HK1209291B - Article of footwear having a flat knit upper construction or other upper construction - Google Patents

Description

Article of footwear with flat knit upper construction or other upper construction

This application is a divisional application with application number 201210340178.1, originally filed as an invention application entitled "article of footwear with flat knit upper construction or other upper construction" with application number 200780042559.9 (international application number PCT/US2007/084013) filed on 8.11.2007.

Background

Conventional articles of athletic footwear include two primary elements, an upper structure and a sole structure. The upper provides a covering for the foot that securely receives and positions the foot with respect to the sole structure. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing moisture vapor. The sole structure is secured to a lower surface of the upper and is generally positioned between the foot and the ground. In addition to attenuating ground reaction forces, the sole structure may provide traction and control foot motions, such as pronation. Accordingly, the upper structure and the sole structure operate cooperatively to provide a comfortable structure that is suited for a variety of athletic activities, such as walking and running. The general features and construction of conventional uppers are described in detail below.

The upper forms a void on the interior of the footwear for receiving the foot. The void has a general foot shape, and access to the void is provided through the ankle opening. Thus, the upper extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. A lacing system is often incorporated into the upper to selectively increase the size of the ankle opening and allow the wearer to modify certain dimensions of the upper to accommodate feet with varying proportions. In addition, the upper includes a tongue that extends under the lacing system and a heel counter that limits movement of the heel.

The materials forming the upper may be selected based upon the characteristics of wear, such as abrasion resistance, flexibility, extensibility, and breathability. For the outer layer, the toe area and the heel area may be formed of leather, synthetic leather, or a rubber material to impart a high degree of wear resistance. However, leather, synthetic leather, and rubber materials do not have the desired degree of flexibility and breathability. Thus, many other areas of the exterior layer of the upper may be formed from synthetic or natural textile materials. The exterior layer of the upper may thus be formed from a variety of material elements that impart different characteristics to specific portions of the upper.

The middle layer of the upper may be formed from a lightweight polymer foam material that provides cushioning. Similarly, the interior layer of the upper may be formed from a moisture-wicking textile that removes moisture from the area immediately surrounding the foot. In some articles of athletic footwear, the various layers may be joined with adhesives, and stitching may be used to join various elements in one layer or to reinforce specific areas of the upper.

Although the materials selected for the upper vary widely, textile materials typically form at least a portion of the exterior and interior layers. A fabric may be defined as a structure made from fibers, filaments, or yarns that are flexible, delicate, and have a large length to thickness ratio. Fabrics generally fall into two categories. The first category includes fabrics made directly from a web of filaments or fibers by randomly interlocking to construct a nonwoven fabric and mat. The second type is a fabric formed by mechanical manipulation of the yarns, for example by interlacing or interlooping, whereby for example a woven or knitted fabric is produced.

Yarns are the raw material used to form the second type of fabric. In general, a yarn is defined as an article having a substantial length and a relatively small cross-section, the yarn being formed from at least one filament or a plurality of fibers. The fibers have a relatively short length and require a spinning or twisting process to make a yarn of the appropriate length for use in the fabric. Typical examples of fibers are cotton or wool. However, filaments have an indefinite length and only other filaments can be combined to make a yarn suitable for use in a fabric. Modern filaments include a variety of synthetic materials such as rayon, nylon, polyester, and polyacrylic, with silk being one exception to the predominant natural occurrence. The yarn may be formed from one filament, which is typically referred to as a monofilament yarn, or from a plurality of individual filaments combined together. The yarn may also include separate filaments formed from different materials, or the yarn may include filaments that are each formed from two or more different materials. Similar concepts also apply to yarns formed from fibers. Thus, the yarns may have various configurations generally suitable for the above definition.

Various techniques for mechanically manipulating yarns into fabrics include interlacing, entangling and twisting. Interweaving is the crossing of two yarns that cross and interweave at right angles to each other. The yarns used in interweaving are commonly referred to as "warp" and "weft". Twisting and twisting filaments includes processes such as braiding and knotting, in which yarns are twisted around each other to form a fabric. Interlooping involves the formation of a plurality of columns of intermeshed loops, knitting being the most common method of interlooping.

Textiles utilized in footwear uppers generally provide a lightweight, breathable structure that flexibly and comfortably receives a foot. Additional materials are often used in conjunction with textiles to impart other characteristics to the footwear, including durability and stretch-resistance, including leather, synthetic leather, or rubber, for example. For durability, U.S. patent No. 4,447,967 to Zaino discloses an upper formed of a textile material having a polymer material injected into specific areas to enhance the areas' ability to resist abrasion or other forms of abrasion. With respect to stretch resistance, U.S. Pat. Nos. 4,813,158 to Brown and 4,756,098 to Boggia both disclose a substantially inextensible material that is secured to the upper, thereby limiting the degree of stretch in specific portions of the upper. U.S. patent publication No.2006-0048413 discloses, among other things, a rubber/foam mesh sandwiched between two fabric structures to provide support, and which also allows for localized breathability, stretch and durability.

Disclosure of Invention

One example structure according to this invention relates to an article of footwear having an upper and a sole structure secured to the upper. The upper includes a knit element formed from at least one mechanically-manipulated yarn. The knit element of this example structure has a region with a first layer and a coextensive second layer. The first layer and the second layer are formed of unitary construction, and the second layer is joined to the first layer at opposite sides of the second layer.

Another exemplary aspect of the invention relates to a method of manufacturing an article of footwear. The method includes the steps of flat knitting (flat knitting) a textile element and incorporating the textile element into an article of footwear. The step of flat knitting may include forming a textile element having a first layer and a coextensive second layer. These two layers may be used, for example, to form channels. In some configurations, the step of flat knitting may include forming a first region and a second region, the first region having a stitch type and a yarn type that is different from a stitch type and a yarn type of the second region.

Yet another example structure according to this invention relates to an article of footwear having a knit element that includes a foot-receiving portion and one or more straps formed of unitary construction with the foot-receiving portion. The foot-receiving portion defines a void for receiving the foot, and one or more straps extend outwardly from one or more sides of the foot-receiving portion.

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

Drawings

FIG. 1 is a lateral elevational view of an article of footwear having a first upper in accordance with the present invention.

FIG. 2 is a medial elevational view of the article of footwear.

Fig. 3 is a top view of the article of footwear.

Fig. 4A-4C are cross-sectional views of the article of footwear, as defined by section lines 4A-4C in fig. 3.

FIG. 5 is a plan view of a lateral textile element of the first upper.

FIG. 6 is a plan view of a medial textile element of the first upper.

FIG. 7 is a plan view of a medial textile element of the first upper.

Fig. 8A is a perspective view of a first step of assembling an article of footwear.

Fig. 8B is a perspective view of a second step of assembling the article of footwear.

Fig. 8C is a perspective view of a third step of assembling the article of footwear.

Fig. 8D is a perspective view of a fourth step of assembling the article of footwear.

Fig. 8E is a perspective view of a fifth step of assembling the article of footwear.

Figure 9A is a plan view of another configuration of an outer textile element.

Figure 9B is a plan view of yet another configuration of an outer textile element.

Figure 10A is a perspective view of a textile element of a second upper according to the present invention.

Figure 10B is a top view of a textile element of the second upper.

Figure 10C is a side elevational view of the textile element of the second upper.

FIG. 11A is a perspective view of an article of footwear having a third upper in accordance with the present invention.

FIG. 11B is a side elevational view of the third upper in combination with the foot.

FIG. 12 is a perspective view of an article of footwear having another upper configuration in accordance with the present invention.

FIG. 13 is a perspective view of an article of footwear having yet another upper configuration in accordance with the present invention.

Detailed Description

The following description and the annexed drawings disclose various uppers for articles of footwear, the uppers (or at least portions thereof) being at least partially formed from materials manufactured through a flat knitting process. The upper is associated with footwear that is suitable for activities that include running and yoga. Concepts associated with the shoes and uppers are not limited to shoes designed for running and yoga, but they may be applied to a wider range of athletic shoe varieties, including baseball shoes, basketball shoes, cross-training shoes (cross-training), cycling shoes, football shoes, tennis shoes, soccer shoes, hiking shoes, and hiking boots, for example. The concept may also be referred to in terms of footwear of the type commonly considered to be non-athletic, including dress shoes (dress shoes), loafers, sandals, and work boots. The concepts disclosed herein are thus applicable to a variety of footwear types. Also, the concepts of the present invention may be used in conjunction with other portions of footwear structures, such as layers in the construction of upper members, linings for footwear products (e.g., sock liners), bootie (bootie) members (optionally included in footwear structures), and the like.

Flat knitting, when used in an exemplary structure according to the present invention, may provide various advantages. For example, flat knitting may be used to provide a textile structure for use in a footwear upper having a desired shape such that a textile cutting step may be avoided (which eliminates waste, avoids the need to modify cut edges, saves time, saves money, etc.). The flat knitted element may also be formed directly into the desired three dimensional shape, which helps to avoid the need to use additional support structures throughout the footwear structure (which also saves time and money, etc.; lighter and/or more flexible products can be manufactured; seams and at least some sewing work can be eliminated, etc.). By selectively placing multiple different yarns and/or stitch patterns at different locations throughout the structure during the knitting process, flat knitted products may have multiple different physical properties (e.g., different stretchability, different moisture control capabilities, etc.) at multiple different locations or regions in a single construction. In addition, flat knitting may be used to make pockets, tunnels, or other layered structures in the final product. These and other features, aspects, and advantages of structures and methods according to examples of the present invention will be described in more detail below in conjunction with various example structures shown in fig. 1-13.

General shoe structure

The article of footwear 10 shown in fig. 1-4C includes a sole structure 20 and an upper 30. For reference purposes, footwear 10 may be divided into three main areas: a forefoot region 11, a midfoot region 12, and a heel region 13, as shown in fig. 1 and 2. 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 metatarsals with the phalanges. Midfoot region 12 generally includes portions of footwear 10 corresponding with the arch area of the foot, and heel region 13 corresponds with rear portions 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 that will aid in the following description. In addition to footwear 10, regions 11-13 and sides 14-15 may also apply to sole structure 20, upper 30, and their respective elements.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when footwear 10 is worn. In addition to providing traction, sole structure 20 provides cushioning for ground reaction forces as the foot squeezes between the ground during walking, running, or other athletic activities. As shown in the figures, one suitable configuration for sole structure 20 includes a midsole 21, an outsole 22, and an insole 23. Midsole 21 is secured to a lower surface of upper 30 and is primarily formed from polymer foam elements (e.g., polyurethane or ethylvinylacetate foam, phylon, phylite, etc.) that impart ground reaction force attenuation properties to sole structure 20. The midsole may incorporate a fluid-filled bladder that assists with ground reaction force cushioning properties. Outsole 22 is secured to a lower surface of midsole 21 and may be formed from a textured rubber or other material that imparts relatively high abrasion resistance and/or traction properties. Insole 23 is positioned within upper 30 and is positioned to extend below the lower surface of the foot. Although this configuration for sole structure 20 provides a suitable example for a sole structure that may be used in association with upper 30, other conventional or nonconventional configurations for sole structure 20 may also be utilized without departing from this invention.

Upper 30 defines a void within footwear 10 for receiving and securing the foot relative to sole structure 20. More specifically, the void is shaped to accommodate the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, and under the foot. Access to the void is provided through an ankle opening 31 located in at least heel region 13. A lace 32 extends through various lace elements 33 and allows the wearer to modify dimensions of upper 30, thereby accommodating feet with varying proportions. Lace 32 also allows the wearer to loosen the upper and facilitate removal of the foot from the void. Lace elements 33 in this example footwear structure 10 are formed of a flexible material that each has a pair of loops 35 formed on opposite ends of a medial portion 36, loops 35 having a configuration that receives lace 32. In addition, upper 30 includes a heel counter 34 that extends around heel region 13 and limits movement of the heel. Various other lace engaging elements and/or other footwear fastening systems may be provided if desired.

Fabric element

The void in this example footwear structure 10 is primarily defined by lateral textile element 40, medial textile element 50, and medial textile element 60. Lateral textile element 40 forms a portion of upper 30 that corresponds with lateral side 14. Medial textile element 50 forms a portion of upper 30 that corresponds with medial side 15. In addition, medial textile element 60 forms a portion of upper 30 that extends under the foot, over a front portion of the foot, and around the heel of the foot. Textile elements 40, 50, and 60 extend around the foot and are the primary elements of footwear 10 that contact the foot or a sock worn on the foot. In general, and as described in detail below, upper 30 is primarily assembled by joining the edges of textile elements 40, 50, and 60 to impart the general shape of a void. Moreover, assembling upper 30 in this example structure 10 involves incorporating lace 32, lace elements 33, and heel counter 34 into footwear 10.

Textile elements 40, 50, and 60 are depicted as forming an exterior surface and an opposite interior surface of footwear 10. In other configurations, textile elements 40, 50, and 60 may form only exterior surfaces or only interior surfaces (e.g., when an interior lining or bootie is used in a footwear structure). Textile elements 40, 50, and 60 may also be located between other footwear elements to form portions of footwear 10 that are not visible or exposed. Furthermore, textile elements 40, 50, and 60 are depicted as extending through each of regions 11-13, but they may be limited to smaller portions of footwear 10.

Lateral textile element 40 is depicted separately in figure 5 and is formed of unitary (i.e., one-piece) construction through a flat knitting process. That is, the flat knitting process is used to mechanically manipulate one or more yarns in a manner that forms upper edge 41, lower edge 42, rear edge 43, and four channels 44 in lateral textile element 40. As shown in the cross-section of fig. 4B, channels 4 are formed from two layers of material that are at least partially coextensive, form lateral textile element 40, and that are formed from a unitary (i.e., one-piece) construction through a flat knitting process. When viewed from the side of footwear 10, as shown in FIG. 1, channels 44 are oriented in a generally vertical direction or at an angle relative to the vertical.

Inner textile element 50 is depicted separately in figure 6 and is similar in shape and configuration to outer textile element 40. Accordingly, inner textile element 50 is formed from a unitary (i.e., one-piece) construction through a flat knitting process. That is, the flat knitting process is used to mechanically manipulate one or more yarns in a manner that forms upper edge 51, lower edge 52, rear edge 53, and four channels 54 in medial textile element 50. As shown in the cross-section of FIG. 4B, channels 54 are formed from two at least partially co-axially extending layers of material that form medial textile element 50, and the two layers are formed from a unitary (i.e., one-piece) construction through a flat knitting process. When viewed from the side of the footwear 10, as shown in FIG. 2, the channels 54 are oriented in a generally vertical direction or are angled with respect to the vertical direction. Accordingly, channels 54 are similar in structure and orientation to channels 44 of lateral textile element 40.

Intermediate textile element 60 is depicted individually in FIG. 7 and includes a front portion 61, a middle portion 62, and a rear portion 63 that are formed of unitary (i.e., one-piece) construction. The forward portion 61 is primarily located in the throat area of the footwear 10 (i.e., below the lace 32) and has an elongated configuration defined by a lateral edge 64a and a medial edge 64 b. As shown in FIG. 3, and as described in detail below, at least a portion of lateral edge 64a is joined to lateral textile element 40 and at least a portion of medial edge 64b is joined to medial textile element 50. Central portion 62 is primarily positioned adjacent the sole structure (i.e., in an area that extends under the foot) to form a lower portion of the void in upper 30. The central portion 62 has a shape approximating the shape of a foot and is defined by an outer edge 65a and an inner edge 65 b. As described in detail below, outer edge 65a is joined to outer textile element 40 and inner edge 65b is joined to inner textile element 50. Rearward portion 63 is primarily located in heel region 13 and has a Y-shaped configuration defined by a lateral edge 66a, a medial edge 66b, and an ankle edge 66 c. As described in detail below, lateral edge 66a is joined to lateral textile element 40, medial edge 66b is joined to medial textile element 50, and ankle edge 66c forms a portion of an upper edge of ankle opening 31.

Flat knitting and yarn

Each textile element 40, 50, and 60 may be formed through a flat knitting process. Generally, flat knitting is a method for manufacturing knitted materials in which the material is periodically twisted (i.e., the material is knitted from alternating sides). The two sides (or "faces") of the material are typically divided into a "front side" (i.e., the side facing outward, toward the viewer) and a "back side" (i.e., the side facing inward, away from the viewer). Flat knitting (flat knitting) is in contrast to circular knitting (circular knitting), in which the fabric is always knitted from the same side. Various techniques for circular knitting are known, such as narrow tube circular knitting (narrow tube circular knitting) and wide tube circular knitting (wide tube circular knitting). More specific examples of circular knitting techniques are found in U.S. published patent publication No. 2005/0193592, the disclosure of which is incorporated herein by reference in its entirety. Flat knitting, as opposed to circular knitting, is more complicated because the same stitch (as viewed from the front) is formed by two different motions when knitting from the front and back. Thus, the lower needle (knit stitch) is formed (as seen from the front) by a lower needle on the front or by a purl stitch on the back. In flat knitting, the fabric is usually turned over after each row. While flat knitting provides a suitable means for forming textile elements 40, 50, and 60, other types of knitting may be used, including wide-tube circular knitting, narrow-tube circular knitting jacquard, single-needle circular knitting jacquard, double-needle circular knitting jacquard, and warp knitting jacquard, for example.

An advantage of flat knitting over various other types of knitting is that the flat knitting process may be used to form generally three-dimensional structure(s) in which layers of material overlap (i.e., are at least partially coextensive) with one another to form loops or other overlapping structures, such as channels 44 and 54. More specifically, the flat knitting process may produce a structure that: wherein the layers are joined to one another such that opposing sides of one layer are formed with unitary construction with the other layer, such as channels 44 and 54. Further, flat knitting may be used to form regions having different types of stitches and regions having different types of yarns. For example, the front portion 61 of the intermediate element 60 is depicted as having a ribbed configuration that stretches to a different degree than the non-ribbed configuration of the central and rear portions 62, 63. Moreover, textile elements 40 and 50 may be formed with a less stretchable type of stitch than forward portion 61, and the yarn selected for textile elements 40 and 50 may be more abrasion resistant than the yarn selected for forward portion 61. As another example, the stitch/yarn combination for rear portion 63 may be selected to impart stretch and recovery to ankle opening 31. Thus, the flat knitting process may be used to form a generally three-dimensional or overlapping structure having regions with different properties formed with different types of stitches and combinations of different types of yarns.

The flat knitting process may also be used to form elements having defined shapes that do not need to be cut from a large textile element. For example, each textile element 40, 50, and 60 may be knitted to have a respective shape as shown in figures 5-7 without cutting textile elements 40, 50, and 60 from a larger textile element. Thus, unlike textile elements that are cut from larger textile elements, the edges of textile elements 40, 50, and 60 need not be finished to prevent unraveling. Also this feature reduces waste and saves time and money in the manufacturing process.

Yarns forming textile elements 40, 50, and 60 may include cotton and wool fibers, natural filaments such as silk, and synthetic filaments including rayon, nylon, polyester, and acrylic. Other materials may be used without departing from the scope of the invention. The yarns may be monofilament yarns or a plurality of individual filaments. The yarn may also be formed from separate filaments formed from different materials, or the yarn may be formed from filaments that are each formed from two or more different materials. Similar concepts can also be applied to yarns formed from fibers. To provide upper 30, and in particular textile elements 40, 50, and 60, with the ability to stretch and recover, a yarn incorporating elastic fibers (elastane fibers) may be utilized. The elastic fibers are available from e.i. dupont de Nemours Company andis obtained by the trademark of (c). The fibres may have a coatingWherein the fibers compriseThe core being surrounded by a nylon sheath. One suitable yarn, for example, includes a 70 denier elastic core covered by 2ply, 80 denier, 92 filament construction nylon. Other fibers or filaments having elastic properties may also be used.

The characteristics of the yarns selected for textile elements 40, 50, and 60 are primarily dependent upon the materials from which the various filaments and fibers are formed. For example, cotton provides a soft hand, natural aesthetics, and biodegradability. The elastic fibers provide significant stretch and recovery capabilities as described above. Rayon provides coverage and moisture absorption capabilities. Wool materials can also provide high moisture absorption capacity in addition to providing insulation properties. The polytetrafluoroethylene coating provides a low frictional contact between the fabric and the skin. Nylon is a durable and abrasion resistant material with high strength, and polyester is a hydrophobic material that dries quickly and can also provide relatively high durability. Flat filaments of nylon/polyester may provide gloss, while textured filaments may provide lumpy and matte gloss. Thus, the materials comprising yarns may be selected to impart various physical properties to textile elements 40, 50, and 60, and the physical properties may include, for example, strength, stretch, support, stiffness, recovery, comfort, and formability.

And (5) assembling.

A suitable assembly process for footwear 10 is generally shown in fig. 8A-8E. The sequence of various steps outlined below is described as one example of the manner in which footwear 10 may be assembled. However, those skilled in the art will appreciate that a different order may be used to assemble footwear 10. Referring to fig. 8A, each textile element 40 and 50 is shown as being sewn or otherwise joined to intermediate textile element 60. More specifically, lower edge 42 of lateral textile element 40 is stitched to lateral edge 65a of central portion 62, and lower edge 52 of medial textile element 50 is stitched to medial edge 65b of central portion 62. Various types of stitches may be used to join edges 42, 52, 65a, and 65b in the manner described above. For example, once stitching is applied, edges 42, 52, 65a, and 65b may abut one another or overlap one another. In addition to sewing, edges 42, 52, 65a, and 65b may be joined to one another with an adhesive or with a thermal joining operation. Accordingly, various methods may be utilized to join textile elements 40, 50, and 60. Furthermore, those skilled in the art will appreciate that a last having the general shape of a foot may be utilized in the joining of textile elements 40, 50, and 60 to form upper 30.

Once the lower portions of textile elements 40 and 50 are joined to central portion 62, textile elements 40 and 50 may be joined to rear portion 63, as shown in FIG. 8B. More specifically, rear edge 43 of lateral textile element 40 is stitched to lateral edge 66a of rear portion 63, and rear edge 53 of medial textile element 50 is stitched to medial edge 66b of rear portion 63. Referring to fig. 8C, the assembly process continues by joining textile elements 40 and 50 to front portion 61. More specifically, upper edge 41 of lateral textile element 40 is stitched to lateral side 64a of forward portion 61, and upper edge 51 of medial textile element 50 is stitched to medial edge 64b of forward portion 61.

To this end, textile elements 40, 50, and 60 are joined to one another during assembly to form an interior void shaped to receive the foot. Various other elements of footwear 10 may now be added. With reference to FIG. 8D, lace elements 33 are positioned to extend through channels 44 and 54 and also extend under central portion 62 of central textile element 60. Each loop 35 is positioned to extend outward from the upper portions of channels 44 and 54, and medial portion 36 of lace elements 33 is positioned below and on the exterior of medial textile element 60. As a final step in this exemplary assembly process, as depicted in fig. 8E, lace 32 is adhesively-joined or otherwise secured to the exterior of upper 30 in heel region 13 by lace elements 33, heel counter 34, and sole structure 20 is adhesively-joined or otherwise secured to a lower region of upper 30.

Additional construction

Footwear 10 provides an example of a suitable configuration for an article of footwear having an upper formed at least in part from a flat knit material construction. Referring to FIG. 9A, another configuration for lateral textile element 40 is shown with various lace loops 45 at the locations of channels 44 and lace elements 33. As noted above, the flat knitting process may be used to form a generally three-dimensional structure in which the various layers of material overlap (i.e., are at least partially coextensive) with one another to form loops or other overlapping configurations, as with channels 44 and 45. Lace loops 45 may replace lace elements 33 to accommodate portions of lace 32. Lace elements 33 may be formed from a substantially inextensible material, although this is not required. To provide lace loops 45 with similar properties, the yarns and stitches selected for lace loops 45 may impart a substantially non-stretch configuration to upper 30 in the area of lace loops 45.

Another configuration of lateral textile element 40 is shown in FIG. 9B, with pocket 46, in place of channel 44 and lace element 33. The pocket 46 has an upper opening and can be closed to allow small items (e.g., keys, identification cards, or change) to be secured into the footwear 10. Like channels 44 and lace loops 45, pockets 46 are formed as a unitary structure with textile element 40 through a flat knitting process. If desired, a flap or other closure element may be provided to assist in securing the article in the pocket 46 (alternatively, the flap may be formed as part of the fabric element 40 (e.g., as a unitary, one-piece structure therewith) during flat knitting.

As another example of a three-dimensional structure formed by a flat knitting process, upper 70 is depicted in FIGS. 10A-10C. Upper 70 includes a central portion 71, a pair of side portions 72, and eight lace loops 73, with side portions 72 each including a side edge 74, a rear edge 75, and a medial edge 76. When assembled into an article of footwear, medial portion 71 extends over the foot, and lateral portions 72 wrap under the foot. More specifically, the side edges 74 are joined to one another (or by stitching) to form a seam that extends under the foot and along the longitudinal length of the foot. In addition, the rear edges 75 are joined to one another (e.g., by stitching) to form a seam that extends upward along the heel. In this configuration, medial edge 76 may define an opening that allows the foot to enter and exit the void in upper 70. The lace may extend through lace loops 73 to provide adjustability.

Although the side portions 72 are relatively flat in configuration, the central portion 71 has a domed shape formed by a flat knitting process. That is, the flat knitting process forms the intermediate portion 71 into a three-dimensional structure having a shape that extends over the foot. The middle portion 71 may be ribbed, as opposed to the side portions 72 having non-ribbed type stitches. In addition to different stitch types, different areas may incorporate different yarns to further modify the properties of upper 70. Thus, in addition to providing a three-dimensional structure, the flat knitting process may be utilized to impart different stitch types and yarns to different areas of upper 70, thereby changing the properties of upper 70 in the different areas.

Another article of footwear 10 ' is shown in FIGS. 11A and 11B, including a sole structure 20 ' and an upper 30 '. Although footwear 10 includes sole structure 20 that is separate from upper 30 and attached to upper 30, sole structure 20 'of this example is a lower surface of the textile material that forms upper 30'. Thus, footwear 10' may be used for activities such as yoga, where a small sole is acceptable. In other configurations, sole structure 20' may include polymer foam or rubber elements that impart force attenuation and abrasion resistance. If desired, a separate sole structure may be utilized for upper 30'.

Upper 30 ' includes a foot-receiving portion 31 ' and a pair of straps (straps) that extend outward from the sides of foot-receiving portion 31 '. The foot-receiving portion 31' has a general sock-like structure that is formed by a flat knitting process with a unitary (i.e., one-piece) construction. Foot-receiving portion 31 'is thus a textile element shaped to extend around the foot, and foot-receiving portion 31' has an opening 33 'for inserting and removing the foot from upper 30'. Straps 32 'are each formed of unitary (i.e., one-piece) construction with foot-receiving portion 31' and are joined with foot-receiving portion 31 'proximate opening 33'. Such as the foot-receiving portion 31 ', the straps 32' are formed through a flat knitting process. In this example structure, each strap 32 'tapers from the area where strap 32' joins with foot-receiving portion 31 'to the end of strap 32'. That is, the end of strap 32 ' has a smaller width than the portion of strap 32 ' adjacent opening 33 '. Straps 32 'may each be formed from one layer of fabric material, or each strap 32' may have a tubular configuration that is effectively formed from two layers of fabric material.

Straps 32 'are used to secure footwear 10' to the foot. As such, straps 32' may have a length ranging, for example, between three inches and twenty-four inches, depending on the size of footwear 10And uses thereof. However, as noted, strap 32' is approximately six inches long. Each strap 32 'has an end and a fastener 34' located at the end. The fastener 34' is shown as being a corresponding part of a hook and loop fastener, such asBut they may also be snaps, buttons, or other desired fasteners. Referring to fig. 11B, strap 32 ' wraps around the ankle such that fastener 34 ' is used to secure the end of strap 32 ' to the rear of the ankle. Alternatively, straps 32 'may be tied on the upper surface of the foot or may wrap around the foot to secure footwear 10' to the foot. Thus, various methods for securing footwear 10' to the foot may be used, depending on the foot size and preferences of the wearer.

Although upper 30 is formed from three separate textile elements 40, 50, and 60 that are joined by stitching, upper 30' is formed from one textile element formed of unitary construction. Thus, in contrast with upper 30, upper 30' has no seams that would contact the foot during use. That is, the foot-receiving portion 31 'of this example structure 10' is formed to extend around the foot and does not include a seam adjacent the foot. In turn, the seamless union of sole structure 20 ' and upper 30 ' in this example structure 10 ' further reduces seams near the foot. Thus, the flat knitting process may be used to form a seamless footwear component that extends around the foot.

Fig. 12 and 13 show additional examples of articles of footwear similar to the example shown in fig. 11A and 11B, but with some different straps and/or fastening devices. In the example of article of footwear 100 shown in fig. 12, article of footwear 100 includes sole structure 120 and upper 130. If desired, a separate sole structure 120 may be provided that is attached to the upper 130, or the upper 130 and sole structure 120 may be provided as a unitary, one-piece construction (e.g., a flat knit yoga shoe, slipper, bootie, etc.). Upper 130 of this example structure 100 includes a foot-receiving portion 131 that defines an opening 133 through which a wearer's foot may be inserted. This example structure 100 includes a strap 132 that extends over the wearer's foot to secure the foot to the article of footwear 100. Although any type of fastening system (e.g., button, snap, hook, buckle, etc.) may be provided, in the exemplary structure 100, a portion of the hook-and-loop fastener 134 is provided on the free end of the strap 132, and that portion of the fastener 134 is secured to another portion of the hook-and-loop fastener (not shown) provided on the side of the upper 130. The strap 132 may be provided on the lateral or medial side of the upper member 130 without departing from the invention. This strap 132 may be provided with the upper member 130 as a unitary, one-piece construction through a flat knitting process, for example, in the manner described in connection with strap 32 of fig. 11A and 11B. If desired, the straps 132 (as well as straps 32 described above) may be constructed from a stretchable material, such as to achieve a comfortable and secure fit to the wearer's foot.

Fig. 13 shows an example of an article of footwear 200 with another strap/securing arrangement. In this example, the same or similar parts to those described in conjunction with fig. 12 are denoted by the same reference numerals (and their corresponding descriptions are omitted). Rather than a single strap, in this example a plurality (e.g., four in the example shown) of long, relatively thin and flexible straps 232 are provided. If desired, the straps 232 may be sufficiently thin and/or flexible to allow the wearer to tie them together around the foot (e.g., to buckle or tie a lace) to thereby secure the foot in the article of footwear 200. The straps 232 may be of sufficient length to wrap around the wearer's ankle for one or more weeks and optionally up the wearer's lower leg, for example in a manner similar to straps provided in conventional ballet and/or Greco Roman type shoes. If desired, rather than tying, fastening elements (e.g., hook and loop fasteners, etc.) may be provided, for example, in a manner similar to that described with respect to FIGS. 11A through 12.

The straps 232 are formed of a unitary, one-piece construction with the upper member 130, such as during a flat knitting process, as described in connection with the process depicted in figures 11A through 12. Alternatively, if desired, the straps 232 may be separate from the upper member 130 (e.g., as with laces, straps, ribbons, or other strap elements), optionally extending through channels formed in the upper member 130, e.g., in a manner similar to the channels 44 and 54 described in connection with fig. 1-8E. Other strap and/or fastener arrangements may be provided without departing from the scope of the invention.

Although the footwear structures 10', 100 and 200 shown in fig. 11A through 13 are shown as ballet or yoga-style shoes, the structures and techniques may be used with their upper members or portions (e.g., liners, bootie elements, etc.) in a variety of different footwear products without departing from the scope of the invention.

Conclusion

As discussed above, the flat knitting process may be used to form various uppers or other structures for inclusion in an article of footwear. The advantage of flat knitting is that a substantially three-dimensional structure can be formed. Further, structures may be formed in which layers of material overlap one another to form loops or other overlapping configurations. The flat knitting process may also be used to form regions having different properties, such as by using different types of stitches and/or combinations of different types of yarns. Thus, flat knitting may be used to form the shape of the upper and may also provide different properties to different areas of the upper.

The present invention is disclosed above and in the accompanying drawings with reference to various embodiments. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to aspects of the invention, not to limit the scope of aspects of the invention. It will be appreciated by persons skilled in the art that numerous variations and modifications may be made to the above described embodiments without departing from the scope of the invention as defined by the appended claims.

Claims (20)

1. An article of footwear comprising an upper including a flat knit element formed from at least one mechanically manipulated yarn during a flat knitting process, the flat knit element comprising a first layer having:

a medial portion having a dome-shaped three-dimensional structure configured to extend over a foot surface;

a first side portion formed of unitary construction with the intermediate portion and extending from a first side of the intermediate portion; and

a second side portion formed of unitary construction with the intermediate portion and extending from a second side of the intermediate portion opposite the first side.

2. The article of footwear of claim 1, further comprising a first loop formed as a second layer of unitary construction with the first layer.

3. The article of footwear according to claim 2, wherein the first loop extends outwardly from the central portion.

4. The article of footwear of claim 2, further comprising eight loops formed into the second layer of unitary construction with the first layer.

5. The article of footwear of claim 1, wherein the knit element defines a void for receiving a foot of a wearer.

6. The article of footwear according to claim 1, wherein the knit element defines at least a portion of an exterior surface of the upper and the knit element defines at least a portion of a void for receiving a foot of a wearer.

7. The article of footwear recited in claim 1, wherein the knit element includes a first region and a second region, the first region including a first type of knit structure and the second region including a second type of knit structure, the first type being different from the second type.

8. The article of footwear of claim 1, wherein the at least one mechanically operated yarn includes a first yarn and a second, different yarn, the first yarn being located in a first region of the upper and the second yarn being located in a second region of the upper.

9. The article of footwear of claim 1, wherein the knit element forms a defined shape with a finished edge during flat knitting.

10. An article of footwear comprising an upper including a flat knit element formed from at least one mechanically manipulated yarn during a flat knitting process, the flat knit element comprising:

a first layer having:

a middle portion;

a first side portion formed of unitary construction with the intermediate portion and extending from a first side of the intermediate portion; and

a second side portion formed of unitary construction with the intermediate portion and extending from a second side of the intermediate portion opposite the first side; and

a second layer flat knitted with the first layer at opposite ends of the second layer to form overlapping loops.

11. The article of footwear according to claim 10, wherein the intermediate portion has a three-dimensional structure configured as a dome extending above the instep.

12. A method of manufacturing an article of footwear, comprising forming an upper during a flat knitting process, the upper comprising a flat knit element, the flat knit element comprising a first layer having:

a medial portion having a dome-shaped three-dimensional structure configured to extend over a foot surface;

a first side portion formed of unitary construction with the intermediate portion and extending from a first side of the intermediate portion; and

a second side portion formed of unitary construction with the intermediate portion and extending from a second side of the intermediate portion opposite the first side.

13. The method recited in claim 12, wherein the flat knitting process includes forming a first area and a second area, the first area having a different stitch type than the second area.

14. The method of claim 12, wherein the flat knitting process includes forming a first area and a second area, the first area having a different yarn type than the second area.

15. The method of claim 12, wherein the flat knitting process includes forming a first area and a second area, the stitch type and yarn type of the first area being different from the stitch type and yarn type of the second area.

16. The method recited in claim 12, further including assembling the flat knit element into an article of footwear.

17. The method of claim 16, wherein the assembling includes joining side edges of the first side and the second side to form a seam extending under the foot and along a longitudinal length of the foot.

18. The method according to claim 16, wherein the assembling includes joining the rear edges of the first side portion and the second side portion to form a seam extending upward along the heel.

19. The method recited in claim 12, wherein the flat knitting process includes forming a first loop of unitary construction in the textile element.

20. The method recited in claim 19, further including extending lace elements through the first loop.