HK1249558B - An upper for an article of footwear with a cuff and a method of making same - Google Patents

Description

Upper with a welt for footwear and method of making the same

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Serial No. 62/307,115, filed March 11, 2016, which is incorporated herein by reference in its entirety.

background

Conventional footwear typically includes two main components: an upper and a sole structure. The upper is secured to the sole structure and forms a cavity within the footwear for comfortably and securely receiving the foot. The sole structure is secured to the lower surface of the upper so as to be positioned between the upper and the ground. For example, in some articles of athletic footwear, 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 reduce stress on the foot and leg during walking, running, and other ambulatory movements. The outsole is secured to the lower surface of the midsole and forms the ground-engaging portion of the sole structure, which is formed from a wear-resistant material.

The upper of an article of footwear typically extends over the instep and toe area of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. Access to the cavity on the interior of the upper is typically provided through an ankle opening in the heel area of the article of footwear. A lacing system is typically incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the cavity within the upper. Additionally, the upper may include a tongue that extends under the lacing system to enhance the adjustability of the article of footwear, and the upper may include a heel counter to limit movement of the heel. Description

In one aspect, an upper for an article of footwear may include a knit element, a collar region configured to form an ankle opening, and a cuff in the collar region. The cuff may be formed at least in part by the knit element and may include a ribbed knit structure of the knit element.

The knit element may include a second knit structure, wherein a lower portion of the upper is formed by the second knit structure.

The rib knit structure may include at least one rib having a length extending in a longitudinal direction along the mouth.

The rib knit structure may include yarns formed from an elastic material.

The bead may comprise at least one opening, and the opening may be formed on a knitting machine by skipping a series of consecutive needles on a needle bed, the series of consecutive needles occupying a distance that is at least three times greater than the unstretched width of the opening.

The bead may include at least one yarn that is substantially hidden from view when the bead is in an unstretched state and from a perspective directed toward an outer surface of the bead. When the bead is in a stretched state, the at least one yarn may be revealed at that perspective.

The bead may be configured to form an inverted state in which end portions of the bead are inverted to form overlapping portions.

The knitted element may include at least one inlaid strand in a toe region of the upper.

In another aspect, an upper for an article of footwear may include a knitted element having a first region including a first side and a second side opposite the first side. The first side may be formed from at least 30% more material than the second side, such that the first region is configured to curve convexly away from the first side.

The first side may be formed from at least 50% more material than the second side.

The first area may be at least partially positioned in a toe box region of the upper.

The first side may include a plurality of loops forming an exterior surface of the upper.

The knitted element may include a second area having a different knit structure than the first area.The second area may include a welt positioned in a collar area of the upper.

The first region of knitted elements can be formed on a knitting machine having a first series of needles on a first needle bed and a second series of needles on a second needle bed.

The first region may comprise at least one yarn which forms a loop around each of the first series of needles during threading when forming the first region.The at least one yarn may be tucked at least one of the second series of needles during threading.

The at least one yarn may be tucked during threading at every other needle in the second series of needles.

In another aspect, a method of manufacturing an upper for an article of footwear may include knitting a first threading of a knitted element using a knitting machine having a first series of needles on a first needle bed and a second series of needles on a second needle bed, wherein knitting the first threading comprises: looping at least one yarn on each needle in the first series of needles and pleating the at least one yarn on at least one needle in the second series of needles.

The step of tucking the at least one yarn against at least one needle of the second series of needles during the first threading may comprise tucking the at least one yarn against every other needle of the second series of needles.

The method may also include knitting a second threading of the knitted element with a knitting machine, wherein knitting the second threading includes forming a loop with at least one yarn on each needle in a first series of needles, and wherein knitting the second threading includes plucking the at least one yarn at needles in the second series of needles that were not occupied during the first threading.

The method may further include knitting a third threading of the knitted element with the knitting machine, wherein the third threading includes forming a loop on each needle in the first series of needles and skipping all needles in the second series of needles. The method may further include knitting a fourth threading of the knitted element with the knitting machine, wherein the fourth threading includes forming a loop on each needle in the second series of needles and skipping all needles in the first series of needles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 illustrates an article of footwear according to certain aspects of the present disclosure;

FIG2 illustrates a medial side view of an article of footwear including a welt;

FIG3 shows a sequence for knitting a first knit structure;

FIG4 illustrates a medial side view of an article of footwear including a bead, wherein the bead is in an inverted position;

FIG5 shows a sequence for knitting a second knit structure; and

FIG. 6 illustrates an upper formed from knitted elements having a curved portion in the toe box area.

Detailed description

The various aspects are described below with reference to the accompanying drawings, in which similar elements are generally represented by similar reference numerals. The relationship and function of the various elements of the various aspects may be better understood by reference to the following detailed description. However, the various aspects are not limited to those shown in the accompanying drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale and that in some cases, details not necessary for understanding the aspects disclosed herein, such as conventional manufacturing and assembly, may be omitted.

Certain aspects of the present disclosure relate to uppers configured for use in articles of footwear. The uppers can be used with any type of footwear. Illustrative, non-limiting examples of articles of footwear include basketball shoes, cycling shoes, cross-training shoes, international football (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski boots or snowboard boots, tennis shoes, running shoes, and walking shoes. The uppers can also be incorporated into non-athletic shoes, such as dress shoes, loafers, and sandals.

1 , an article of footwear is generally depicted as including a sole 110 and an upper 120. Upper 120 includes a lateral side 104, a medial side 105, and a heel region 122. The area of the shoe where sole 110 joins the outer edge of upper 120 may be referred to as a biteline 116. Upper 120 may be attached to sole 110 in a fixed manner using any suitable technique (e.g., by using an adhesive, by stitching, etc.).

In some embodiments, sole 110 includes a midsole 111 and an outsole 112. The article of footwear may further include a throat 107 and an ankle opening 121, which is surrounded by a collar 129 and opens into a cavity 128. Upper 120 defines a cavity 128 of the article of footwear that receives a person's foot. Throat 107 is disposed in midfoot region 102 of upper 120. Midfoot region 102 is generally the section of upper 120 located between heel region 122 and toe portion 101.

In FIG1 , a tongue 124 is disposed within the throat 107 of the article of footwear, but the tongue 124 is an optional component, as is the lace 103. Although the tongue 124 shown in FIG1 is a conventional tongue, the tongue 124, if included, can be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included, the lateral and medial sides of the throat 107 can, for example, be connected together.

Upper 120 may be formed at least in part by knitted element 140 (and as depicted, upper 120 may be formed substantially or entirely by knitted element 140). Although upper 120 is described herein as including knitted element 140, upper 120 may alternatively or additionally include a textile component formed by a process other than knitting (e.g., braiding). Knitted element 140 may be a multi-layer knitted element, such as a two-layer knitted element, wherein a first layer forms a first side and a second layer forms a second side. The first side may define an exterior surface of upper 120, and the second side may define a surface facing cavity 128 of the article of footwear.

2 , an upper 220 of an article of footwear can have a collar area 229 leading to a cavity (not shown). Collar area 229 can be formed by a knitted element 240. In some embodiments, collar area 229 can include a bead 230. Bead 230 can be configured to surround at least a portion of an ankle and/or leg of a person wearing the article of footwear. In some embodiments, bead 230 can extend about 8 inches or more above the ankle of the person wearing the article of footwear, but the height of bead 230 can be adjusted based on the size of the article of footwear, the type of footwear (e.g., the type of shoe, such as a walking shoe or a basketball shoe), the preferences of the person wearing the article of footwear, or similar factors. The bead 230 can be advantageous, for example, by providing additional support to the ankle and/or calf (e.g., to prevent or reduce ankle inversion), by providing protection from harsh conditions (e.g., when the footwear is a boot for rugged outdoor use), by providing a comfortable and secure fit to the foot, and/or by providing pleasing aesthetics.

Knitting element 240 can include more than one type of knitting structure, such as rib knitting structure, single jersey knitting structure or double jersey knitting structure (single or double jersey knit structure) or similar structure. For example, as depicted, knitting element 240 can have a first portion 232 (which can include a welt 230) formed by a first knitting structure and a second portion 234 formed by a second knitting structure. Although knitting element 240 is described as having two knitting structures, it should be expected that more than two knitting structures can be included. The first portion 232 and the second portion 234 can be knitted integrally on a knitting machine so that they do not need to be attached to each other in a post-knitting process. In addition, each knitting structure can change in some aspects at different positions (for example, some characteristics of the first knitting structure can change at different positions of the first portion 232).

In some embodiments, the first portion 232 can be formed of a rib knit structure (e.g., full rib, full cardigan, 1x1 rib, 2x1 rib, Fisherman rib, English rib), while the second portion 234 can be formed of a second knit structure that is not a rib knit structure (e.g., a single jersey structure or a double jersey structure). As shown in the depicted embodiment, the first portion 232 of the knit element 240 can extend from the end portion 238 of the bead 230 to the second portion 234 and extend through the throat 207 of the upper 220. The second portion 234 can extend generally around the article of footwear adjacent to the bite line 216, extending from the heel area 222 on the medial side, around the toe box area 201, to the heel area 222 on the lateral side (not shown). Although not shown in FIG. 2 , the knit element 240 may include a transition section between the first portion 232 and the second portion 234 , where the first knit structure of the first portion 232 transitions to the second knit structure of the second portion 234 within a certain distance.

The first portion 232 and the second portion 234 may have a common yarn. In some embodiments, at least one of the yarns forming the first portion 232 may be different from at least one of the yarns forming the second portion 234. For example, the first portion 232 may be formed at least in part from yarns comprising an elastic material. It will be understood that the term "elastic material," as used herein, refers to a material that is more elastic than an inelastic material (inelastic materials include thermoplastic polymers, leather, synthetic leather, vinyl, or the like). Exemplary elastic materials suitable for use in the disclosed embodiments may include latex, spandex, or elastane (commonly known as Lycra). Fibers of an elastic material (e.g., spandex fibers) can be stretched to twice their unstretched length, four times their unstretched length, or even eight or more times their unstretched length without breaking. Yarns made substantially of an elastic material may be referred to herein as "elastic yarns." These elastic yarns of the first portion 232 may be combined with yarns made of an inelastic material or other material. On the other hand, the second portion 234 may be substantially free of elastic yarns. In some embodiments, the second portion 234 can be formed primarily from polyester yarn, although other suitable yarns can additionally or alternatively be used.

In some embodiments, the bead 230 can be formed from a knit structure that exhibits a high degree of elasticity, such as a rib knit structure (e.g., a full-rib knit structure or an English rib knit structure). Because rib knit structures are particularly elastic in a direction perpendicular to the length of their ribs, it can be advantageous to provide the bead 230 with a rib knit structure having one or more ribs 231 extending along the longitudinal axis of the bead 230, which can allow the bead 230 to fit snugly around a person's ankle and/or leg. A specific example of a process for forming a rib knit structure suitable for use in the bead 230 is illustrated by the sequential knitting diagram in FIG3 .

Referring to FIG3 , step 3A shows threading in a leftward direction (e.g., the yarn travels past and/or through the needles of the knitting machine), wherein a first yarn 366 forms a loop at each needle on the front needle bed 362 and is pleated at each needle on the rear needle bed 360. The first yarn 366 can be a single yarn or can be multiple yarns or other threads. Note that the directions (left and right) and/or the needle beds (front and back) can be reversed. In step 3B, a second yarn 368 is threaded in a leftward direction, wherein the second yarn 368 forms a loop at each needle on the rear needle bed 360 and is pleated at each needle on the front needle bed 362. The second yarn 368 can have different properties (e.g., elasticity, strength, denier, color) than the first yarn 366. In some embodiments, at least one of the first yarn 366 and the second yarn 368 is an elastic yarn, while the other is a polyester yarn. In another embodiment, both are elastic yarns but of different colors. Next, in step 3C, the first yarn 366, now threaded to the right, is looped at each needle on the front needle bed 362 and pleated at each needle on the back needle bed 360. Note that a different yarn (e.g., the second yarn 368 or the third yarn) can be used during this step. Finally, in the depicted step 3D, the second yarn 368, now threaded to the right, is looped at each needle on the back needle bed 360 and pleated at each needle on the front needle bed 362. Note that this sequence can use any suitable number of yarns and is not limited to only two. Each of the yarns can be selected to have specific properties to optimize the characteristics of the bead 230.

The sequence described in Figure 3 can be advantageous because it can form a stable structure that is particularly elastic in the horizontal direction when referring to Figures 2 and 3A. This elasticity can correspond to a comfortable and secure fit around the wearer's ankle, foot and/or leg. The elastic effect can be enhanced by adopting one or more elastic yarns. In a non-limiting example, at least 20% of the yarns forming the bead 230 are yarns that are at least partially formed by an elastic material, and in some embodiments, about 50% or more (even up to 100%) of the yarns forming the bead 230 are at least partially formed by an elastic material. For example, with reference to Figure 3, the first yarn 366 and/or the second yarn 368 can be formed by spandex. In addition, the stability of the knitted structure formed by sequentially combining the spandex yarn can provide a fully stable bead 230 so that when the footwear is not in use, the bead 230 does not sag, bend or otherwise deform under its own weight. This structure can allow a 6-inch high, 12-inch high, or 16-inch high (or even higher) bead 230 to stand upright without additional support. In an exemplary embodiment, the bead 230 can be about 8 inches high.

In some embodiments, referring back to FIG2 , the rib knit structure forming the bead 230 can exhibit desired aesthetic properties. For example, the first yarn 366 and the second yarn 368 described in FIG3 can have different colors that produce a desired visual contrast. For example, the knit structure formed by the sequence of FIG3 can have two opposing sides, wherein one side appears to be the inverse of the other side. In some embodiments, when the article of footwear is in use, the bead 230 can have a dynamic visual effect. For example, when the bead 230 is in an unstretched state, from at least one perspective directed toward the outer surface of the bead 230, some yarns (e.g., the second yarn 368 of FIG3 ) can be partially or substantially hidden. The unstretched state can refer to a state in which the article of footwear is not worn so that the bead 230 is free to stand upright, and/or it can refer to a state in which the article of footwear is worn but the bead 230 is stretched to a certain extent less than its maximum functional amount of stretch. When the bead 230 is then stretched beyond the unstretched state so that it is converted to a stretched state, the hidden yarn can be revealed to the view from the above-mentioned perspective. This stretching can be the result of a person putting on the footwear and/or moving the ankle to deform the bead 230. As a result, certain colors can alternate between being visible and invisible while the wearer walks, runs, etc. This can produce a desired visual effect for the person wearing the footwear and/or bystanders.

As shown in Figure 2, one or more openings (depicted as opening 236) can be formed in the welt 230 or in another position of the knitted element 240, be included in the region where the elastic yarn is positioned of the knitted element 240 and form. The opening can have any size, and in some embodiments can have an unstretched width from about 1/8 inch to about 1 inch, yet it should be expected that larger or smaller openings can be used. Any suitable number of openings can be provided. Exemplary embodiments can have any opening from about 1 opening to about 100 openings relevant to each ankle of the person, yet more openings can be provided. Opening 236 can be advantageously used to enhance the breathability, flexibility and aesthetic properties of footwear, which may be desirable particularly in the athletic shoes used in situations where athletic performance is important.

In order to form opening 236, any suitable knitting technology or other technology can be used.Opening 236 can be cut out from knitting element 240 after knitting element 240 is formed. In one embodiment, opening 236 can be formed in knitting element 240 by skipping a series of needles on one or more needle beds during the knitting process. Herein, " a series of needles " refers to two or more continuous needles on a single needle bed of a knitting machine. The number of the needles skipped during each threading can have a specific order (for example, skipping two needles during twice threading, skipping four needles during next two threadings, and then skipping six needles during subsequent two threadings) so that the opening formed has a pyramid, a rhombus or similar shape. In some embodiments, each opening 236 can be formed by skipping a series of needles, and this series of needles occupies a distance substantially greater than the unstretched width of opening 236 itself. To illustrate, opening 236 can be formed with a relatively large width when on the knitting machine (e.g., when the yarn surrounding opening 236 is stretched), but the width of opening 236 can be smaller when removed from the knitting machine and when opening 236 is in a relaxed, unstretched state. In one example, opening 236 can correspond to skipping a series of six consecutive needles on a standard-sized needle bed. The six needles in this series can occupy a distance that is equal to approximately 2, 4, or 8 times (or more) the width of each of the plurality of openings 236 in an unstretched state when incorporated into an article of footwear. In an exemplary embodiment, the skipped series of needles occupies a distance equal to approximately 3 times the unstretched width of opening 236.

Referring to FIG4 , bead 230 is shown in an inverted position (as opposed to the upright position shown in FIG2 ), wherein an overlapping portion 242 of bead 230 overlaps another portion of bead 230. Thus, bead 230 can be configured such that at least an end portion 238 of bead 230 can be folded or inverted to overlap another portion of bead 230, thereby forming the inverted position. As depicted, end portion 238 of bead 230 can be pulled downwardly above (or alternatively below) the outer surface of bead 230 and can block a view of at least a portion of the outer surface. It is contemplated that in some embodiments, overlapping portion 242 is permanent (e.g., by sewing or otherwise affixing end portion 238 into position, as depicted in FIG4 ). However, in exemplary embodiments, bead 230 can be configured such that a person can transition back and forth between the upright position of FIG2 and the inverted position of FIG4 while wearing the article of footwear and/or prior to donning the article of footwear. The ability to convert from an upright position to an inverted position (and vice versa) is advantageous because the two positions can be specifically adapted for different functions. For example, the upright position can be particularly suitable for supporting and protecting the upper ankle and calf, while the inverted position can be particularly beneficial for comfort during leisure activities, for providing low-ankle support, and for promoting the removal of a person's foot when putting on footwear and removing the person's foot when taking off footwear. In addition, it is contemplated that a removable protective device (e.g., a shin guard) or another object can be placed and held between the outer layer and the inner layer of overlapping portion 242. The inverted position depicted in Figure 4 can also present advantageous aesthetic properties. For example, because the rib knit structure forming bead 230 (as described above) can have different visual properties (and potentially inverse visual properties) on each side, overlapping portion 242 can produce a desired visual contrast with other parts of knitted element 240.

As mentioned above, the rib knit structure is not limited to the welt 230, but may also occupy any other area of the knit element 240. As shown in Figure 4, the rib knit structure extends within the knit element 240 into the throat 207 of the upper 220, however, this is not required. It is contemplated that the rib knit structure may occupy substantially all of the upper 220, but in an exemplary embodiment, a smaller elastic knit structure may be used to form the second portion 234 of the upper.

The shoe throat area 244 adjacent to the shoe throat 207 may include one or more loops 246 extending from the tensile thread 248 depicted. The tensile thread 248 is an optional component and can form shoelace eyelets (e.g., holes passing through the loops 246) to receive shoelaces and/or can be wrapped around other shoelace eyelets formed in the knitted element 240. The tensile thread can be a yarn, cable, rope (rope) or any other type of line. The tensile thread can be flexible, but it can also have a substantially fixed length measured from the first end to the second end. In this way, the tensile thread can be substantially inelastic. One or more tensile threads can extend across the shoe upper 220 in any direction. The tensile thread can be at least partially embedded in the knitted element 240. The tensile thread can limit the stretching of the knitted element. Moreover, in some aspects, some parts of the tensile thread can be exposed from the knitted element. For example, some parts of the tensile thread can extend out of the knitted element in the shoe throat area to form loops 246. See, for example, U.S. Patent Application Publication No. 2015/0359290, U.S. Patent Application Publication No. 2014/0237861, and U.S. Patent No. 9,145,629, which are incorporated herein in their entireties.

Some tensile strands 256 can extend in the toe box area 201 of the knitted element 240, as shown in Figures 2 and 4. The tensile strands 256 can be at least partially embedded in the knitted element 240, and in some embodiments, the tensile strands 256 can be embedded and not visible on the outer surface of the upper 220. The tensile strands 256 can extend in the toe box area 201 from the bite line 216 on the medial side to the bite line 216 on the lateral side (not shown). Advantageously, the tensile strands 256 can limit the elongation of the toe box area 201 of the knitted element 240, particularly in the lateral direction.

Any suitable knitting structure can be used for second portion 234. An exemplary knitting structure that can be used can be formed by using a knitting sequence as shown in Figure 5 performed on a knitting machine, which can only involve a single yarn (depicted as yarn 570), but multiple yarns can be used. Two or more of step 5A-step 5H can involve a single yarn or multiple yarns with different properties. Some and possibly all of the yarns used in this order can include polyester material. In addition, more than one yarn can be involved at each step of the sequence, and each yarn can be selected to have certain properties to optimize the characteristic of the second portion 234 of knitted element 240.

In Figure 5, the needles of the series depicted on the front needle bed 562 can be associated with the outside (called the first side) of the knitting element 240 (shown in Figures 2 and 4), and the needles of the series depicted on the back needle bed 560 can be associated with the inside (called the second side) of the knitting element 240, but the opposite situation is also possible. It is also expected that the direction of threading described herein can be reversed. Step 5A represents threading in the left direction, wherein pleating is carried out at every other needle on the front needle bed 562 and every other needle on the back needle bed 560 (note that unoccupied needles are not shown in Figure 5). On the contrary, in some embodiments, pleating at 1 out of 3 needles, 2 out of 3 needles, or another ratio of needles can be used in this step. In step 5B, threading is now to the right, loops are formed on each of the needles of the front needle bed 562, and pleating is carried out at every other needle of the back needle bed 560. As shown in step 5B, pleating during this threading can be performed on each opposing needle relative to the pleating represented by step 5A. The loops formed on the front needle bed 562 in step 5B can form part of the outer surface of the knitted element 240 (of Figures 2 and 4). Now threading to the left again, step 5C involves a loop on each needle of the front needle bed 562, and step 5D threading to the right involves a loop on each needle of the back needle bed 560.

The sequence of steps 5A-5D can then be repeated as necessary. In some embodiments, the sequence of Figures 5A-5D is repeated, but offset by one needle (as depicted by steps 5E-5H). For example, as shown by step 5E, when threading the yarn to the left, pleating can be performed on every other needle of front needle bed 562 and every other needle of back needle bed 560, but these pleatings may occupy needles not occupied during threading in step 5A. Then, as shown in step 5F, loops can be formed on every needle of front needle bed 562, while pleating is performed on every other needle of back needle bed 560, where the needles involved in pleating on back needle bed 560 are offset by one relative to the pleating in step 5B. In steps 5G-5H, loops can be formed on every needle of front needle bed 562 and every needle of back needle bed 560, respectively. Although the sequence of Figure 5 is described in detail herein, it is contemplated that any of the steps can be modified at one or more of the needles. Again, this sequence is not intended to be limiting, but rather is provided as an example of a sequence that may form a suitable knit structure for the second portion 234 (FIGS. 2 and 4) of the knit element 240.

A feature of the knitting structure formed by the order of Fig. 5 is that one side of knitting element 240 is relevant with significantly more material (this is measured with the surface area of the yarn relevant with each side) compared to the other side.Similarly, one side can have significantly more loops compared to the other side.For illustration, with reference to the loops formed in the order shown in Fig. 5 (that is, 8 needles of a series of 8 needles on the front needle bed 562 and the corresponding series on the back needle bed 560 are threaded 8 times), 32 loops are formed on the front needle bed 562, and only 16 loops are formed on the back needle bed 560.Therefore, compared to the opposite side (second side) of knitting element 240, significantly more material and significantly more loops can form the outside (first side) of knitting element 240.In some embodiments, one side of knitting element 240 can be relevant with about 10%, 20%, 30%, 40%, 50%, 60% or even 70% or more material and/or more loops compared to the other side. As a result of the additional material and additional loops on the first side of the knit element 240, the first side of the knit element 240 may be relatively compressed (when compared to the second side), and/or the second side of the knit element 240 may be relatively tense (when compared to the first side). This may provide the knit element 240 with a tendency to form and maintain a curved shape (as shown in FIG6 ). The tendency may be to curve convexly away from the first side (e.g., the outside) of the knit element 240, as shown by the curved portion 650 of FIG6 .

Figure 6 shows an upper 620 including a knitted element 640, as it would appear after being formed on a knitting machine and before being formed into its final form (and potentially, before being attached to other elements of an article of footwear, such as the sole 110 of Figure 1). The upper 620 is depicted as having stripes extending laterally across the upper 620 on the outer surface for purposes of illustrating the curvature in Figure 6, but these stripes are not required. In this embodiment, the upper 620 is shown without a welt, however, a welt may be included. Additionally, in this embodiment, the knitted element 640 does not extend into the throat 607. As shown, the knitted element 640 may include a curved portion 650 in the toe box area 601 of the upper 620. The curved portion 650 may be formed due to the natural tendency of the knitted element 640 to bend in this area, for example, due to more material and/or more loops forming one side than the other side. In some embodiments, the curved portion 650 may be formed at different locations of the knitted element 640. A plurality of curved portions may be formed.

The end 652 and the end 654 positioned in the heel area 622 of the upper 620 can be attached together (for example, by sewing or using an adhesive), thereby forming a seam in the heel area 622. In some embodiments, this seam can extend upwards to the shoe collar and/or pass through the edge. The seam can be positioned in any other place on the knitted element 640 in addition or alternatively. In some embodiments (not shown), a seam can appear in the toe box area 601 and can extend through the curved portion 650, which may be advantageous when using a specific knitting machine, which is limited in the amount of curvature of the one integrally knit piece (one integrally-knit piece) of the knitted element that it can provide. In order to overcome this limitation, the knitting machine can knit two pieces of the knitted element separately, both of which show a tendency to bend. The pieces can then be attached (for example, by sewing) so that the sum of the curvature of the two pieces is suitable for use in the upper. In other embodiments, the knitted element can be knitted into one piece and can be seamless at least in its toe box area.

After the knitting process, the upper 620 can go through one or more post-processing steps. For example, in no particular order, the upper 620 can be attached to other elements of the article of footwear (e.g., Strobel and/or sole), can be placed on a last of the foot shape, and can be steamed or otherwise processed to form its shape for incorporation into the final product (i.e., article of footwear). As described above, the tendency to bend can advantageously promote the upper 620 to be formed into its desired shape (and maintain this desired shape) while reducing the necessity of the post-processing steps. In addition, the upper can be formed and maintain its final shape without including heat-activated yarn and/or fusible yarn (such as thermoplastic polymer yarn), which has been included in the knitted upper due to its ability to form and maintain a certain shape of the upper when heat-activated (e.g., melted and then cooled).

In FIG6 , knitting element 640 is depicted as clearly showing the curvature in curved portion 650, but it is also expected that this curvature may not be visually apparent when knitting element 640 is removed from the knitting machine and/or laid flat while still separated from the other components of the article of footwear. However, since knitting element 640 can have more material on its first side (e.g., the outside) than on its second side (e.g., the inside), the curvature can be achieved relatively easily and can be maintained if and when upper 620 undergoes post-processing steps. In addition, the tendency to bend can be enhanced by certain post-processing steps (such as steaming, which can, for example, tighten the yarns of knitting element 640), which can enhance the effect of the difference between the amount of material forming each side of knitting element 640.

The knitting structure formed according to the order described in Fig. 5 can also have other characteristics.For example, the knitting structure of (Fig. 4) second portion 234 can be relatively inelastic at least when compared to the first knitting structure forming first portion 232.Therefore second portion 234 can provide the structural integrity of the part that may need strength and support and may repeatedly experience high stress that is suitable for vamp 220.In addition, the loops exposed on the outer surface of knitting element 240 (for example, the loops formed on the front needle bed 562 of Fig. 5) can form the texture surface (textured surface) of knitting element 240, and this texture surface produces the visual effect of expectation on the outer surface of vamp 220.It is expected that these loops can be formed by multiple yarns with various colors.Each color can be specifically located, thereby forms aesthetically pleasing pattern.In addition, these loops exposed on the outer surface of knitting element 240 can provide desirable functional characteristics (for example, when clamping (grip) or contacting another object (such as ball) when increasing friction) to vamp 220.

In view of the present disclosure, all structures and methods disclosed and claimed herein can be made and realized without excessive experimentation. Although the present invention can be implemented in many different forms, specific aspects of the present invention are described in detail herein. The present disclosure is an example of the principles of the present invention and is not intended to limit the present invention to the specific aspects shown. In addition, unless clearly stated to the contrary, the use of the term "one (a)" is intended to include "at least one" or "one or more". For example, "a yarn (a yarn)" is intended to include "at least one yarn" or "one or more yarns".

Any range given in absolute terms or in approximate terms is intended to encompass both, and any definition used herein is intended to be illustrative and not restrictive. Although the numerical ranges and parameters setting forth the broad scope of the present invention are approximate, the numerical values set forth in the specific examples are recorded as accurately as possible. However, any numerical value inherently contains certain errors that are inevitably caused by the standard deviation found in its respective test measurements. In addition, all ranges disclosed herein are understood to include any and all subranges (including all partial values and overall values) included therein.

In addition, the present invention encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the various aspects described herein will be apparent to those skilled in the art. Various changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing the advantages it is intended to achieve. Therefore, these changes and modifications are intended to be covered by the appended claims.

Claims (16)

1. An upper for footwear articles, the upper comprising: Knitted elements that at least form the collar area and throat area of the shoe upper; The collar area is configured to form an opening at the ankle; and Along the edge, in the area of the shoe collar, The edge is at least partially formed by the knitted element. Wherein, the edge includes a first knitted structure with ribs of the knitted element, and In this embodiment, at least one rib of the first knitted structure with ribs extends from the cuff and through the throat region of the upper. 2. The upper as claimed in claim 1, wherein the knitted element further comprises a second knitted structure, and wherein the lower portion of the upper is formed by the second knitted structure. 3. The upper as claimed in claim 1, wherein the at least one rib has a length extending along the longitudinal direction of the welt. 4. The upper of claim 1, wherein the first knitted structure with ribs comprises yarns formed of an elastic material. 5. The upper of claim 1, wherein the welt includes at least one opening, and wherein the opening is formed on a knitting machine by skipping a series of consecutive needles on a needle bed, the series of consecutive needles occupying a distance at least three times the unstretched width of the opening. 6. The upper of claim 1, wherein the welt comprises at least one yarn, which is substantially hidden from a view pointing toward the outer surface of the welt when the welt is in an unstretched state, and wherein the at least one yarn is exposed at the viewpoint when the welt is in a stretched state. 7. The upper of claim 1, wherein the welt is configured to form a flipped state, wherein, in the flipped state, the end portion of the welt is flipped to form an overlapping portion. 8. The upper as claimed in claim 1, wherein the knitted element includes at least one inlay line in the toe area of the upper. 9. A method for forming an upper for footwear articles, the method comprising: Knitted elements are formed on a knitting machine, wherein the knitted elements at least form the collar area and throat area of the shoe upper; The collar area is configured to form an ankle opening; The knitted element includes an edge in the collar area. Wherein, the edge includes a first knitted structure with ribs of the knitted element, and In this embodiment, at least one rib of the first knitted structure with ribs extends from the cuff and through the throat region of the upper. 10. The method of claim 9, wherein the knitted element further comprises a second knitted structure, and wherein the lower portion of the upper is formed by the second knitted structure. 11. The method of claim 9, wherein the at least one thread has a length extending along the longitudinal direction of the edge. 12. The method of claim 9, wherein the first knitted structure with ribs comprises yarns formed of an elastic material. 13. The method of claim 9, wherein the edging includes at least one opening, and wherein the opening is formed on the knitting machine by skipping a series of consecutive needles on the needle bed, the series of consecutive needles occupying a distance at least three times the unstretched width of the opening. 14. The method of claim 9, wherein the edging comprises at least one yarn, which is substantially hidden from a view pointing toward the outer surface of the edging when the edging is in an unstretched state, and wherein the at least one yarn is exposed at the viewpoint when the edging is in a stretched state. 15. The method of claim 9, wherein the edge is configured to form a flipped state, wherein, in the flipped state, the end portions of the edge are flipped to form an overlapping portion. 16. The method of claim 9, wherein the knitted element includes at least one inlay line in the toe area of the upper.