HK1200289B - Article of footwear having an upper with knitted elements - Google Patents

Abstract

This invention relates to an article of footwear having an upper with knitted elements. An article of footwear may incorporate various elements that are at least partially formed through a knitting process, such as a circular knitting process or a flat knitting process. Examples of the elements include tongue elements, collar elements, and collar-throat elements. In some configurations, the elements include compressible areas and flange areas. The compressible areas may include foam cores or floating yarns that impart compressibility, and the flange areas may be utilized to join the components to the article of footwear.

Description

Article of footwear having an upper with a knit element

The present application is a divisional application of the application entitled "article of footwear with an upper having a knit element" filed on 1/10/2010, application No. 201080045157.6.

Background

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void on the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower area of the upper so as to be positioned between the upper and the ground. In athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole generally includes a polymer foam material that attenuates ground reaction forces to relieve stresses on the foot and leg during walking, running, and other ambulatory activities. In addition, the midsole may include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. The outsole is secured to a lower surface of the midsole and provides a ground-engaging portion of the sole structure that is formed of a durable and wear-resistant material, typically rubber. The sole structure may also include a sockliner positioned within the void and adjacent to a lower surface of the foot to enhance footwear comfort.

The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. In some articles of footwear, such as basketball shoes and boots, the upper may extend upward and around the foot to provide support or protection for the foot. Access to the void on the interior of the upper is typically provided by a bare foot opening in the heel region of the footwear. A lacing system is often included in the upper to adjust the fit of the upper to allow the foot to enter and exit the void within the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly the circumference, to provide variable dimensions to both feet. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may include a heel counter to limit movement of the heel.

In manufacturing the upper, a variety of material elements (e.g., textiles, polymer foams, polymer boards, leather, synthetic leather) may generally be utilized. For example, in athletic footwear, the upper may have multiple layers, each layer including multiple joined material elements. As an example, the material elements may be selected to impart stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, and moisture-wicking to various areas of the upper. In order to impart different properties to different areas of the upper, the material elements are often cut to the desired shape and then joined together, typically by stitching or adhesive bonding. Furthermore, the material elements are often joined in a layered configuration to impart multiple properties to the same area. As the number and type of material elements included in the upper increases, the time and expense associated with transporting, equipping, cutting, and joining the material elements may also increase. As the number and type of material elements included in the upper increases, waste material from the cutting and stitching process also accumulates to a greater extent. In addition, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from fewer types and numbers of material elements. By reducing the number of material elements used in the upper, waste may be reduced, while manufacturing efficiency and recyclability of the upper are improved.

SUMMARY

An article of footwear having an upper and a sole structure secured to the upper is disclosed below. The upper includes a material layer that forms at least a portion of an exterior surface of the upper. The upper also includes a knitted component formed of unitary knit construction. The knitted component may include a compressible region and a flange region. The compressible region forms a portion of an exterior surface of the upper and a portion of an opposing interior surface of the upper, and the flange region extends outward from the compressible region. The flange region may be positioned inwardly from the layer of material, and the flange region may engage the layer of material.

The compressible region may define a chamber within the knitted component.

At least one of a foam member, a fibrous material, and a plurality of floats may be located within the chamber.

The knitted component may form at least one of a tongue and a collar of the upper.

Also disclosed below is an article of footwear having an upper and a sole structure secured to the upper, the upper including:

a first material layer forming at least a portion of an exterior surface of the upper;

a second layer of material positioned parallel to the first layer of material and inward from the outer surface; and

a knitted component having a first knit layer and a second knit layer formed of a single knit construction, the first knit layer forming at least a portion of the exterior surface of the upper and the second knit layer forming at least a portion of an interior surface of the upper, the knitted component defining a flange extending outwardly from at least one of the first knit layer and the second knit layer,

wherein the flange is located between the first material layer and the second material layer and the flange is engaged with at least one of the first material layer and the second material layer.

A region of the first knit layer and a region of the second knit layer may be spaced apart from one another to define a chamber within the knitted component.

At least one of a foam member, a fibrous material, and a plurality of floats may be located within the chamber.

An edge of the first knit layer and an edge of the second knit layer may be joined to one another around at least a portion of the cavity.

The knitted component may form at least one of a tongue and a collar of the upper. In some configurations, the upper may include a tongue element having a knitted component formed of a single knit construction and forming a majority of an exterior of the tongue element. The compressible material may be located within a chamber of the knitted component, and an end of the knitted component may be secured to a throat area of the upper.

In another configuration, the upper may include a collar element (tubular element) having a braided exterior forming at least a portion of an exterior surface of the upper adjacent the open foot opening of the upper and at least a portion of an interior surface of the upper adjacent the open foot opening of the upper. A plurality of floats may be located within the chambers of the knit element. In addition, the collar element may be formed as a separate component from and secured to other portions of the upper.

Various methods may be used to form components of an article of footwear. For example, circular knitting and flat knitting (weaving) processes may be used to form the various components of a single knit construction. After knitting, the component may be incorporated into an article of footwear. In addition, the knitting process may be used to form compressible regions and flange regions of some components. For example, floats may be located in the compressible region to enhance compressibility.

Also disclosed below is an article of footwear having an upper and a sole structure secured to the upper, the upper including a tongue element that includes:

a knitted component formed of unitary knit construction and forming a majority of an exterior of the tongue element, the knitted component defining an interior chamber; and

a compressible material located within the chamber,

wherein an end of the knitted component is secured to a throat area of the upper.

The compressible material may be a foam member.

The end of the tubular structure may comprise an opening for said chamber.

The compressible material may be a plurality of floats that may be formed of a single knit construction with the knitted component.

The knitted component may include a first region having a first stitch type and a second region having a second stitch type, the first stitch type may be different than the second stitch type.

The first region may include a first yarn and the second region may include a second yarn.

The other end of the knitted component may be positioned adjacent an ankle opening of the upper and may have a closed configuration.

Also disclosed below is a method of manufacturing a tongue element for an article of footwear, the method comprising:

braiding a tubular structure having a first end and a second end, at least the first end having a closed configuration;

inserting a compressible material into the tubular structure through the second end; and

securing the second end to an upper of the article of footwear.

The step of knitting may include using one of a flat knitting technique and a circular knitting technique.

The step of knitting may include forming a first region having a first stitch type and a second region having a second stitch type, the first stitch type may be different from the second stitch type.

The inserting step may include selecting the compressible material to be at least one of a foam member and a fibrous material.

The inserting step may include placing a plurality of floats into the tubular structure.

The method may further comprise the steps of: placing a molding within the tubular structure and heating the tubular structure to impart a shape to the tubular structure.

Also disclosed below is an article of footwear having an upper and a sole structure secured to the upper, the upper defining an interior void for receiving a foot of a wearer and having an ankle opening that provides access to the void, the upper having a collar element formed of unitary knit construction and comprising:

a braided exterior forming (a) at least a portion of an exterior surface of the upper adjacent an ankle opening of the upper and (b) at least a portion of an interior surface of the upper adjacent the ankle opening, the braided exterior defining an interior chamber; and

a plurality of floats located within the chamber,

wherein the collar element is formed as a separate component from and secured to other portions of the upper.

The collar element may include a flange that may be formed of unitary knit construction with the knit exterior, the flange may be secured to the other portion of the upper.

The braided outer portion may include a first braided layer and a second braided layer, which may be joined to one another at the ankle opening and at a location spaced from the ankle opening to define the chamber.

The collar element may extend along a portion of a lateral side of the upper, around a heel region of the upper, and along a portion of a medial side of the upper in an area of the ankle opening.

Also disclosed below is an article of footwear having an upper and a sole structure secured to the upper, the upper defining an interior void for receiving a foot of a wearer and having an ankle opening that provides access to the void, the upper having a collar element comprising:

a first knit layer and a second knit layer formed of a single knit construction, the first knit layer forming at least a portion of an exterior surface of the upper adjacent the ankle opening and the second knit layer forming at least a portion of an interior surface of the upper adjacent the ankle opening, areas of the first knit layer and areas of the second knit layer being spaced apart from one another to define a chamber within a knitted component;

a plurality of floating yarns located within the chamber and between the first woven layer and the second woven layer; and

a flange extending outwardly from at least one of the first and second knit layers, the flange being secured to another element of the upper.

An edge of the first knit layer and an edge of the second knit layer may be joined to one another around at least a portion of the cavity.

The collar element may extend along a portion of a lateral side of the upper, around a heel region of the upper, and along a portion of a medial side of the upper in an area of the ankle opening.

Also disclosed below is a method of manufacturing a collar element for an article of footwear, the method comprising:

flat knitting the collar element to have a unitary knit construction including: (a) a tubular structure having an interior chamber and (b) a plurality of floats within the chamber; and

securing the collar element to an upper of the article of footwear.

The step of cross-knitting may include forming a flange extending outwardly from the tubular structure.

The securing step may include placing the flange adjacent to a material layer of the upper and joining the flange to the material layer.

The securing step may include positioning the collar element along a portion of a lateral side of the upper, around a heel region of the upper, and along a portion of a medial side of the upper.

Also disclosed below is a method of manufacturing an article of footwear, the method comprising:

knitting a series of footwear elements, at least two of the footwear elements joined by a release area comprising a release yarn;

removing the release yarn to separate the footwear elements; and

incorporating at least one of the footwear elements into the article of footwear.

The step of knitting may include using one of a flat knitting technique and a circular knitting technique.

The step of knitting may include forming each of the footwear elements in a single knit construction.

The step of knitting may include forming flanges in the footwear element, and the step of incorporating may include securing one of the flanges to the article of footwear.

The method may also include the step of heating and changing the shape of at least one of the footwear elements.

Also disclosed below is a method of manufacturing a first article of footwear for a right foot of a wearer and a second article of footwear for a left foot of the wearer, the method comprising:

weaving a first element and a second element, the first element being substantially identical to the second element;

incorporating the first element into the first article of footwear; and

incorporating the second element into the second article of footwear.

The first element may have differently shaped outer and inner portions and the first element may have substantially symmetrical opposing sides.

The first element may include a compressible region and a flange region extending outward from the compressible region, and the step of incorporating the first element into the first article of footwear may include securing the flange region to a material layer of the first article of footwear.

The advantages and features of novelty characterizing aspects of the present invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various configurations and concepts related to the invention.

Drawings

The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings.

Fig. 1 is a perspective view of an article of footwear.

Fig. 2 is a lateral side view of the article of footwear.

Fig. 3 is a medial side view of the article of footwear.

Fig. 4 is a top plan view of the article of footwear.

Figures 5A-5C are cross-sectional views of the article of footwear as defined by section lines 5A-5C, respectively, in figure 4.

FIG. 6 is a perspective view of a tongue element of the article of footwear.

FIG. 7 is an exploded perspective view of the tongue element.

FIG. 8 is a plan view of the tongue element.

FIGS. 9A and 9B are cross-sectional views of the tongue element, as defined by section lines 9A and 9B, respectively, in FIG. 8.

10A-10J are plan views corresponding with FIG. 8 and depicting additional configurations of the tongue element.

11A-11K are cross-sectional views corresponding with FIG. 9A and depicting additional configurations of the tongue element.

Fig. 12A and 12B are plan views of a plurality of engaged tongue elements.

Fig. 13 is a perspective view of a collar element of an article of footwear.

Fig. 14 is a plan view of the collar element.

FIGS. 15A and 15B are cross-sectional views of the tongue element, as defined by section lines 15A and 15B, respectively, in FIG. 14.

Fig. 16A-16C are plan views corresponding with fig. 14 and depicting additional configurations of collar elements.

Fig. 17A and 17B are plan views of a plurality of engaged collar elements.

FIG. 18 is a lateral side view corresponding with FIG. 2 and depicts another configuration of the article of footwear.

Fig. 19 is a perspective view of a collar-throat element of the configuration of the article of footwear depicted in fig. 18.

Fig. 20 is a plan view of the collar-throat element.

Figures 21A and 21B are cross-sectional views of the collar-throat element as defined by section lines 21A and 21B, respectively, in figure 20.

Fig. 22A-22D are cross-sectional views corresponding with a portion of fig. 5C and describing various methods of incorporating a collar element into an article of footwear.

Fig. 23 is a plan view of another element.

Fig. 24 is a plan view of a tongue-vamp element.

Fig. 25 is a cross-sectional view corresponding with fig. 5A and depicting a tongue-vamp element in the article of footwear.

FIG. 26 is a cross-sectional view corresponding with FIG. 5C and depicting another configuration of the article of footwear.

Fig. 27A and 27B are plan views of another collar element.

Detailed description of the invention

The following discussion and accompanying figures disclose an article of footwear having an upper that includes a plurality of knit elements, such as a tongue and collar. The disclosed article of footwear is of a general configuration suitable for walking or running. Concepts associated with the footwear, including an upper and a plurality of knitted elements, may also be applied to a wide variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, soccer shoes, tennis shoes, soccer shoes, and hiking boots, for example. The concepts may also be applied to footwear styles that are generally understood to be non-athletic, including dress shoes, casual shoes, loafers (loafers), sandals, and work boots. Accordingly, the concepts disclosed herein with respect to the knit elements and methods of making the knit elements apply to a wide range of footwear styles.

General footwear construction

Article of footwear 10 is depicted in figures 1-5C as including a sole structure 20 and an upper 30. For reference purposes, footwear 10 may be divided into three basic regions: forefoot region 11, midfoot region 12, and heel region 13, as shown in fig. 2 and 3. Footwear 10 also includes a lateral side 14 and a medial side 15. Forefoot region 11 generally includes portions of footwear 10 corresponding with the toes and the joints connecting the phalanges with the metatarsals. Midfoot region 12 generally includes portions of footwear 10 corresponding with the arch area of the foot, while heel region 13 corresponds with the heel area of the foot, including the calcaneus bone. Lateral side 14 and medial side 15 extend through each of regions 11-13 and correspond with opposite sides of footwear 10. Regions 11-13 and sides 14-15 are not intended to demarcate precise areas of footwear 10. Rather, regions 11-13 and sides 14-15 are intended to represent general areas of footwear 10 to aid in the following discussion. In addition to footwear 10, regions 11-13 and sides 14-15 may also be applied to sole structure 20, upper 30, and various elements thereof.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when footwear 10 is worn. The primary elements of sole structure 20 are a midsole 21, an outsole 22, and a sockliner 23. Midsole 21 is secured to a lower area of upper 30 and is formed from a compressible polymer foam member (e.g., polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further configurations, midsole 21 may include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot, or midsole 21 may be primarily formed from a fluid-filled chamber. Outsole 22 is secured to a lower surface of midsole 21 and may be formed of a wear-resistant rubber material having a texture that imparts traction. Sockliner 23 is positioned within upper 30 and is positioned to extend under a lower surface of the foot. Although this configuration of sole structure 20 provides an example of a sole structure that may be used in connection with upper 30, a variety of other conventional or nonconventional configurations for sole structure 20 may also be utilized. Accordingly, the configuration and features of sole structure 20 or any sole structure utilized with upper 30 may vary significantly.

Upper 30 is formed from a combination of various elements that provide a structure for securely and comfortably receiving a foot. Although the configuration of upper 30 may vary significantly, the various elements generally define a void within footwear 10 for receiving and securing the foot with respect to sole structure 20. The surface of the void within upper 30 is shaped to receive the foot and extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. A portion of upper 30 is formed from multiple layers 31 and 32, as depicted in figures 5A-5C. Layer 31, however, forms a portion of an exterior surface of upper 30, and layer 32 forms a portion of an interior surface of upper 30 (i.e., the surface that defines the void within upper 30). Each of layers 31 and 32 may be formed from one or more of a variety of material elements (e.g., fabric, polymer foam, leather, synthetic leather) that may be stitched or bonded together. As an example, layer 31 may be formed of a synthetic leather material, and layer 32 may be formed of a hygroscopic fabric material. As another example, each of layers 31 and 32 may be formed from different fabric materials. In some configurations, another polymer foam layer may be positioned between layers 31 and 32 to enhance comfort. In other configurations of upper 30, layers 31 and 32 may be replaced with a single layer, three layers, or other multi-layer structure formed from multiple materials.

A lace 33 extends through a plurality of lace apertures 34 and across a throat area of upper 30 to allow the wearer to modify dimensions of upper 30 and receive portions of the foot. That is, lace 33 operates in a generally conventional manner for tightening upper 30 about the foot (i.e., when lace 33 is tied) and loosening upper 30 (i.e., when lace 33 is opened). Tongue element 40 extends under lace 33 to enhance the comfort and adjustability of footwear 10. Upper 30 also includes a collar element 50 located in at least heel region 13. In addition to enhancing the comfort of footwear 10, collar element 50 forms an ankle opening for the foot into the void within upper 30. That is, the ankle opening defined by collar element 50 facilitates entry and egress of the foot from the void, particularly when lace 33 is not tied to impart a loose-fitting configuration to upper 30 around the foot.

Portions of upper 30, including tongue element 40 and collar element 50, may be a knitted component formed with a relatively small number of material elements. As discussed in the background section above, reducing the number of material elements used in the upper may reduce waste, while also improving the manufacturing efficiency and recyclability of the upper. The tongue and collar of a conventional upper are typically formed from a plurality of joined material elements. However, as discussed in more detail below, the tongue element 40 and collar element 50 may be formed primarily by a knitting process (rather than a repeat and turn method) that reduces waste and improves manufacturing efficiency and recyclability. In addition, the configuration of tongue element 40 and collar element 50 may include a lesser number of seams or other discontinuities to enhance the overall comfort of footwear 10. Tongue element construction

Tongue element 40 is centrally located in the throat area of upper 30 and extends from forefoot region 11 to heel region 13, and from lateral side 14 to medial side 15. Side areas of tongue element 40 are positioned adjacent to and in contact with areas of layer 32 that form lace apertures 34, and a central area of tongue element 40 is in contact with lace 33 and may be exposed between areas of lace 33 that cross each other. In forefoot region 11, tongue element 40 is joined to layers 31 and 32, but the remainder of tongue element 40 is generally free or unsecured to other areas of upper 30. In heel region 13, tongue element 40 may protrude from an ankle opening formed by collar element 50.

The primary components of tongue element 40, as depicted in FIGS. 6-9B, are a braided sheath 41 and a compressible core 42. In general, the sheath 41 is formed as a braided element extending around the core 42. More specifically, the sheath 41 forms a majority of the exterior of the tongue element 40 and also defines an interior chamber in which the core 42 is located. Core 42 is a compressible structure within tongue element 40 that enhances the overall comfort of footwear 10. While the core 42 may be formed from a polymer foam material (e.g., polyurethane or ethylvinylacetate foam), the core 42 may also be formed from, for example, yarns or fluid-filled chambers. In some constructions, the tongue element 40 may include additional features such as (a) logos or trademarks that are screen printed, stitched, or bonded to the sheath 41, (b) lace loops that receive a portion of the lace 34 to restrict movement of the tongue element 40, or (c) instructions and material placards that are stitched or bonded to the sheath 41.

The sheath 41 has a generally tubular structure forming a chamber in which the core 42 is located. In general, the sheath 41 includes an upper region 43, a lower region 44, a first end 45, a second end 46, and a pair of flanges 47. Upper region 43 extends over one surface of core 42 and is exposed to the exterior of footwear 10 between the areas where lace 33 cross each other. Lower region 44, which is located opposite upper region 43, extends over another surface of core 42 and forms a portion of an interior surface of upper 30 (i.e., the surface that defines the void within upper 30). Referring to fig. 9A and 9B, for example, regions 43 and 44 effectively form layers of woven material that are located on opposite sides of core 42 and are joined to one another, thereby effectively extending around core 42. However, the first end 45 has a closed configuration and the second end 46 forms an opening through which the wick 42 is inserted into a chamber within the sheath 41. A flange 47 is located at the second end 46 on the opposite side of the opening. Flanges 47 extend outward from tongue element 40 and may be used to join tongue element 40 to upper 30. Referring to fig. 5A, for example, flange 47 extends between layers 31 and 32 in a throat area of upper 30 and is secured to one or both of layers 31 and 32. Although each of the regions 43 and 44 includes one of the flanges 47, the sheath 41 may form only one flange 47 or in some configurations there may be two flanges 47.

Many conventional footwear tongues, however, have sheaths formed from multiple textile elements or other material elements joined by stitching or bonding, for example, sheath 41 is formed as a unitary element by a knitting process such as circular knitting or flat knitting. More specifically, the sheath 41 is typically formed of a single braided construction through a braiding process. As used herein, a knitted component, such as sheath 41, is defined as being formed of a "unitary knit construction" when constructed as a unitary knit element that is substantially free of additional stitching or bonding processes. That is, the braiding process substantially forms the various features and structures of the sheath 41 without the need for significant additional manufacturing steps or processes. In some configurations, the sheath 41 is still formed of a single braided construction when the first end 45 or the second end 46 is closed by stitching or bonding to seal the core 42 within the sheath 41, or when trimming the area after the braiding process. In addition, when other secondary elements (e.g., logos, trademarks, lace loops, instructions for use, and material placards) are added to tongue element 40 after the knitting process, sheath 41 is still formed of unitary knit construction.

The braiding process for forming the sheath 41 of a single braided construction generally includes mechanically manipulating one or more yarns to form a series of stitches. A variety of different types of yarns may be incorporated into the sheath 41 during the knitting process. Polyester, for example, provides relatively high durability and recyclability, and may also impart non-stretchability according to the weave pattern within the sheath 41. Cotton provides a soft hand, natural aesthetics, and biodegradability. The elastic polyester and the stretched polyester each provide substantial stretch and recoverability, with the stretched polyester also providing relatively easy recyclability. Rayon provides high luster and moisture absorption. Wool provides high moisture absorption in addition to insulation. Nylon is a durable, wear-resistant material with relatively high strength. In addition to the specific materials, other aspects associated with the yarn may affect the performance of the sheath 41 and tongue 40. For example, the yarns may be monofilament or multifilament yarns. The yarn may also include separate filaments each formed of a different material. The yarn may also include filaments that are each formed of two or more different materials, for example a bicomponent yarn includes filaments having a sheath-core construction or two halves formed of different materials. Different twists and turns, as well as different deniers, may affect the performance of the sheath 41 and tongue 40. The yarns may also retain a desired shape when formed from a material that is easily heat-set. Accordingly, various types of yarns may be incorporated into the sheath 41, depending on the desired properties of the sheath 41 and tongue 40.

The tongue element 40 provides a number of advantages over conventional footwear tongues. For example, tongue element 40 enhances footwear comfort by incorporating few seams or other discontinuities into the area in contact with the foot. As another example, the tongue element 40 includes relatively few material elements. As discussed in the background section above, by reducing the number of material elements used in the upper, waste may be reduced while improving the manufacturing efficiency and recyclability of the upper. To further enhance efficiency, forming the sheath 41 by a braiding process limits the number of cutting operations or other processes that typically produce waste material, while allowing for the creation of profiles that are relatively difficult using a heavy-end method.

Additional tongue element construction

The above-discussed configurations of tongue element 40 provide examples of suitable configurations for footwear 10 and various other types of footwear. However, the tongue element 40 may include a variety of other features. Whether the sheath 41 is formed by circular knitting or flat knitting, the overall shape of the tongue element 40 may vary significantly. For example, FIG. 10A depicts a configuration in which the tongue element 40 has a greater length and a lesser width than the configuration of FIGS. 6-8, whereas FIG. 10B depicts a configuration in which the tongue element 40 has a lesser length and a greater width. Referring to FIG. 10C, the tongue element 40 has recessed side areas. Another configuration is depicted in FIG. 10D, in which the tongue element 40 is tapered to impart a generally triangular shape. Additionally, the tongue element 40 may exhibit a generally diamond-shaped configuration as depicted in FIG. 10E. Referring to fig. 10F, the flange 47 may also be absent from the sheath 41.

Various methods may be used to impart the various shapes described in fig. 6-8 and fig. 10A-10E. For example, a circular knitting or flat knitting process for forming the sheath 41 may impart any of a variety of shapes. That is, the knitting machine may be programmed to mechanically manipulate the yarns to form stitches that combine to impart any of the various shapes discussed above as well as various other shapes. As another example, a stretcher form may be located within a chamber in the sheath 41, and by applying heat or steam, the stretcher form may change the overall shape of the sheath 41. In addition, the shape of the core 42 may vary, thereby imparting a different shape to the sheath 41. An advantage of utilizing an extender form or a differently shaped core 42 is that multiple sheaths 41 having substantially the same shape may be formed and the extender form or differently shaped core 42 may be used to impart a shape to tongue 40 suitable for footwear having multiple sizes or different types of footwear.

The construction of the sheath 41 depicted in fig. 6-8 includes a single type of yarn and a single stitch type (stitchtype). That is, the sheath 41 has a generally continuous configuration in which the properties imparted by the yarn and stitch type are generally the same across multiple areas of the sheath 41. By varying one or both of the yarn and stitch types used in the various regions of the sheath 41, the properties of the various regions can be varied. Accordingly, the yarn and stitch types may be varied to impart different characteristics to different areas of the tongue 40. Further, both circular knitting and flat knitting allow for the combination of selected yarn and stitch types for multiple regions of the sheath 41, allowing for the selection of characteristics of the regions based on comfort or performance characteristics.

As discussed above, the sheath 41 may include a variety of yarn and stitch types. By way of example, the sheath 41 is depicted in fig. 10G as having two regions formed from different types of yarns. However, the area adjacent the first end 45 is formed from one type of yarn and the area adjacent the second end 46 is formed from another type of yarn. However, one region may include elasticity to enhance stretch and other regions may include nylon to enhance wear resistance and durability. Similarly, however, one zone may include yarns having a denier of 1, and other zones may include yarns having a greater denier to enhance caliper or bulk. As another example, the type of stitches between the areas may vary, as depicted in fig. 10H. However, the area adjacent first end 45 includes stitching that imparts a relatively non-textured configuration, and the area adjacent second end 46 has a textured configuration that may impart stretch or a different aesthetic quality. The types of yarns used in the different areas of fig. 10H may also be varied to further enhance or alter the characteristics of the tongue 40. As a related matter, the braid density within the sheath 41 may vary between regions to form, for example, a less permeable or stiffer portion. Thus, the sheath 41 may exhibit multiple characteristics in separate regions, depending on the particular yarn and weave type selected for the regions.

The yarns and weave types may also be varied to enhance aspects associated with assembling footwear 10. Referring to fig. 10I, the sheath 41 presents a ribbed configuration around the opening of the second end 46. The ribs may be stretchable to allow insertion of the core 42, and then the ribs may be collapsible to ensure that the core 42 remains properly positioned within the sheath 41. The braided type may also form a plurality of holes in the sheath 41, as depicted in fig. 10J. In addition to imparting greater breathability, which allows air to circulate within upper 30, the apertures may enhance the flexibility and stretch of tongue 40. As additional examples, other characteristics that may be varied by the selection of the particular yarn and weave type used for the sheath 41 include permeability to liquids, the direction in which the sheath 41 is stretched or stretch-resistant, and the stiffness of the sheath 41.

The overall construction of core 42 may also vary, depending on a number of factors, including the size and type of footwear in which tongue 40 is incorporated. For example, the thickness, length, and width of the core 42 may be varied. Referring to fig. 11A, the core 42 assumes a tapered configuration. The core 42 may also have a profile as depicted in fig. 11B. In some configurations of tongue 40, core 42 may be formed from two separate elements (e.g., foam elements having different densities), as depicted in FIG. 11C. In a similar configuration, the core 42 may be formed from two overlapping elements (e.g., foam elements having different densities), as depicted in fig. 11D, which imparts greater thickness and profile. Although foam elements may be used as the core 42, a variety of other materials may also be used. Referring to fig. 11E, the various floats are located within the chamber formed by the sheath 41. As described in more detail below with respect to collar element 50, the flat knitting process may position the floating yarns within the cavities formed between the knit layers. Referring to fig. 11F, cut ends of yarns, such as from a circular knitting process, provide material for the core 42. Similarly, loops of yarn similar to those in a terry loop fabric material may provide the material for core 42. In some configurations, core 42 may also be formed from a fiber mat made from recycled fabric and yarn materials used in other areas of upper 30, or core 42 may be a fluid-filled bladder.

While the sheath 41 may be formed of a single braided construction, the sheath 41 may also be formed of joined elements, each element being formed by a braiding process. Referring to fig. 11G, sheath 41 includes a first braided element adjacent first end 45 and a second braided element extending from the first braided element to second end 46, and the braided elements are joined by stitching. In some configurations, stitching may extend entirely through the tongue 40, as depicted in fig. 11H, to impart contours or other features to the tongue 40. While the second end 46 may have an open configuration for the insert 42, flaps may be formed in the lower region 44, as depicted in fig. 11I, for the insert 42. As mentioned above, other elements including lace loops may be added to the sheath 41, as depicted in fig. 11J. Alternatively, during the flat knitting process, the lace loops may be formed of a single knit construction with the sheath 41, as depicted in fig. 11K.

Based on the above discussion, various features of the sheath 41 and the core 42 may be varied to impart different characteristics to the tongue 40. As discussed, the overall shape of the sheath 41 may vary depending on the type of footwear or the size of the footwear in which the tongue 40 is incorporated. In some configurations, the yarn and/or stitch type may also be varied in different areas of the sheath 41 to impart different characteristics. The core 42 may also have a variety of shapes or be formed from a variety of types of elements.

Knitting process

A variety of knitting processes, including circular knitting and flat knitting, may be used to make the sheath 41. Circular knitting is a form of knitting that produces a seamless tube, which effectively forms the sheath 41. A variety of braiding machines may be used to form the sheath 41 having a circular braided structure. For example, certain sock knitting machines use individual latch needles to keep each stitch in a circular frame. Depending on the type of circular knitting machine used, first end 45 may be closed as part of a knitting circle, or an additional finishing step (finishing step) may be performed to close first end 45. Flat knitting is a method for manufacturing regularly rotating knitted material (i.e., material is knitted from alternating sides). The two sides (also referred to as faces) of the material are conventionally designed as a front side (i.e. the side facing outwards towards the viewer) and a reverse side (i.e. the side facing inwards away from the viewer).

Advantageously, both circular knitting and flat knitting may be used to form the sheath 41 to have, for example, (a) multiple yarn types that impart different properties to separate regions of the sheath 41 and (b) multiple knitting types that impart different properties to separate regions of the sheath 41. While each of circular knitting and flat knitting may be used to make the sheath 41 in many configurations, flat knitting may be used to add additional features to the tongue 40, including (a) positioning floating yarns within the sheath 41 to form the core 42, as in FIG. 11D, and (b) overlapping knit layers to form a lace loop of a single knit configuration, as in FIG. 11I.

Although the edges of many of the textile elements incorporated into the footwear tongue are cut to expose the ends of the yarns forming the textile elements, the sheath 41 may be formed to have a finished construction (finish) when manufactured by circular knitting or flat knitting. That is, circular knitting or flat knitting may be used to form the sheath 41 such that the ends of the yarns within the sheath 41 are substantially absent from the edges of the sheath 41. The advantage of the completed construction is that the yarns forming the edges of the sheath 41 are less likely to unravel and fewer finishing steps are required after manufacturing the sheath 41. By forming the finished edge, the integrity of the sheath 41 is enhanced and less or no post-processing steps are required to prevent unraveling. In addition, loose yarns are less likely to detract from the aesthetic appearance of the tongue 40. In other words, the completed construction of the sheath 41 may enhance the durability and aesthetic qualities of the tongue 40, while increasing manufacturing efficiency.

A circular knitting machine and a flat knitting machine may be used to form the individual sheaths 41. To enhance manufacturing efficiency, the braiding machine may also be used to form a series of joined sheaths 41, as depicted in fig. 12A and 12B. That is, the braiding machine may form a single component that includes multiple sheaths 41. Referring to fig. 12A, each of the sheaths 41 may have substantially the same shape and size. Alternatively, each of the sheaths 41 may have a different shape and size, as depicted in fig. 12B. Furthermore, a braided release region may be braided into the series of sheaths 41 to allow multiple sheaths 41 to be separated without the need for a cutting operation.

Structure of collar element

Collar element 50 extends around heel region 13 and extends from lateral side 14 to medial side 15 to form an ankle opening for the foot to enter the void within upper 30. Collar element 50, depicted separately in fig. 13-15B, is formed from two overlapping and at least partially coextensive layers of knitted material, specifically an outer layer 51 enclosing a plurality of floating yarns 53 and an opposing inner layer 52. While the edges of layers 51 and 52 are secured to one another in a seamless manner (i.e., having a single knit construction) through the knitting process, the central region between layers 51 and 52 is typically not secured to one another to form a chamber in which floats 53 are located. Also, the layers of woven material effectively form a tube or tubular structure, and the floats 53 may be positioned or located between the layers 51 and 52 and oriented generally parallel to the surfaces of the layers 51 and 52. That is, the floats 53 extend between the layers 51 and 52 and also pass through the interior chamber between the layers 51 and 52 and fill the interior chamber between the layers 51 and 52. Whereas layers 51 and 52 are formed from yarns that are mechanically manipulated (e.g., via a flat knitting process), floating yarns 53 are generally free or otherwise located within the chamber between layers 51 and 52 during the knitting process.

Whereas exterior layer 51 forms a portion of an exterior surface of upper 30 in the area of the ankle opening, interior layer 52 forms a portion of an interior surface of upper 30 (i.e., the surface that defines the void within upper 30). In the upper region of collar element 50, layers 51 and 52 are seamlessly joined to one another. Similarly, layers 51 and 52 are seamlessly joined to one another in the lower area of collar element 50. Additionally, flange 54 extends outwardly from layers 51 and 52 and serves to join collar element 50 to the remainder of upper 30. More specifically, the flange 54 extends between the layers 31 and 32 and is secured to one or both of the layers 31 and 32, as depicted in fig. 5A and 5C.

The presence of floating yarns 53 imparts a compressible aspect to collar element 50, thereby enhancing the comfort of footwear 10 in the ankle opening area. Many conventional articles of footwear incorporate a polymer foam element or other compressible material into the collar region. In contrast to conventional articles of footwear, collar element 50 uses floating yarns 53 to provide a compressible structure. In some constructions, foam elements or other fibrous elements (e.g., cut ends of floats and yarns) may be located within collar element 50 and replace floats 53.

One of the various types of yarn discussed above for the sheath 41 may be used in the collar element 50. In some configurations, the yarns used in layers 51 and 52 may be the same as the yarns used for floats 53, or a different type of yarn may be used for floats 53. With respect to sheath element 41, collar element 50 may be formed from different yarns in multiple regions or different stitch types in multiple regions.

Collar element 50 may be formed to have a unitary knit construction by a flat knitting process. As such, collar element 50 is constructed as a unitary knit element that is substantially free of additional stitching or bonding processes. That is, the knitting process substantially forms the various features and structures of collar element 50 without significant additional processing. As discussed above, flat knitting may be used to form collar element 50 to have, for example, (a) a plurality of yarn types that impart different properties to separate areas of collar element 50 and (b) a plurality of knit types that impart different properties to separate areas of collar element 50. Flat knitting may also be used to add additional features to collar element 50, including (a) forming the tubular structures of layers 51 and 52, (b) forming flange 54 to extend seamlessly outward from the tubular structures of layers 51 and 52, and (c) positioning floating yarns 53 between layers 51 and 52.

As a further matter, when manufactured by flat knitting, collar element 50 may be formed to have a finished configuration. That is, flat knitting may be used to form collar element 50 such that the ends of the yarn are substantially absent from the edges of collar element 50. With respect to the sheath 41, the advantage of the finished construction is that the yarn is less likely to unravel and fewer finishing steps are required after manufacture. By forming the finished edges, the integrity of collar element 50 is enhanced and less or no post-processing steps are required to prevent unraveling. In addition, the loose yarn is also less likely to inhibit the aesthetic appearance of collar element 50.

The particular shape of collar element 50 in fig. 13 and 14 is intended to provide an example of a shape that is suitable for footwear 10. Various other shapes may also be used. By way of example, fig. 16A depicts a more contoured configuration. As a further example, fig. 16B and 16C depict a simpler collar contour that may be incorporated into a variety of footwear types.

A flat knitting machine may be used to form the individual collar elements 50. To improve manufacturing efficiency, the knitting machine may also be used to form a series of joined collar elements 50, as depicted in fig. 17A and 17B. That is, the knitting machine may form a single component that includes multiple collar elements 50. Referring to fig. 17A, each of collar elements 50 may have substantially the same shape, but different sizes that are suitable for different sizes of footwear 10. Alternatively, each of collar elements 50 may have a different shape and size, as depicted in fig. 17B. The knit release region may be knit into the series of collar elements 50 to allow for separation of multiple collar elements 50 without requiring a cutting operation. More specifically, release lines 55 located in the release area during the knitting process may extend between the plurality of collar elements 50. By pulling or otherwise removing release wire 55, collar element 50 can be separated without the need for cutting or other manufacturing steps. A similar release wire may be used to separate the multiple sheaths depicted in fig. 12A and 12B. Collar-throat element

Another configuration of footwear 10 is depicted in fig. 18 as including a collar-throat element 60 that extends at least partially around the ankle opening and also extends into a throat area of footwear 10, and defines a plurality of lace apertures 34 on lateral side 14. A similar collar-throat element may also be located on medial side 15. Collar-throat element 60 is similar in construction to collar element 50 and includes an outer layer 61, an opposing inner layer 62, a plurality of floating yarns 63, and a flange 64. Although the edges of layers 61 and 62 are secured to each other, the central region between layers 61 and 62 is typically not secured to each other to form a chamber in which floats 63 are located. Likewise, the layers of woven material effectively form a tube or tubular structure, and the floats 63 may be positioned or located between layers 61 and 62.

Whereas exterior layer 61 forms a portion of an exterior surface of upper 30 in the area of the ankle opening, interior layer 62 forms a portion of an interior surface of upper 30 (i.e., the surface that defines the void within upper 30). In the upper region of collar-throat element 60, layers 61 and 62 are seamlessly joined to one another. Similarly, in the lower region of collar-throat element 60, layers 61 and 62 are seamlessly joined to one another. Additionally, flange 64 extends outwardly from layers 61 and 62 and serves to join collar-throat element 60 to the remainder of upper 30. With respect to collar element 50, flange 64 may extend between layers 31 and 32 and be secured to one or both of layers 31 and 32. Flange 64 extends to the throat area and defines a plurality of lace apertures 34. A portion of flange 64 adjacent lace apertures 34 may also extend between layers 31 and 32 and be secured to one or both of layers 31 and 32.

Collar-throat element 60 may be formed to have a single knit construction through a flat knitting process, and may also be formed to have a finished construction. Additionally, any of the various types of yarns or stitch types discussed above may also be used for collar-throat element 60. The particular shape of collar-throat element 60 in fig. 19 and 20 is intended to provide an example of a shape that is suitable for footwear 10. In the configuration depicted in fig. 19 and 20, collar-throat element 60 is limited to lateral side 14, and another element may be used on medial side 15. However, in other configurations, a single collar-throat element 60 may extend around heel region 13 to form an ankle opening on both sides 14 and 15, and single collar-throat element 60 may extend through throat regions on both sides 14 and 15 to form each lace aperture 34. Various other shapes may also be used. With respect to sheath 41 and collar element 50, the braiding machine may form a single component including a plurality of joined collar-throat elements 60 to improve manufacturing efficiency.

Another element 70 is depicted in FIG. 23 as a combination tongue element 40 and collar-throat element 60. While flat knitting and circular knitting may be utilized to form discrete and relatively small areas of upper 30 (i.e., the areas formed by tongue element 40, collar element 50, and collar-throat element 60), the knitting process may also be utilized to form larger areas having a single knit construction. As another example, tongue-vamp element 80 is depicted in FIG. 24. Tongue-vamp element 80 includes a tongue region 81 and a vamp region 82 formed of a single knit construction. Given that tongue region 81 may have the general configuration of tongue element 40, vamp region 82 may be a single layer of material, for example. As depicted in fig. 25, vamp region 82 may form an interior lining when vamp region 82 is incorporated into footwear 10. In addition, a portion of vamp region 82 may be exposed through apertures in layers 31 and 32. Vamp region 82 may be formed to exhibit a single type of knit structure or may have multiple knit structures. For example, the areas exposed by the apertures in layers 31 and 32 may define a plurality of apertures to enhance breathability.

Footwear assembly

Each of tongue element 40, collar element 50, and collar-throat element 60 includes a compressible region and a flange region. In general, the compressible regions form a comfortable structure that may withstand the foot, whereas the flange regions are used to join elements to footwear 10 (e.g., by being joined between layers 31 and 32). With respect to tongue element 40, the compressible area includes the portion of tongue element 40 in which core 42 is located, and the flange area includes two flanges 47. With respect to collar element 50, the compressible region includes layers 51 and 52 and floating yarns 53, and the flange region includes flange 54. Similarly, with respect to collar-throat element 60, the compressible region includes layers 61 and 62 and floats 63, and the flange region includes flange 64. In each element or elements, a plurality of flanges 47, 54, and 64 extend outwardly from the compressible region and are positioned inwardly from one of the material layers forming upper 30 (i.e., layer 31), and the plurality of flanges 47, 54, and 64 are engaged with the material layer or another portion of upper 30.

Referring to fig. 5A and 5C, flange 47 from tongue element 40 and flange 54 from collar element 50 are positioned between layers 31 and 32 and engage at least one of layers 31 and 32. In other constructions, flanges 47 and 54 may be joined to an upper formed from a single layer or may be joined to an upper formed from multiple layers. For example, fig. 22A depicts a configuration in which collar element 50 is joined with an area of upper 30 that includes only layer 31. Although flange 54 may be joined to upper 30 inwardly from a material layer (e.g., layer 32), fig. 22B depicts a configuration in which collar element 50 is joined with an exterior of layer 31. Fig. 22C depicts a configuration in which collar element 50 is joined to an area of upper 30 where central layer 35 is present, and flange 54 is positioned between layers 32 and 35. In another configuration depicted in fig. 22D, collar element 50 includes two compressible regions where floating yarns 53 are present, and one of the compressible regions is exposed through an aperture in layer 31. Similar concepts may be applied to the manner in which tongue element 40 and collar-throat element 60 engage other areas of upper 30. In another configuration depicted in fig. 26, tongue 54 from collar element 50 extends along an interior surface of the void within upper 30 to form a continuous liner. Thus, the manner in which flanges 47, 54, and 64 are used to join elements to an article of footwear may vary significantly.

When knitting collar-throat element 60, the opposite sides of layers 61 and 62 and flange 64 may be symmetrically knit and of the same quality. When formed in this manner, collar-throat element 60 may be used on either lateral side 14 or medial side 15. That is, collar-throat element 60 may have a symmetrical aspect that allows collar-throat element 60 to be incorporated on either side of footwear 10, thereby reducing the types of elements manufactured for footwear 10.

An additional advantage of forming knit elements with opposite sides of the same mass is that separate elements may be incorporated onto variations of footwear 10 for either the right or left foot. With reference to fig. 27A and 27B, for example, the opposite side of another collar element 80 is depicted. Collar element 80 is similar to collar element 50 and has (a) a lateral portion 81 intended to extend to lateral side 14 of footwear 10 and (b) a medial portion 82 intended to extend to medial side 15 of footwear 10. Portions 81 and 82 are shaped differently and give collar element 80 the asymmetrical aspect of fitting to sides 14 and 15. However, the opposite sides or faces of collar element 80 are symmetrical and of the same mass. When collar element 80 is incorporated into footwear 10, the outward facing side is shaped for either a right shoe or a left shoe depending on whether footwear 10 is being molded. That is, one side (i.e., the side depicted in fig. 27B) will face outward when collar element 80 is incorporated into footwear 10 for the right foot, and the opposite side (i.e., the side depicted in fig. 27A) will face outward when collar element 80 is incorporated into footwear 10 for the left foot. Thus, the same collar element 80 may be incorporated into footwear 10 for both the right and left feet, depending on which side faces outward. An advantage of this configuration is that the types of elements manufactured that are used in different variations of footwear 10 are reduced.

To facilitate incorporating a knit element into footwear 10, registration indicia may be knit into the element. That is, different colored yarns or different types of stitches may be woven into the element to form the registration mark. By way of example, element 70 includes centrally located registration mark 71 as depicted in FIG. 23. When element 70 is incorporated into footwear 10, registration marks 71 may be used to ensure that element 70 is centrally located and properly aligned with other elements. Similar registration indicia may be used for tongue element 40 (i.e., on flange 47), collar element 50, and collar-throat element 60.

The present invention is disclosed above and in the accompanying drawings by reference to a variety of configurations. However, the purpose of this disclosure is to provide an example of the various features and concepts related to the invention, but not to limit the scope of the invention. One skilled in the relevant art will appreciate that various changes and modifications may be made to the above described configurations without departing from the scope of the present invention, as defined in the appended claims.

Claims (11)

1. An article of footwear having an upper and a sole structure secured to the upper, the upper defining an interior void for receiving a foot of a wearer and having an ankle opening that provides access to the void, the upper having a collar element, characterized in that the collar element is formed of unitary knit construction and comprises:

a braided exterior that forms (a) at least a portion of an exterior surface of the upper adjacent the ankle opening of the upper and (b) at least a portion of an interior surface of the upper adjacent the ankle opening, wherein the exterior surface is seamlessly joined to the interior surface in at least a lower region of the collar element, and the braided exterior defines an interior chamber; and

a plurality of floats located within the chamber,

wherein the collar element is formed as a separate component from and secured to other portions of the upper.

2. The article of footwear recited in claim 1, wherein the collar element includes a flange formed of unitary knit construction with the knit exterior, the flange being secured to the other portion of the upper.

3. The article of footwear recited in claim 1, wherein the knitted exterior includes a first knitted layer and a second knitted layer, the first knitted layer and the second knitted layer being joined to each other at the ankle opening and at a location spaced apart from the ankle opening to define the chamber.

4. The article of footwear recited in claim 1, wherein the collar element extends along a portion of a lateral side of the upper, around a heel area of the upper, and along a portion of a medial side of the upper in the area of the ankle opening.

5. An article of footwear having an upper and a sole structure secured to the upper, the upper defining an interior void for receiving a foot of a wearer and having an ankle opening that provides access to the void, the upper having a collar element, characterized in that the collar element comprises:

a first knit layer and a second knit layer formed of a single knit construction, the first knit layer forming at least a portion of an exterior surface of the upper adjacent the ankle opening and the second knit layer forming at least a portion of an interior surface of the upper adjacent the ankle opening, areas of the first knit layer and areas of the second knit layer being spaced apart from one another to define a chamber within a knitted component, wherein the exterior surface is seamlessly joined to the interior surface in at least a lower area of the collar element;

a plurality of floating yarns located within the chamber and between the first woven layer and the second woven layer; and

a flange extending outwardly from at least one of the first and second knit layers, the flange being secured to another element of the upper.

6. The article of footwear recited in claim 5, wherein an edge of the first knit layer and an edge of the second knit layer are joined to each other around at least a portion of the cavity.

7. The article of footwear recited in claim 5, wherein the collar element extends along a portion of a lateral side of the upper, around a heel area of the upper, and along a portion of a medial side of the upper in the area of the ankle opening.

8. A method of manufacturing a collar element of an article of footwear, the method comprising:

flat knitting the collar element to have a unitary knit construction including: (a) a tubular structure having an interior chamber and (b) a plurality of floats within the chamber; and

securing the collar element to an upper of the article of footwear, wherein an exterior surface of the upper is seamlessly joined to an interior surface of the upper in at least a lower area of the collar element.

9. The method recited in claim 8, wherein the step of cross-weaving includes forming a flange extending outwardly from the tubular structure.

10. The method recited in claim 9, wherein the step of securing includes placing the flange adjacent a material layer of the upper and joining the flange to the material layer.

11. The method recited in claim 8, wherein the step of securing includes positioning the collar element along a portion of a lateral side of the upper, around a heel region of the upper, and along a portion of a medial side of the upper.