, and may enable infrared radiation. They may be suitable for sensors. Antibacterial yarns, such as silver yarns, for example, prevent odor formation.
Stainless steel yarn contains fibers made of a blend of nylon or polyester and steel. Its properties include high abrasion resistance, higher cut resistance, high thermal abrasion, high thermal and electrical conductivity, higher tensile strength and high weight.
In textiles made from knitwear, electrically conducting yarns may be used for the integration of electronic devices. These yarns may, for example, forward impulses from sensors to devices for processing the impulses, or the yarns may function as sensors themselves, and measure electric streams on the skin or physiological magnetic fields, for example. Examples for the use of textile-based electrodes may be found in European patent application EP 1 916 323.
Fused yarns may be a mixture of a thermoplastic yarn and a non-thermoplastic yarn. There are essentially three types of fused yarns: a thermoplastic yarn surrounded by a non-thermoplastic yarn; a non-thermoplastic yarn surrounded by thermoplastic yarn; and pure melted yarn of a thermoplastic material. After being heated to the melting temperature, thermoplastic yarn fuses with the non-thermoplastic yarn (e.g. polyester or nylon), stiffening the knitwear. The melting temperature of the thermoplastic yarn is determined accordingly and it is usually lower than that of the non-thermoplastic yarn in case of a mixed yarn.
A shrinking yarn is a dual-component yarn. The outer component is a shrinking material, which shrinks when a defined temperature is exceeded. The inner component is a non-shrinking yarn, such as polyester or nylon. Shrinking increases the stiffness of the textile material.
A further yarn for use in knitwear are luminescent or reflecting yarns and so-called “intelligent” yarns. Examples of intelligent yarns are yarns which react to humidity, heat or cold and alter their properties accordingly, e.g. contracting and thus making the stitches smaller or changing their volume and thus increasing permeability to air. Yarns made from piezo fibers or yarn coated with a piezo-electrical substance are able to convert kinetic energy or changes in pressure into electricity, which may provide energy to sensors, transmitters or accumulators, for example.
Yarns may furthermore generally be reworked, e.g. coated, in order to maintain certain properties, such as stretching, water resistance/repellency, color or humidity resistance.
Due to its structure, weft-knitted or warp-knitted knitwear is considerably more flexible and stretchable than weaved textile materials. For certain applications and requirements, e.g. in certain areas of a shoe upper according to the present invention, it is therefore necessary to reduce flexibility and stretchability in order to achieve sufficient stability.
For that purpose, a polymer layer may be applied to one side or both sides of knitwear (weft-knit or warp-knit goods), but generally also to other textile materials. Such a polymer layer causes a reinforcement and/or stiffening of the knitwear. In a shoe upper it may, for example, serve the purpose of supporting and/or stiffening and/or reducing elasticity in the toe region, in the heel region, along the lace eyelets, on lateral and/or medial surfaces or in other areas. Furthermore, elasticity of the knitwear and particularly stretchability are reduced. Moreover, the polymer layer protects the knitwear against abrasion. Furthermore, it is possible to give the knitwear a three-dimensional shape using the polymer coating by compression-molding. The polymer coating may be thermoplastic urethane (“TPU”), for example.
In the first step of polymer coating, the polymer material may be applied to one side of the knitwear. It may also be applied on both sides, however. The material may be applied by spraying, knife coating, laying, printing, sintering, ironing or spreading. If it is polymer material in the form of a film, the latter is placed on the knitwear and connected with the knitwear by heat and pressure, for example. Spraying may be carried out by a tool similar to a hot glue gun. Spraying enables the polymer material to be applied evenly in thin layers. Moreover, spraying is a fast method. Effect pigments such as color pigments, for example, may be mixed into the polymer coating.
According to certain embodiments, the polymer is applied in at least one layer with a thickness of 0.2-1 mm. One or several layers may be applied, with it being possible for the layers to be of different thicknesses and/or colors. For example, a shoe may comprise a polymer coating with a thickness of 0.01 to 5 mm. Further, with some shoes, the thickness of the polymer coating may be between 0.05 and 2 mm. Between neighboring areas of a shoe with polymer coatings of various thicknesses there may be continuous transitions from areas with a thin polymer coating to areas with a thick polymer coating. In the same manner, different polymer materials may be used in different areas, as will be described in the following.
During application, polymer material attaches itself to the points of contact or points of intersection, respectively, of the yarns of the knitwear, on the one hand, and to the gaps between the yarns, on the other hand, forming a closed polymer surface on the knitwear after the processing steps described in the following. However, in case of larger mesh openings or holes in the textile structure, this closed polymer surface may also be intermittent, e.g. so as to enable airing. This also depends on the thickness of the applied material: The more thinly the polymer material is applied, the easier it is for the closed polymer surface to be intermittent. Moreover, the polymer material may also penetrate the yarn and soak it and thus contributes to its stiffening.
After application of the polymer material, the knitwear is pressed in a press under heat and pressure. The polymer material liquefies in this step and fuses with the yarn of the textile material.
In a further optional step, the knitwear may be pressed into a three-dimensional shape in a machine for compression-molding. For example, the area of the heel or the area of the toe region of a shoe upper may be shaped three-dimensionally over a cobbler's last. Alternatively, the knitwear may also be directly fitted to a foot.
After pressing and molding, the reaction time until complete stiffening may be one to two days, depending on the used polymer material.
The following polymer materials may be used: polyester; polyester-urethane pre-polymer; acrylate; acetate; reactive polyolefins; co-polyester; polyamide; co-polyamide; reactive systems (mainly polyurethane systems reactive with H2O or O2); polyurethanes; thermoplastic polyurethanes; and polymeric dispersions.
The described polymer coating may be used sensibly wherever support functions, stiffening, increased abrasion resistance, elimination of stretchability, increase of comfort, increase of friction, and/or fitting to prescribed three-dimensional geometries are desired. It is also possible to fit the shoe upper to the individual shape of the foot of the person wearing it, by polymer material being applied to the shoe upper and then adapting to the shape of the foot under heat.
Additionally or alternatively to a reinforcing polymer coating, knitwear may be provided with a water-repellent coating to avoid or at least reduce permeation of humidity, e.g. into a shoe upper. The water-repellent coating may be applied to the entire shoe upper or only a part thereof, e.g. in the toe region. Water-repellent materials may be based e.g. on hydrophobic materials such as polytetrafluoroethylene (“PTFE”), wax, or white wax. A commercially available coating is Scotchgard™ from 3M.
As was already defined, a monofilament is a yarn formed by one single filament, that is, one single fiber. Therefore, in certain embodiments, stretchability of monofilaments is considerably lower than that of yarns which are manufactured from many fibers. This also reduces the stretchability of knitwear that is manufactured from monofilaments or include monofilaments and which are used in the present invention. Monofilaments are typically made from polyamide. However, other materials, such as polyester or a thermoplastic material, are also possible.
So whereas knitwear made from a monofilament is considerably more rigid and less stretchable, this knitwear may not include the desired surface properties, such as e.g. smoothness, colors, transport of moisture, outer appearance and variety of textile structures as usual knitwear has. This disadvantage is overcome by the knitwear described in the following.
A monofilament may also be melted slightly in order to connect with the layer of the first yarn and limit stretching even more. The monofilament then fuses with the first yarn at the points of contact and fixates the first yarn with respect to the layer made from monofilament.
The weft-knitted fabric having two layers described in the preceding section may additionally be reinforced by a polymer coating as was already described in the section “polymer coating”. The polymer material is applied to the weft-knitted layer made from monofilament. In doing so, it does not connect to the material (e.g. polyamide material) of the monofilament, since the monofilament has a very smooth and round surface, but substantially penetrates the underlying first layer of a first yarn (e.g. polyester yarn). During subsequent pressing, the polymer material therefore fuses with the yarn of the first layer and reinforces the first layer. In doing so, the polymer material has a lower melting point than the first yarn of the first layer and the monofilament of the second layer. The temperature during pressing is selected such that only the polymer material melts but not the monofilament or the first yarn.
For reinforcement and for the reduction of stretching, the yarn of the knitwear which is used according to the invention may additionally or alternatively also be a fused yarn that fixes the knitwear after pressing. There are substantially three types of melted yarns: a thermoplastic yarn surrounded by a non-thermoplastic yarn; a non-thermoplastic yarn surrounded by thermoplastic yarn; and pure melted yarn of a thermoplastic material. In order to improve the bond between thermoplastic yarn and the non-thermoplastic yarn, it is possible for the surface of the non-thermoplastic yarn to be texturized.
In certain embodiments, pressing takes place at a temperature ranging from 110 to 150° C., and may further be approximately 130° C. The thermoplastic yarn melts at least partially in the process and fuses with the non-thermoplastic yarn. After pressing, the knitwear is cooled, so that the bond is hardened and fixed. The fused yarn may be arranged in the entire knitwear or only in selective areas.
In some embodiments, the fused yarn is weft-knitted or warp-knitted into the knitwear. In case of several layers, the fused/melted yarn may be weft-knitted into one, several or all layers of the knitwear.
In certain embodiments, the fused/melted yarn may be arranged between two layers of knitwear. In doing so, the fused/melted yarn may simply be placed between the layers. Arrangement between the layers may be desirable in certain instances, as the mold is not contaminated or soiled during pressing and molding, since there is no direct contact between the fused/melted yarn and the mold.
A further possibility for reinforcing knitwear that is used for the present invention is the use of a thermoplastic textile. This is a thermoplastic woven fabric or thermoplastic knitwear. A thermoplastic textile fuses at least partially when subjected to heat and stiffens as it cools down. A thermoplastic textile may, for example, be applied to the surface of the knitwear by applying pressure and heat. When it cools down, the thermoplastic textile stiffens and specifically reinforces the shoe upper in the area in which it was placed, for example.
The thermoplastic textile may be specifically manufactured for the reinforcement in its shape, thickness and structure. Additionally, its properties may be varied in certain areas. The stitch structure, the knitting stitch, and/or the yarn used may be varied such that different properties are achieved in different areas.
According to certain embodiments, a thermoplastic textile is a weft-knitted fabric or warp-knitted fabric made from thermoplastic yarn. Additionally, the thermoplastic textile may also comprise a non-thermoplastic yarn. In some embodiments, the thermoplastic textile may be applied to the shoe upper of the soccer shoe, for example, by pressure and heat.
A woven fabric whose wefts and/or warps are thermoplastic are other embodiments of a thermoplastic textile. Different yarns may be used in the weft direction and the warp direction of the thermoplastic woven fabric, so as to achieve different properties, such as stretchability, in the weft direction and the warp direction.
A spacer weft-knitted fabric or spacer warp-knitted fabric made from thermoplastic material are other embodiments of a thermoplastic textile. In this regard, only one layer may be thermoplastic, for example, so as to be attached to the shoe upper of the soccer shoe. Alternatively, both layers are thermoplastic, for example, in order to connect the sole to the shoe upper.
A thermoplastic weft-knitted fabric or warp-knitted fabric may be manufactured using the manufacturing techniques for knitwear described in the section “knitwear”.
A thermoplastic textile may be connected with the surface to be reinforced only partially subject to pressure and heat so that only certain areas or only a certain area of the thermoplastic textile connects to the surface. Other areas or another area do not connect, so that the permeability for air and/or humidity is maintained there, for example. The function and/or the design of e.g. the shoe upper of the soccer shoe may be modified by this.
a, 9b, and 10 illustrate certain embodiments of a soccer shoe 91 from different perspectives.
The soccer shoe 91 shown in
The soccer shoe 91 further comprises a sole 61 comprising cleats, three of which are denoted with the reference number 92. The sole 61 is connected to the knitwear of the upper 51. The sole 61 may be manufactured in any known manner. For example, the sole 61 may be manufactured via injection molding and may subsequently be connected to the knitwear of the upper 51, e.g. via gluing or welding. Alternatively, the sole 61 may be injection molded to the upper 51. In some embodiments, the sole 61 may be separately manufactured in a 3D printing process and then connected to the shoe upper 51 via gluing or welding. Alternatively, the sole 61 may be directly printed to the shoe upper in a 3D printing process. Materials used to form the sole 61 include but are not limited to TPU, PU, polyamide, rubber, EVA, or combination thereof.
The knitwear of the upper 51 is capable of coupling the sole 61 to a foot of a wearer while wearing the soccer shoe 91, i.e. the knitwear is substantially (more than 50% of the required forces) responsible for positioning the sole 61 under the foot of the wearer and holding it in position. In the shown exemplary embodiments, this coupling is caused by the knitwear of the upper 51 firmly enclosing the foot of the wearer (not shown in the figures) and thereby holding the sole 61 in its position. Also, the stretchability of the knitwear of the upper 51 adds to the firm coupling of the sole 61 to the foot by tightly enclosing the foot.
Cleats are understood as any type of bump on the sole that is capable of increasing the traction of the sole with the ground, for example grass. For example, the cleats and the sole may be a single integrally-formed piece, i.e. the cleats are formed out of the sole. Alternatively, the cleats may have threads and may be screwed into the sole. The cleats may have the form of knobs or knolls and may round, oval, elongated, or any other suitable shape. Further possible forms include but are not limited to pyramid, cone, or truncated cone.
In the shown embodiments, the knitwear of the upper 51 is capable of extending above an ankle of the wearer of the soccer shoe 91 during wear and, thereby, creates a good coupling of the sole 61 to the foot. In general, the upper 51 may comprise such a height that the upper edge of the upper 51 overlaps a section of a shin guard (not shown in the figures) of a wearer when wearing the soccer shoe 91.
The upper 51 may also comprise a coupling mechanism to connect the upper to the shin guard or to a soccer sock (not shown in the figures). This could, for example, be a hook-and-loop fastener. Alternatively or additionally, a good coupling to a shin guard or sock may also be achieved by compression of the knitwear, i.e. the knitwear exerts sufficient pressure on the shin guard or the sock to avoid or at least reduce slipping of the shin guard or sock relative to the knitwear. In this way, a smooth transition between the knitwear and the shin guard may be achieved. The knitwear may be configured to extend to a knee of a wearer.
In alternative embodiments of the invention (not shown in the figures), the shoe upper may comprise a pocket or channel for the shin guard. The pocket or channel may, for example, be weft-knitted or warp-knitted in the knitwear of the shoe upper as a single piece. Alternatively, the pocket or the channel may be made from a different material and may be sewn, glued, or welded to the shoe upper. Further pockets or channels may be arranged on the shoe upper to fix, for example, elements such as electronic elements, protection elements, paddings, thermal elements (e.g. cool or heat packs) to the shoe upper. Further, in embodiments of the present invention, yarns, support structures, and/or weft-knit or warp-knit structures, respectively, may be combined, such that the protection areas are formed. For example, a shock-absorbing area may be formed in the shoe upper 51 protecting the shin.
In alternative embodiments of the invention (not shown in the figures), the knitwear of the upper 51 may extend below an ankle or may extend to an ankle. In these embodiments, the knitwear provides the function of coupling the sole 61 to the foot.
In certain embodiments, as illustrated in
In certain exemplary embodiments, as shown in
Instead of two sections comprising knitwear, the soccer shoe 91 according to the invention may comprise an arbitrary number of sections comprising knitwear. The soccer shoe 91, according to certain embodiments, may alternatively comprise a one-piece knitwear that was manufactured in one piece on a weft-knitting or warp-knitting machine. Additionally or alternatively, the shoe upper 91 may comprise sections of other materials, such as textile, mesh, woven fabric, fibrous web, etc.
In certain exemplary embodiments, as shown in
The soccer shoe 91 shown in
In certain exemplary embodiments, as shown in
The knitwear of the upper according to the invention may be manufactured on a flat weft-knitting machine or a flat warp-knitting machine, respectively, or on a circular weft-knitting machine or a circular warp-knitting machine, respectively. Different sections of the knitwear of the upper 51 may be manufactured on different machines. For example, one section may be manufactured on a flat weft-knitting machine, whereas another section may be manufactured on a circular warp-knitting machine. The sections may subsequently be joined, as described for example in the section “functional knitwear.”
The knitwear of the upper 51 according to the invention may be reinforced with a polymer coating, as described for example in the sections “polymer coating” and “thermoplastic textile for reinforcement.” Such a polymer reinforcement may stiffen and/or thicken the knitwear. Furthermore, the polymer reinforcement may increase the friction of the knitwear with a soccer ball. TPU may, for example, be used as polymer coating.
Reinforcements may also be directly injection molded to the shoe upper, e.g. to the knitwear. For example, a heel counter may be directly injection molded to the shoe upper. Alternatively, a reinforcement may be applied, for example glued, to the shoe upper externally. Further alternatively, a reinforcement may be arranged, e.g. glued, to the inner side of the shoe upper.
In
The knitwear of the soccer shoe 91 shown in
The four sections are joined by corresponding seams 112a, 112b, 112c and 112d. Seam 112a connects the toe region 111a to the metatarsal section 111b. Seam 112b connects the metatarsal section 111b to the lateral section 111c and to the medial section 111d. Seam 112c connects the lateral section 111c to the medial section 111d on the front side of the soccer shoe 91. Seam 112d connects the lateral section 111c to the medial section 111d on the rear side of the soccer shoe 91.
In some embodiments, a strap is glued over the seams 112a, 112b, 112c and 112d on the outer side of the upper 51. This design decreases or avoids a chance that a football is deflected when contacting one of the seams in an undesirable way.
Instead of sewing sections of the shoe upper together, these sections may also be glued or welded (under heat or with ultrasound). Combinations of different connection techniques are possible. Basically, a different number and/or arrangement of sections of knitwear and corresponding joining seams is possible.
The knitwear of the soccer shoe shown in
Below the weldseam shown with the reference numeral 113, a plastic reinforcement may be arranged between the outer layer and the inner layer. Such a reinforcement may be arranged on the medial side, as well as on the lateral side of the soccer shoe. It is also possible that such reinforcements are located in the toe and/or heel regions of the soccer shoe.
Basically, the upper 51 and, in particular, the knitwear may be provided with profile elements which increase the friction between a soccer ball and soccer shoe 91 and/or which allow for a better control of the ball. DE 10 2012 207 300 A1 describes, for example, a method for connecting a profile element to an upper.
a and 14b show further exemplary embodiments of the present invention. The soccer shoe 91 shown in
a to 15f show still further exemplary embodiments of the present invention. The soccer shoe 91 shown in
a to 16d show still further exemplary embodiments of a shoe with several sections. The materials in each section may be selected based on different requirements and properties, like for example stiffness, stretching, stability, waterproofness/water repellence, breathability, cushioning/padding, sensitivity, control (e.g. ball control), etc., or a combination thereof. As shown in
The sections of the soccer shoe 91 shown in
As shown in
a and 17b show embodiments of three soccer shoes 91, 91a, and 91b, wherein the soccer shoe 91 on the right-hand side is an exemplary embodiment of
Further, the soccer shoes 91a and 91b each comprise a sole 61 comprising a grid-shaped structure to increase traction with respect the ground. In the shown exemplary embodiments of
The two soccer shoes 91a and 91b comprise a midsole 171 from eTPU. The midsole 171 is arranged above the sole 61. eTPU is especially elastic, i.e. comprises high resilience. It maintains this property over a wide temperature range compared to e.g. EVA. Furthermore, eTPU comprises a considerably reduced abrasion than ordinary midsoles compared e.g. with EVA.
Each of the shoe uppers 51 of the soccer shoes 91a and 91b comprise a section 172 in the toe region, which is made from rubber and provided with an alveolar structure to increase friction with a soccer ball. The shoe upper 51 of soccer shoes 91a and 91b furthermore comprise knitwear in sections 173, which is able to couple the soccer shoe 91a, 91b to a foot of a wearer when wearing the shoe.
The shoe uppers 51 of the soccer shoes 91, 91a, and 91b shown in
a and 18b show the soccer shoe 91a on the left side of
a, 19b, and 19c show further exemplary embodiments of the present invention. The soccer shoe 91 shown in
A different course of the straps 201 and 202 according to requirements may be included in other embodiments. Also, a different number of straps may be used, for example, only one. The straps 201 and 202 may be laminated to the shoe upper 51. However, it is also possible to print the straps.
In the exemplary embodiments of
Further, some embodiments of the soccer shoe according to the invention may comprise a support element or support elements, e.g. one or more elastic straps to provide additional support in certain areas of the foot. For example, one support element may be arranged such that it extends from a medial side over a foot arranged in the soccer shoe to the lateral side of the soccer shoe.
The soccer shoe 91 according to certain embodiments of the invention described above may be manufactured with a method comprising the following steps: providing the sole 61, weft-knitting or warp-knitting the knitwear for the upper 51, such that the knitwear is capable of coupling the sole 61 to a foot of a wearer of the soccer shoe 91 while the soccer shoe 91 is worn and, finally, connecting the sole 61 to the upper 51. The provided sole 61 may be a rigid sole.
The knitwear may be weft-knitted or warp-knitted such that the knitwear may extend above an ankle of a foot while the soccer shoe 91 is worn. The step of weft-knitting or warp-knitting the knitwear may further comprise the steps of: weft-knitting or warp-knitting multiple weft-knitted or warp-knitted sections and joining the multiple weft-knitted or warp-knitted sections to form the knitwear.
The invention has been described in relation to soccer shoes. Basically, however, the invention is not restricted to soccer shoes, but may be applied to any kind of shoe, in particular a sports shoe. The invention may in particular be applied to climbing shoes, running shoes and shoes for ball sports. Further sports where the described invention may be used are yoga, rambling, trekking, hiking, tennis, cycling, football, rugby, baseball and volleyball, and activities on sports equipment such as for example cross trainers and steppers. The mentioned sports shoes, sports and activities are not to be understood as limiting.
In the following, further examples are described to facilitate the understanding of the invention:
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2014 202 432.3 | Feb 2014 | DE | national |
