UPPER FOR AN ARTICLE OF FOOTWEAR HAVING ANGLED TUBULAR KNIT STRUCTURES

Abstract

An upper for an article of footwear may include a first tubular knit structure, where the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passage is located between the first layer and the second layer. A second tubular knit structure may be included, where the second tubular knit structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passage is located between the third layer and the fourth layer. A longitudinal direction of the first tubular knit structure may be angled at least 5 degrees relative to a longitudinal direction of the second tubular knit structure.

Description

BACKGROUND

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is generally secured to the sole structure and may form a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is generally secured to a lower surface of the upper so as to be positioned between the upper and the ground. In some articles of athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. The outsole may be secured to a lower surface of the midsole and may form a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material.

The upper of the article of footwear generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot and in some instances under the foot. Access to the void in the interior of the upper is generally provided by an ankle opening in and/or adjacent to a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate other structures such as, for example, a heel counter to provide support and limit movement of the heel.

BRIEF DESCRIPTION OF THE DRAWINGS

The aspects of the present disclosure may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, with emphasis instead being placed upon illustrating the principles of the present disclosure. Moreover, in the figures, like referenced numerals designate similar or identical features.

FIG. 1 is an illustration showing a perspective view of an article of footwear having a fastening system incorporating angled tubular knit structures in accordance with certain aspects of the present disclosure.

FIG. 2 is an illustration showing a knitted component forming at least a portion of an upper for an article of footwear in accordance with certain aspects of the present disclosure.

FIG. 3 is an illustration showing the knitted component of FIG. 2 as it is being manipulated into a wearable shape in accordance with certain aspects of the present disclosure.

FIG. 4 is an illustration showing a sectional view about section 4-4 of FIG. 3.

FIG. 5 is an illustration showing a close-up view of a first tubular structure and a second tubular knit structure being angled in accordance with certain aspects of the present disclosure.

FIG. 6 is an illustration showing a close-up view of a merged tubular area of a knitted component in accordance with certain aspects of the present disclosure.

FIG. 7 is an illustration showing a close-up view of another aspect of a merged tubular area in accordance with certain aspects of the present disclosure.

FIG. 8 is an illustration showing a close-up view of another aspect of a merged tubular area in accordance with certain aspects of the present disclosure.

FIG. 9 is an illustration showing a knit diagram representing a merged tubular knit area in accordance with certain aspects of the present disclosure.

FIG. 10 is an illustration showing a knit diagram representing a base area having at least one surface characteristic in accordance with certain aspects of the present disclosure.

DETAILED DESCRIPTION

Various aspects are described below with reference to the drawings in which like elements generally are identified by like numerals. The relationship and functioning of the various elements of the aspects may better be understood by reference to the following detailed description. However, aspects are not limited to those illustrated in the drawings or explicitly described below. It also should be understood that the drawings are not necessarily to scale, and in certain instances, details may have been omitted that are not necessary for an understanding of aspects disclosed herein, such as conventional fabrication and assembly.

Certain aspects of the present disclosure relate to uppers configured for use in an article of footwear and/or other articles, such as articles of apparel. When referring to articles of footwear, the disclosure may describe basketball shoes, running shoes, biking shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennis shoes, and/or walking shoes, as well as footwear styles generally considered non-athletic, including but not limited to dress shoes, loafers, and sandals.

FIG. 1 is an illustration showing an article of footwear 100 having an upper 102, where the upper 102 may be formed from any suitable type of textile (e.g., a woven or non-woven textile) or another suitable material, and in some aspects the textile(s) may be formed as a knitted component 104 through the mechanical manipulation of yarns (as described in more detail below).

The upper 102 may be secured to a sole structure 106. The area where the sole structure 106 joins the upper 102 may be referred to as a biteline 108. The upper 102 may be joined to the sole structure 106 in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, and the like. The sole structure 106 may define the bottom surface of a void for receiving and accommodating a user's foot. The void may be accessible through an ankle opening 110.

The upper 102 may include a lateral side 112 and a medial side 114. A throat area 116 may be included between the lateral side 112 and the medial side 114, and the throat area 116 may be positioned to cover the top (dorsal) surface of the foot during typical use. A midfoot area 118 of the upper 102 may be located between a heel area 120 and a toe area 122. The throat area 116 may be primarily located in the midfoot area 118.

In some aspects, an optional tongue may be disposed at least partially in the throat area 116. The tongue may be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included (or in combination with a tongue), the lateral and medial sides of the throat area 116 may be joined together. In the depicted example, a tongue 117 is located in the throat area 116, and the tongue 117 is attached to the knitted component 104 after the knitting process (e.g. via non-knit means, such as sewing or tying, using an adhesive, using a clam or other mechanical fastener, etc.). Alternatively, the tongue 117 may be knit integrally with the remainder of the knitted component (e.g., as described in U.S. Pat. No. 8,448,474, entitled “ARTICLE OF FOOTWEAR INCORPORATING A KNITTED COMPONENT WITH A TONGUE,” and having an assignee of NIKE, Inc., which is hereby incorporated by reference in its entirety).

As stated above, at least a portion of the upper 102 may be formed with a knitted component (or another suitable textile component). For example, the upper 102 may be formed primarily as an integral one-piece element during a knitting process, such as a weft knitting process (e.g., with a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine may substantially form the knit structure of the knitted components without the need for significant post-knitting processes or steps. Alternatively, the knitted component 104 may be formed separately as distinct integral one-piece elements and then the respective elements attached (e.g., via sewing).

Forming the upper 102 with a knitted component 104 may impart advantageous characteristics 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 single layer or multi-layer knit structure (e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), and/or a combination thereof. The weight of the upper 102, and thus the overall weight of the article of footwear 100, may be reduced with respect to alternative components typically used in footwear. The knitted component 104 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 of the knitted components may be varied at different locations to provide different knit portions with different properties (e.g., a portion forming the throat area 116 of the knitted component 104 may be relatively elastic while a portion forming the heel area 120 or another area may be relatively inelastic).

In some aspects, the knitted component 104 may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). For example, as described in more detail below, the knitted component 104 may include yarns formed of a thermoplastic polymer material (e.g., a polyurethane, polyamide, polyolefin, and/or nylon) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to the solid state when cooled. The thermoplastic polymer material may provide the ability to heat and then cool a portion of the knitted component 104 to thereby form an area of bonded or continuous material (herein referred to as a “fused area”) that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example.

In some aspects, the lacing pattern of the article of footwear 100 may include a fastening system 123 (which also may be called a “tensioning system”) to move the upper 102 between a loosened state and a tightened state (e.g., to adjust the geometry of upper 102 to tighten the upper 102 around the foot of a user). In some aspects, the fastening system 123 may incorporate a shoelace 126, but other devices for manipulate the fastening system 123 may alternatively be included (e.g., a more advanced tensioning member, such as those involved in systems involving dynamic lacing systems such as those (and variations thereof) described in U.S. patent application Ser. No. 15/655,769, filed on Jul. 20, 2017, and entitled “DYNAMIC LACING SYSTEM,” which is hereby incorporated by reference in its entirety, and/or U.S. patent application Ser. No. 16/534,702, filed on Aug. 7, 2019, and entitled “KNITTED COMPONENT HAVING A KNITTED ANCHOR PORTION,” which is hereby incorporated by reference in its entirety). Optionally, it is contemplated that the shoelace 126 or other tensioning member may be knitted (e.g., secured to the remainder of the knitted component 104 on the knitting machine).

FIG. 2 shows a top view of the knitted component 104 as it may appear in a flattened state prior to being manipulated into a wearable shape, for example. FIG. 3 is a side view of the knitted component 104 as it is being manipulated into a wearable shape (but prior to finalization of the article of footwear), and FIG. 4 is a section view about section 4-4 in FIG. 3. Referring to FIGS. 2-4, the knitted component 104 may form at least a portion of the fastening system 123. As discussed above, the fastening system 123 may operate to tighten and/or otherwise adjust the article of footwear 100 around a foot of a wearer. While certain variations are contemplated (e.g., such as one or more dynamic lacing systems as mentioned above), in the depicted example, the fastening system 123 may be adjustable through manual adjustment of a tensioning member, which in this case is a shoelace 126. That is, the shoelace 126 may be manually manipulated (e.g., pulled) and tied by a user, thereby providing tension to one or more tensile strands 124 that extend through the lateral side 112 and the medial side 114 of the knitted component 104.

To transfer force/tension to the tensile strands 124, the shoelace 126 may be routed through various anchors 132 formed by the tensile strands 124 along the lateral side of the throat area 116 and the medial side of the throat area 116. As shown, the anchors 132 may be defined by loops 150 where the tensile strands 124 change direction (i.e., such that the tensile strands 124 extend from the biteline 108 (shown in FIG. 1), to the throat area 116, and back). Without limitation, the tensile strands 124 (or strands) may include at least one of a cable, a yarn (e.g., with multiple filaments for example), a monofilament strand, or any other suitable elongated member. The tensile strand 124 (which may incorporate more than one individual strand) may form multiple anchors 132 on each of the lateral side 112 and the medial side 114 of the throat area 116, as shown, to ensure the fastening system 123 provides adequate tightening.

The knitted component 104 may include one or more passages for guiding the tensile strands 124. For example, the knitted component 104 may include one or more tubular knit structures 134 (e.g., multi-layer knit structures formed with a tubular knitting process) or other knitted features that are incorporated into the fastening system 123. In the depicted aspect, the knitted component 104 includes the first tubular knit structure 140, the second tubular knit structure 142, and several other tubular knit structures that are positioned and oriented for guiding the path of the tensile strand 124. Without limitation, a sufficient number of tubular knit structures 134 may be included such that there are at least three anchors 132 on each side of the throat area 116, for example. For example (and as discussed in more detail below), these tubular knit structures may be positioned and/or angled (or otherwise oriented) such that the tensile strand 124 distributes forces throughout the article of footwear to facilitate footwear performance and user comfort. While the tubular knit structures 134 are located only on the lateral side 112 and the medial side 114 of the upper 102 in the depicted example, they may also (or alternatively) be located in other areas (such as the heel area 120, the toe area 122, and the like). As discussed in more detail below, corresponding tubular knit structures may be angled relative to one-another to enhance the force distribution through the upper 102 during footwear use.

As shown in FIGS. 2-3, the tubular knit structures 134 may generally extend longitudinally in a course-wise direction (e.g., in a direction corresponding to the lengthwise dimension of a plurality of courses forming the knitted component 104), although angled orientations may be present, as discussed below. For example, in the depicted aspect, the courses may generally extend medial-to-lateral, and wales may extend heel-to-toe. Such an orientation is advantageous for allowing the knitting machine to utilize tubular knitting to form the tubular knit structures 134, where, during formation, the longitudinal direction the tubular knit structures 134 are substantially parallel to the lengthwise direction of the knitting machine's needle beds.

Optionally, each of the tubular knit structures 134 may have a similar multi-layer construction, though variations are contemplated. For simplicity, this description discusses the particular multi-layer construction of the first tubular knit structure 140, which may be representative of the other tubular knit structures 134. As shown in FIG. 4, the first tubular knit structure 140 may include a first layer 144 and a second layer 146 (see FIG. 4). A first passage 136 (which also may be referred to as a pocket or channel) may be located between the first layer 144 and the second layer 146 such that a component may be inserted between the first layer 144 and the second layer 146. In this example, the tensile strand 124 is at least partially located within the first passage 136 between the first layer 144 and the second layer 146, for example. The first layer 144 of the tubular knit structure 134 may be on a first side 190, and thus the front surface (e.g., exterior surface 194), of the knitted component 104, and the second layer 146 of the tubular knit structure 134 may be on a second side 192, and thus on an inner-facing surface (e.g., second surface 196), of the knitted component 104.

The tubular knit structure 134 may be formed using a tubular knitting process where the first layer 144 is formed on a first needle bed of a flat knitting machine and where the second layer 146 is formed on a second needle bed of the flat knitting machine (e.g., where a base area 156 may be formed using both needle beds, for example). While any suitable tubular knit construction may be used, certain specific examples of suitable knitting techniques are described in more detail below (e.g., with reference to FIGS. 9-10).

Again referring to FIGS. 2-3, the second tubular knit structure 142 may be included, where the second tubular knit structure 142 is adjacent to the first tubular knit structure 140 in at least one location (in this instance at the throat area 116) Like the first tubular knit structure 140, the second tubular knit structure 142 may include a multi-layer knit structure defining a second passage 138 for receiving the tensile strand 124. As shown in FIG. 2, the tensile strand 124 may also extend through the first tubular knit structure 140 and the second tubular knit structure 142. In a location where the tensile strand 124 transitions from the first tubular knit structure 140 to the second tubular knit structure 142, a loop 150 may be formed, which may be configured (e.g., sized, shaped, provided with particular friction characteristics, and the like) to engage a shoelace (as shown in FIG. 1) and/or another fastening system. As discussed above, the loop 150 may be considered an “anchor” utilized in a fastening system that manually or automatically tightens the article of footwear 100 around a wearer's foot.

The first tubular knit structure 140 and/or the second tubular knit structure 142 may extend from a biteline of the upper 102 to the throat area 116 of the upper 102. Such a configuration may be advantageous for distributing forces through the article of footwear 100 in an appropriate manner. For example, when the article of footwear 100 is in use, forces may be distributed from the throat area 116, through the tensile strands 124 (e.g., due to engagement with a shoelace for example), and to the sole structure 106 (shown in FIG. 1). Such force distribution may prevent “hot spots,” or areas of high pressure and/or abrasion, and/or otherwise increase the comfort and/or performance of the article of footwear 100. Additionally or alternatively, the knitted loops and/or other knit structures of the knitted component 104 may be engineered to distribute forces throughout the article of footwear in a desirable manner.

The tensile strand 124 may be inserted within the first tubular knit structure 140 and/or the second tubular knit structure 142 during a knitting process, such as by utilizing an inlay process. For example, an inlay process may include using an inlay feeder or other mechanical inlay device on a knitting machine (e.g., a combination feeder) to place the tensile strand 124 between two needle beds (e.g., front and back needle beds) during a knitting process. One example of an inlay process, along with a combination feeder for enabling such a process, is described in U.S. Patent Application Publication No. 2013/0145652, published Jun. 13, 2013, and having an applicant of NIKE, Inc., which is hereby incorporated by reference in its entirety. Optionally, similar insertion techniques (perhaps including guide elements located in a merged tubular area 170 shown in FIG. 7, for example) may be utilized, as described in U.S. Provisional Patent Application No. 62/863,660, filed Jun. 19, 2019, and having an applicant of NIKE, Inc., which is hereby incorporated by reference in its entirety.

Alternatively, the tensile strand 124 may be fed through the first tubular knit structure 140 and/or the second tubular knit structure 142 of the knitted component 104 by hand and/or other manual method (e.g., after knitting is complete). Further, it is contemplated that the tensile strand 124 may be attached to the remainder of the knitted component 104 in a different way (e.g., other than being located in a tube), such as by using an adhesive to secure the tensile strand 124 directly to the exterior surface 194 of the article of footwear.

In some aspects, the first tubular knit structure 140 may be angled relative the second tubular knit structure 142. For example, referring to FIG. 2, the first tubular knit structure 140 and the second tubular knit structure 142 may be respectively oriented such that they are closer together in or near the throat area 116 than at the biteline 108. The inventors have found that such an aspect is advantageous for creating a more natural distribution of forces through the upper 102 and reducing hotspots on a user's foot. Further, since forces are better distributed, the components of the article of footwear 100 (particularly those of the fastening system) may be better capable of handling particular loads, increasing the overall durability of the article of footwear 100 (and/or providing the ability to use different materials, which may reduce the overall weight and/or cost of the article of footwear 100). This aspect is also advantageous for providing enhanced aesthetics relative to other aspects.

While any suitable angle is contemplated, the first tubular knit structure 140 may be angled at between about 5 degrees and about 85 degrees relative to the second tubular knit structure 142, such as between about 10 degrees and about 45 degrees. The depicted aspect includes an angle of about 35 degrees, and it is contemplated that the angle may vary along the length of the tubular knit structures. Measurement of such an angle is preferably executed when the article of footwear 100 is at rest. In the depicted example (and referring to FIG. 5, showing a close-up view of the first tubular knit structure 140 and the second tubular knit structure 142), the first tubular knit structure 140 is located a first distance 152 from the second tubular knit structure 142 at the biteline 108 of the upper 102. When the article of footwear is at rest, the first distance may be between about 1 cm and about 5 cm, such as between about 2 cm and about 4 cm, such as about 3 cm in certain non-limiting example aspects. At the throat area 116, the first tubular knit structure 140 may be located a second distance 154 from the second tubular knit structure 142, where the second distance 154 is less than the first distance. Without limitation, when the article of footwear 100 is at rest, the second distance 154 may be less than about 2 cm, such as less than about 1 cm, and such as less than about 0.5 cm in certain example aspects.

As shown in FIGS. 2-5, the base area 156 may be located between the first tubular knit structure 140 and the second tubular knit structure 142 (as well as between other tubular knit structures). Optionally the base area 156 may vary throughout the knitted component 104 to impart zonal characteristics (such as elasticity and/or other functional characteristics) throughout the article of footwear 100. Optionally, the base area 156 of the knitted component 104 may include one or more surface features that provide unique and desirable aesthetics to the upper 102, as well as certain functional characteristics. For example, the base area 156 may include one or more scallop elements 198. The scallop elements 198 may be similar or identical to those described in U.S. patent application Ser. No. 15/429,945, filed Feb. 10, 2017, entitled “KNITTED ARTICLE WITH AT LEAST ONE SCALLOP ELEMENT AND METHODS OF MANUFACTURE,” and having an assignee of NIKE, Inc., which is hereby incorporated by reference in its entirety. Other suitable texture-related and/or surface-related features in the base area 156 are also contemplated. For example, in some aspects, the base area 156 may include one or more pods that impart functional characteristics similar and/or identical to those described in U.S. patent application Ser. No. 16/054,132, filed Aug. 3, 2018, entitled “ARTICLE WITH AT LEAST ONE LAYERED POD,” and having an assignee of NIKE, Inc., which is hereby incorporated by reference in its entirety.

In some aspects, the knit structures within the base area 156 may include a knitted wedge or other structure to form the angle between the first tubular knit structure 140 and the second tubular knit structure 142. That is, referring to FIG. 5, a first area 158 of the base area 156 (corresponding to the first distance 152) may include a first number of courses, a second area 160 of the base area 156 (corresponding to the second distance 154) may include a second number of courses, where the first number of courses may be greater than the second number of courses. Such an aspect may be formed by varying the number of courses over the length of a needle bed within a certain number of time. For example, the first area 158 and the second area 160 may be completed in approximately (or exactly) the same amount of time on a knitting machine, but the first area 158 may be formed via more active passes of a knitting feeder (and thus more courses, and typically more knitted loops) than the second area 160.

In some aspects, certain yarns within the tubular structures may also extend through the base area 156. For example, referring to the first tubular knit structure 140 (and notably the same may apply for other tubular areas), at least one layer of the first tubular knit structure 140 may include a yarn that is common with the base area 156. Other yarn(s) of the first tubular knit structure 140 may be excluded from the base area 156. To illustrate, referring back to FIG. 4, the first layer 144 of the first tubular knit structure 140 may include a first yarn 162 that is substantially excluded from the base area 156, and the second layer 146 of the first tubular knit structure 140 may include a second yarn 164 that is common with the base area 156 (and therefore extends through the base area 156, perhaps forming knitted loops in both the second layer 146 of the first tubular knit structure 140 and also in the base area 156). Thus, the connection between the first tubular knit structure 140 and the surrounding base area 156 may primarily be via the second yarn 164.

Advantageously, by isolating the first yarn 162 on the first layer 144 of the first tubular knit structure 140 (i.e., such that is does not extend into the base area 156 beyond loops at the edges of the first tubular knit structure 140), the first yarn 162 may be specifically selected and configured for having a desirable surface characteristic without affecting the remainder of the structure. In some aspects, the first layer 144 may be formed substantially entirely from the first yarn 162 to enhance this feature (although this is optional). For example, in some instances, it may be desirable to use a transparent yarn such that the tensile strand 124 within the tubular knitted structures 134 is visible, but available yarns with a desirable aesthetic may not be suitable for inclusion in the base area 156 (e.g., due to having a particular elasticity, an incompatible bend modulus for loops within the base area 156, and the like). Further, yarns that may be desirable for use as the first yarn 162 may be incompatible with certain post-knitting manufacturing processes that affect the base area 156 (e.g., heat applied to the base area 156 to activate a meltable yarn may be incompatible with the first yarn 162, for example).

From the perspective of manufacturing efficiency, this unique feature of isolating the first yarn 162 from the base area 156 is advantageous for allowing simple substitution of one yarn type for another (as the first yarn 162) without requiring re-programming of a knitting machine to account for yarn changes when knitting the base area 156 (which is typically required when substituting one yarn type for another). Thus, it is contemplated that a consumer could customize an article of footwear with a particular look (e.g., color, transparency, and the like of the top layer of the tubular knit structure) and/or functional characteristic as determined by the first yarn 162, and the customized article of footwear may be quickly formed on a knitting machine without substantial re-programming of the respective knitting machine.

The first yarn 162 and the second yarn 164 may be the same yarn type or different yarn types. For example, the first yarn 162 may be a monofilament yarn, a high tenacity yarn (e.g., a yarn having a tenacity of at least 5 g/D, such as at least 10 g/D, 20 g/D, or more), and the like. In certain aspects, the second yarn 164 may preferably be a polyester yarn, which the inventors have found is suitable for forming the inner surface of an article of footwear as well as primarily forming the base area 156. Optionally, the depicted first yarn 162 and second yarn 164 may represent multiple yarns (e.g., the second yarn 164 shown in the figures may represent multiple strands of the same or different yarn types, for example one or more strands of polyester yarn combined with one or more strands of a fusible yarn configured for heat treatment).

FIG. 6 shows close-up perspective view of area 6 shown in FIG. 2. As shown in FIG. 6, the first tubular knit structure 140 and the second tubular knit structure 142 may optionally merge (i.e., converge together such that they lack space therebetween) at least at one location. In the depicted example, the first tubular knit structure 140 and the second tubular knit structure 142 merge near or in the throat area 116 such that a merged tubular area 170 is formed. Like the first tubular knit structure 140 and/or the second tubular knit structure 142, the merged tubular area 170 may include a tubular knit structure having multiple separable layers (e.g., where a first layer 172 of the merged tubular area 170 is formed on a first needle bed, where a second layer 174 of the merged tubular area 170 is formed on a second needle bed, and where a cavity/pocket between the first layer 172 and the second layer 174 form a cavity 176 for receiving the tensile strand 124.

The first layer 172 of the merged tubular area 170 may be continuous with the first layer 144 (FIG. 4) of the first tubular knit structure 140 (and similarly a first layer of the second tubular knit structure 142), and the second layer 174 of the merged tubular area 170 may be continuous with the second layer 146 (FIG. 4) of the first tubular knit structure 140 (and similarly a second layer of the second tubular knit structure 142). Further, the cavity 176 formed by the merged tubular area 170 may directly communicate (i.e., create a continuous passage) with the first passage 136 of the first tubular knit structure 140 and the second passage 138 of the second tubular knit structure 142. Thus, the same (continuous) tensile strand 124 may extend through each of the first passage 136 of the first tubular knit structure 140, the cavity 176 of the merged tubular area 170, and the second passage 138 of the second tubular knit structure 142.

In some aspects, an opening 178 may provide access to the cavity 176 of the merged tubular area 170. For example, the opening 178 may be a location where the first layer 172 and the second layer 174 of the merged tubular area 170 terminate (in the throat area 116) without connecting at the edge such that the cavity 176 can be directly accessed. Advantageously, the opening 178 may allow the loop 150 of the tensile strand 124 to extend beyond an edge 180 of the first layer 172 and/or the second layer 174, thereby providing space for engagement with a shoelace and/or other tensioning member. Advantageously, such an aspect may facilitate quick and efficient installation (e.g., lacing) of a shoelace, for example.

FIG. 7 shows a similar aspect to that of FIG. 6, but where the loop 150 of the tensile strand 124 remains within the cavity 176 of the merged tubular area 170. When a tensioning member is included (such as the shoelace 126), it may extend into the cavity 176 of the merged tubular area 170 such that it reaches the loop 150. From an external perspective (e.g., when the article of footwear 100 is in use), the loop 150 may not be visible, and/or it may be visually apparent that the shoelace 126 reaches into the merged tubular area 170. Such an aspect may be advantageous from protecting the tensile strands 124 from abrasion and/or for unique and striking visual characteristics, for example. It is also contemplated that such an aspect may protect tensile strand 124 from losing certain friction-related characteristics (e.g., lubrication) when such characteristics are involved in the performance of the article of footwear 100.

To facilitate lacing the shoelace 126 in the aspect of FIG. 7 (or otherwise installing a fastening system component), the first layer 172 and/or the second layer 174 may be sufficiently elastic such that the user can displace them enough to cause engagement between the shoelace 126 and the loop 150. Additionally or alternatively, it is contemplated that the tensile strand 124 may be pulled out of the cavity 176 during lacing (e.g., via stretchability and/or another type of elongation or displacement of the tensile strand 124).

FIG. 8 shows an aspect of the merged tubular area 170, where an opening 186 extends through the first layer 172 and/or the second layer 174, and where the opening 186 is configured (e.g., sized, shaped, and positioned) to receive the shoelace 126 (or other tensioning member). As shown, the tensile strand 124 may extend around the opening 186 such that lacing the shoelace 126 causes engagement between the shoelace 126 and the tensile strand 124. In this aspect, the opening 178 (shown in FIG. 6 but not FIG. 8) is not necessary. The openings 186 in the knitted component 104 may be formed through any suitable process. In some aspects, a piece of the knitted component 104 may be cut away, punched away, or otherwise removed to form the opening 186. In other aspects, the opening 186 may be formed by a particular structure of the knitted component 104. For example, during a knitting process on a flat knitting machine with at least one needle bed, one or more of needles of the needle bed(s) may be skipped while forming certain courses of the knitted component 104 such that a void is formed, and that void may eventually define the opening 186. Other suitable knit structures may additionally or alternatively be used to form the openings 186. When the openings 186 are formed by particular knit structures rather than by removing a portion of the knitted component 104 through cutting, punching, or another method, the openings 186 are said to be “knit-formed” in this disclosure.

Other suitable aspects are also contemplated. For example, in certain variations, a shoelace or other tensioning member may extend through a channel or passages of a tubular knit structure similar to those disclosed herein such that a separate anchor is not necessary. Additionally or alternatively, certain tubular knit structures may have different lengths (e.g., terminating prior to reaching the biteline and/or throat area of an upper), may extend in different directions (e.g., substantially longitudinally along the upper), may be located in different areas (e.g., in the toe area, heel area, in an underfoot area), etc.

FIG. 9-10 are illustrations showing example knit diagrams representing a knitting process for forming different portions of the knitted component 104 discussed above. FIG. 9, for example, shows a diagram representing a knitting process for knitting area 9 shown in FIG. 2. FIG. 10 shows an example where scallops are formed in a base area (e.g., similar to the base area 156 shown in FIG. 2). These diagrams are non-limiting, and one or both of these diagrams may be altered in a suitable manner to accommodate variations in the knitted component in other aspects.

As shown in FIG. 9, a first yarn 262 may form a first layer (e.g., similar to the first layer 144 of FIG. 4) of a first tubular knit structure 240 and a second tubular knit structure 242. The first tubular knit structure 240 and the second tubular knit structure 242 are each shown as being formed of a tubular knit construction (e.g., where yarns on the first needle bed 302 do not loop onto needles of the second needle bed 304, and vice versa). The first tubular knit structure 240 and the second tubular knit structure 242 may be separated by a base area 256, which is an area where yarns loop on both of the front and back needle bed (e.g., such that a cavity or passages formed between the needle beds is traversed by such yarn).

On the left side of FIG. 9, a merged tubular area 270 may be formed, where the merged tubular area 270 includes a tubular construction. As shown, the merged tubular area 270 lacks the base area 256 therebetween. In other words, the base area 256 terminates prior to reaching the merged tubular area 270, and thus passages of the first tubular knit structure 240 and the second tubular knit structure 242 are continuous with a cavity located within the merged tubular area 270.

As discussed above, a first yarn 262 may be isolated from the base area 256. In fact, the first yarn 262 is only looped on one of the two needle beds in this example (e.g., the first yarn 262 only loops onto needles of the first needle bed 302), and it never reaches any needle of the second needle bed 304. Thus, the first yarn 262 in this example is only located in a single layer (e.g., similar to the first layer 144 discussed above) and is excluded elsewhere. A second yarn, by contrast, is looped onto needles of both needle beds (at least in the base area 256). Advantageously, such an aspect allows for substitution of yarn types for the first yarn 262 without redesigning and/or reprogramming the base area 256 and/or other portions of the knitted component to account for a new yarn type (as discussed above).

Having described various aspects of the subject matter, additional disclosure is provided below, which includes certain aspects consistent with the originally-filed claims located at the end of this specification.

A first aspect includes an upper for an article of footwear, including one or more of the following: a first tubular knit structure, where the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passage is located between the first layer and the second layer; and a second tubular knit structure, where the second tubular knit structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passage is located between the third layer and the fourth layer. The first tubular knit structure may extend from a biteline of the upper to a throat area of the upper, where the second tubular knit structure extends from the biteline of the upper to the throat area of the upper, and where a longitudinal direction of the first tubular knit structure is angled at least 5 degrees relative to a longitudinal direction of the second tubular knit structure. Implementations may include one or more of the following aspects in the paragraphs below.

A first portion of a tensile strand may extend through the first passage, and a second portion of the tensile strand extends through the second passage. A loop of the tensile strand may be located between the first portion of the tensile strand and the second portion of the tensile strand, where the loop is configured for engagement to a tensioning member of a fastening system. The loop may extend from an opening providing access to a cavity of a merged tubular area located in the throat area of the upper. Or, the loop may be located inside a cavity of a merged tubular area located in the throat area of the upper.

The first tubular knit structure and the second tubular knit structure may merge at a location in or adjacent to the throat area of the upper.

The first tubular knit structure may be a first distance from the second tubular knit structure at the biteline of the upper, where the first tubular knit structure is a second distance from the second tubular knit structure at the throat area of the upper, and where the first distance is greater than the second distance.

A knitted base area may be located between the first tubular knit structure and the second tubular knit structure. The knitted base area may include a first number of courses in a first area adjacent to the upper, where the knitted base area includes a second number of courses adjacent to the biteline, and where the first number of courses is greater than the second number of courses to create the angled orientation of the first tubular knit structure relative to the second tubular knit structure.

The first layer may include a first yarn, where the first yarn is excluded from the knitted base area.

An additional aspect relates to an upper for an article of footwear including one or more of the following: a first tubular knit structure, where the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passage is located between the first layer and the second layer; and a second tubular knit structure, where the second tubular knit structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passage is located between the third layer and the fourth layer. The first tubular knit structure may extend from a biteline of the upper to a throat area of the upper, where the second tubular knit structure extends from the biteline of the upper to the throat area of the upper, where a knitted base area is located between the first tubular knit structure and the second tubular knit structure at a location adjacent to the biteline, and where the first tubular knit structure and the second tubular knit structure merge at a merged tubular area located in or adjacent to the throat area of the upper. Implementations may include one or more of the following aspects in the paragraphs below.

A first portion of a tensile strand may extend through the first passage, where a second portion of the tensile strand extends through the second passage, where a loop of the tensile strand is located between the first portion of the tensile strand and the second portion of the tensile strand, and where the loop is configured for engagement to a tensioning member of a fastening system. The loop may extend from an opening providing access to a cavity of the merged tubular area located in the throat area of the upper. Or, the loop may be located inside a cavity of the merged tubular area located in the throat area of the upper.

The knitted base area may include a first number of courses in a first area adjacent to the upper, where the knitted base area includes a second number of courses adjacent to the biteline, and where the first number of courses is greater than the second number of courses to create the angled orientation of the first tubular knit structure relative to the second tubular knit structure.

The first layer may include a first yarn, where the first yarn is excluded from the knitted base area.

An additional aspect relates to an upper for an article of footwear including one or more of the following: a first tubular knit structure, where the first tubular knit structure that includes a first layer and a second layer, the first layer and the second layer being separable such that a pocket is located between the first layer and the second layer; and a knitted base area located adjacent to the first tubular knit structure on at least one side of the first tubular knit structure. The first layer of the first tubular knit structure may include a first yarn, where the second layer of the first tubular knit structure includes a second yarn, and where the first yarn is substantially excluded from the knitted base area. Implementations may include one or more of the following aspects in the paragraph below.

The first yarn and the second yarn may include different yarn types.

The second yarn may be knitted within the knitted base area.

The first yarn may include a monofilament yarn, and where the second yarn includes a polyester yarn.

While various embodiments of the present disclosure have been described, the present disclosure is not to be restricted except in light of the attached claims and their equivalents. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims. Moreover, the advantages described herein are not necessarily the only advantages of the present disclosure and it is not necessarily expected that every embodiment of the present disclosure will achieve all of the advantages described.

Claims

1. An upper for an article of footwear, comprising: a first tubular knit structure, wherein the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passage is located between the first layer and the second layer; anda second tubular knit structure, wherein the second tubular knit structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passage is located between the third layer and the fourth layer,wherein the first tubular knit structure extends from a biteline of the upper to a throat area of the upper,wherein the second tubular knit structure extends from the biteline of the upper to the throat area of the upper, andwherein a longitudinal direction of the first tubular knit structure is angled at least 5 degrees relative to a longitudinal direction of the second tubular knit structure.

2. The upper for the article of footwear of claim 1, wherein a first portion of a tensile strand extends through the first passage, and wherein a second portion of the tensile strand extends through the second passage.

3. The upper for the article of footwear of claim 2, wherein a loop of the tensile strand is located between the first portion of the tensile strand and the second portion of the tensile strand, and wherein the loop is configured for engagement to a tensioning member of a fastening system.

4. The upper for the article of footwear of claim 3, wherein the loop extends from an opening providing access to a cavity of a merged tubular area located in the throat area of the upper.

5. The upper for the article of footwear of claim 3, wherein the loop is located inside a cavity of a merged tubular area located in the throat area of the upper.

6. The upper for the article of footwear of claim 1, wherein the first tubular knit structure and the second tubular knit structure merge at a location in or adjacent to the throat area of the upper.

7. The upper for the article of footwear of claim 1, wherein the first tubular knit structure is a first distance from the second tubular knit structure at the biteline of the upper, wherein the first tubular knit structure is a second distance from the second tubular knit structure at the throat area of the upper, and wherein the first distance is greater than the second distance.

8. The upper for the article of footwear of claim 1, wherein a knitted base area is located between the first tubular knit structure and the second tubular knit structure.

9. The upper for the article of footwear of claim 8, wherein the knitted base area includes a first number of courses in a first area adjacent to the upper, wherein the knitted base area includes a second number of courses adjacent to the biteline, and wherein the first number of courses is greater than the second number of courses to create the angled orientation of the first tubular knit structure relative to the second tubular knit structure.

10. The upper for the article of footwear of claim 8, wherein the first layer includes a first yarn, and wherein the first yarn is excluded from the knitted base area.

11. An upper for an article of footwear, comprising: a first tubular knit structure, wherein the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passage is located between the first layer and the second layer; anda second tubular knit structure, wherein the second tubular knit structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passage is located between the third layer and the fourth layer,wherein the first tubular knit structure extends from a biteline of the upper to a throat area of the upper,wherein the second tubular knit structure extends from the biteline of the upper to the throat area of the upper,wherein a knitted base area is located between the first tubular knit structure and the second tubular knit structure at a location adjacent to the biteline, andwherein the first tubular knit structure and the second tubular knit structure merge at a merged tubular area located in or adjacent to the throat area of the upper.

12. The upper for the article of footwear of claim 11, wherein a first portion of a tensile strand extends through the first passage, and wherein a second portion of the tensile strand extends through the second passage, wherein a loop of the tensile strand is located between the first portion of the tensile strand and the second portion of the tensile strand, and wherein the loop is configured for engagement to a tensioning member of a fastening system.

13. The upper for the article of footwear of claim 12, wherein the loop extends from an opening providing access to a cavity of the merged tubular area located in the throat area of the upper.

14. The upper for the article of footwear of claim 12, wherein the loop is located inside a cavity of the merged tubular area located in the throat area of the upper.

15. The upper for the article of footwear of claim 11, wherein the knitted base area includes a first number of courses in a first area adjacent to the upper, wherein the knitted base area includes a second number of courses adjacent to the biteline, and wherein the first number of courses is greater than the second number of courses to create the angled orientation of the first tubular knit structure relative to the second tubular knit structure.

16. The upper for the article of footwear of claim 11, wherein the first layer includes a first yarn, and wherein the first yarn is excluded from the knitted base area.

17. An upper for an article of footwear, comprising: a first tubular knit structure, wherein the first tubular knit structure that includes a first layer and a second layer, the first layer and the second layer being separable such that a pocket is located between the first layer and the second layer; anda knitted base area located adjacent to the first tubular knit structure on at least one side of the first tubular knit structure,wherein the first layer of the first tubular knit structure includes a first yarn,wherein the second layer of the first tubular knit structure includes a second yarn, andwherein the first yarn is substantially excluded from the knitted base area.

18. The upper for the article of footwear of claim 17, wherein the first yarn and the second yarn include different yarn types.

19. The upper for the article of footwear of claim 17, wherein the second yarn is knitted within the knitted base area.

20. The upper for the article of footwear of claim 17, wherein the first yarn includes a monofilament yarn, and wherein the second yarn includes a polyester yarn.