HK1211445B - Footwear upper incorporating a knitted component with sock and tongue portions - Google Patents

Abstract

An article of footwear may include a knitted component formed of unitary knit construction. The knitted component includes a sock portion and a tongue portion. The sock portion has a hollow structure (a) forming an ankle opening in a heel region of the footwear and (b) extending between the heel region and a forefoot region of the footwear to define a void within the footwear for receiving a foot. The tongue portion has an elongate configuration (a) extending through at least a portion of a length of a throat area of the upper and (b) including two knit layers that lay adjacent to each other.

Description

Footwear upper incorporating a knitted component with a sock portion and a tongue portion

Technical Field

The present invention relates to a footwear upper incorporating a knitted component having a sock portion and a tongue portion.

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. For example, in athletic footwear, the sole structure may include a midsole and an outsole. The midsole generally includes a polymer foam material that attenuates ground reaction forces to reduce pressure 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, such as rubber. The sole structure may also include a sockliner positioned within the void and proximate a lower surface of the foot to enhance footwear comfort.

The upper generally extends over instep and toe areas of the foot, along medial and lateral sides of the foot, under the foot, and around a heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection to the ankle. Access to the void on the interior of the upper is typically provided through an ankle opening in the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, allowing the foot to be inserted into and removed from the void within the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet having different dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.

A variety of material elements (e.g., textiles, polymer foams, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing the upper. For example, in athletic footwear, the upper may have multiple layers that each include multiple joined material elements. As an example, the material elements may be selected to impart stretch-resistance, wear-resistance, flexibility, air-permeability, compression, comfort, and moisture-absorption to different areas of the upper. To impart different properties to different areas of the upper, the material elements are typically cut to the desired shape and then joined together, typically with a stitched or adhesively bonded connection. In addition, the material elements are often joined in a layered configuration to impart multiple properties to the same region. As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, storing, cutting, and joining the material elements may also increase. As the number and type of material elements incorporated into the upper increases, waste 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. Accordingly, by reducing the number of material elements used in the upper, scrap may be reduced while increasing production efficiency and the recyclability of the upper.

Disclosure of Invention

An article of footwear is disclosed below as having an upper and a sole structure secured to the upper. The knitted component of the upper is formed of unitary knit construction and includes a sock portion (sock portion) and a tongue portion. The sock portion has a hollow structure that (a) forms an ankle opening in a heel region of the footwear and (b) extends between the heel region and a forefoot region of the footwear to define a void within the footwear for receiving a foot. The tongue portion has an elongate configuration that (a) extends across at least a portion of a length of a throat area of the upper and (b) includes two knit layers positioned adjacent to one another.

In one embodiment, one of the knit layers may abut the sock portion in the throat area.

In one embodiment, the tongue portion may be located within the cavity.

In one embodiment, a first end of the tongue portion may be formed of unitary knit construction with the sock portion, and a second end of the tongue portion may be stitched to the sock portion, the first end and the second end may be opposite.

In one embodiment, (a) the peripheral zones of the knit layers may be joined to one another, and (b) the central zones of the knit layers may be unjoined to one another.

In one embodiment, the upper may include a cover component that may extend (a) between the heel region and the forefoot region and (b) between the throat region and the sole structure, and the knitted component may be at least partially located within the cover component.

In one embodiment, the covering component may be secured to the knitted component.

In one embodiment, the braided component may be removable from within the covering component.

In one embodiment, the cover member may not be present in the throat area to expose an area of the cover portion located in the throat area.

In one embodiment, a lace may extend through the throat area and may extend between opposite sides of the cover component.

In one embodiment, the upper may include: (a) a plurality of tensile cords extending through an area between the throat area and the sole structure, and (b) a lace coupled to the tensile cords and repeatedly extending through the throat area.

The article of footwear may also have a knitted component and a cover component. The knitted component (a) forms an ankle opening in a heel region of the footwear and (b) extends between the heel region and a forefoot region of the footwear to define a void within the footwear for receiving a foot. A majority of the knitted component is formed from the first knit layer, but a portion of the knitted component is located in a throat area of the upper having a layered structure including the first knit layer, the second knit layer, and the third knit layer. Each of the first, second, and third woven layers is formed of unitary woven construction. The cover component is secured to the sole structure and extends between the throat area and the sole structure, with the knitted component at least partially located within the cover component.

In one embodiment, the covering component may be secured to the knitted component.

In one embodiment, the braided component may be removable from within the covering component.

In one embodiment, the second woven layer and the third woven layer may be located within the cavity.

In one embodiment, the first braided layer may be a sheath portion of the braided component and may have a hollow structure.

In one embodiment, the second knit layer and the third knit layer may be a tongue portion of the knitted component and may have an elongate configuration that extends through at least a portion of a length of the throat area.

In one embodiment, the second woven layer may be located between the first woven layer and the third woven layer, and may be against each of the first woven layer and the third woven layer.

In one embodiment, (a) peripheral regions of the second and third woven layers may be joined to one another, and (b) central regions of the second and third woven layers may be unjoined to one another.

In one embodiment, an area of the cover component may be absent from the throat area to expose an area of the first knit layer located in the throat area.

A knitted component formed of unitary knit construction and comprising a sock portion and a tongue portion, the sock portion having a hollow structure forming an ankle opening and defining a void for receiving a foot, and the tongue portion having an elongate configuration extending through at least a portion of a length of the sock portion and comprising two knit layers positioned adjacent to one another.

In one embodiment, one of the braided layers may be against the sheath portion.

In one embodiment, the tongue portion may be located within the cavity.

In one embodiment, a first end of the tongue portion may be formed of unitary knit construction with the sock portion, and a second end of the tongue portion may be stitched to the sock portion, the first end and the second end may be opposite.

In one embodiment, (a) the peripheral zones of the knit layers may be joined to one another, and (b) the central zones of the knit layers may be unjoined to one another.

A method for manufacturing an article of footwear may include forming a knitted component using a circular knitting process by knitting a sock and two substantially coextensive layers within the sock and extending along at least a portion of the length of the sock. In addition, the knitted component is incorporated into an upper of the article of footwear.

In one embodiment, the step of using the circular knitting process may include forming the sheath to have a hollow structure.

In one embodiment, the step of incorporating the knitted component may include (a) positioning the sock to extend from a forefoot region to a heel region of the article of footwear, and (b) positioning the two substantially coextensive layers to extend through at least a portion of a length of a throat area of the upper.

A method for manufacturing an article of footwear, the method comprising:

knitting a knitted component comprising a sock portion and a tongue portion, the sock portion having a hollow structure and the tongue portion comprising two knit layers extending outwardly from the sock portion and positioned within the sock portion; and

incorporating the knitted component into an upper of the article of footwear, the sock portion being positioned to extend from a forefoot region to a heel region of the article of footwear, and the tongue portion being positioned to extend through at least a portion of a length of a throat area of the upper.

In one embodiment, the step of knitting may include utilizing a circular knitting process.

In one embodiment, the step of knitting may include forming apertures in the sock portion, and the step of incorporating may include positioning the apertures to form ankle openings of the upper.

In one embodiment, the step of knitting may include (a) forming the two knit layers to be substantially coextensive with each other, and (b) joining peripheral regions of the two knit layers to each other.

In one embodiment, the step of incorporating may include connecting the knitted component to a cover component extending between the throat area and the sole structure.

The benefits and novel features which characterize aspects of the present invention are pointed out with particularity in the appended claims. To gain an improved understanding of these benefits and novel features, 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 lateral side elevational view of an article of footwear.

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

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

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

Fig. 5 is an exploded lateral side view of the article of footwear.

FIG. 6 is a perspective view of a knitted component forming a portion of an upper of an article of footwear.

Figure 7 is a perspective view corresponding to figure 6 and showing an interior portion of the knitted component.

Figure 8 is a lateral side view of a knitted component.

Figure 9 is a lateral side view corresponding to figure 8 and showing an interior portion of the knitted component.

Figure 10 is a medial side view of the knitted component.

Figures 11A-11D are cross-sectional views of the knitted component as defined by section lines 11A-11D in figure 7.

Fig. 12A-12C are lateral side views corresponding with fig. 1 and depicting additional configurations of the article of footwear.

Figures 13A-13D are lateral side views corresponding with figure 8 and depicting additional configurations of the knitted component.

Figures 14A-14F are cross-sectional views corresponding with figure 11D and depicting additional configurations of the knitted component.

Figures 15A-15D are cross-sectional views corresponding with figure 11C and depicting additional configurations of the knitted component.

Detailed Description

The following discussion and accompanying figures disclose various concepts related to a knitted component and the manufacture of a knitted component. Although the knitted component is disclosed with reference to an article of footwear having a configuration suitable for running and basketball, concepts associated with the knitted component may be applied to a wide range of athletic footwear styles, including baseball shoes, football shoes (football boots), golf shoes, hiking shoes and boots, ski and snowboard boots, soccer shoes (soccers), tennis shoes, training shoes, and walking shoes, for example. Concepts associated with the knitted component may also be utilized with footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, a variety of footwear types and configurations may incorporate the concepts discussed herein.

General footwear configuration

In fig. 1-5, article of footwear 100 is depicted as including a sole structure 110 and an upper 120. Sole structure 110 is positioned below and supports a wearer's foot, while upper 120 provides a comfortable and secure covering for the foot. As such, the foot may be positioned within upper 120 to effectively secure the foot within footwear 100 or otherwise unite the foot and footwear 100. In addition, sole structure 110 is secured to a lower area of upper 120 and extends between the foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence foot motions, for example.

For reference purposes, footwear 100 may be divided into three general regions: a forefoot region 101, a midfoot region 102, and a heel region 103. Forefoot region 101 generally includes portions of footwear 100 corresponding with the toes of the foot and the joints connecting the metatarsals with the phalanges. Midfoot region 102 generally includes portions of footwear 100 corresponding with an arch area of the foot. Heel region 103 generally corresponds with rear portions of the foot, including the calcaneus bone. Footwear 100 also includes a lateral side 104 and a medial side 105, with lateral side 104 and medial side 105 extending through each of regions 101 and 103 and corresponding with opposite sides of footwear 100. More particularly, lateral side 104 corresponds with an outer side area of the foot (i.e., a surface that faces away from the other foot), and medial side 105 corresponds with an inner side area of the foot (i.e., a surface that faces toward the other foot). Regions 101 and sides 103 and 104 are not intended to demarcate precise areas of footwear 100. Rather, regions 101 and sides 103 and 105 are intended to represent general areas of footwear 100 to aid in the following discussion. In addition to footwear 100, regions 101-103 and sides 104-105 may also be applied to sole structure 110, upper 120, and individual elements thereof.

The primary elements of sole structure 110 are a midsole 111 and an outsole 112. Midsole 111 is secured to a lower surface of upper 120 and may be formed from a compressible polymer foam element (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 additional configurations, midsole 111 may incorporate plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motion of the foot, or midsole 111 may be primarily formed from a fluid-filled chamber. Outsole 112 is secured to a lower surface of midsole 111 and may be formed of a wear-resistant rubber material that is textured to impart traction. In addition, sole structure 110 may include a sockliner located within upper 120 and positioned to extend below a lower surface of the foot to enhance the comfort of footwear 100. While this configuration for sole structure 110 provides an example of a sole structure that may be used in connection with upper 120, a variety of other conventional and non-conventional configurations for sole structure 110 may also be utilized. Accordingly, the features of sole structure 110 or any sole structure utilized with upper 120 may vary considerably.

Upper 120 defines a void 121 within footwear 100 for receiving and securing a foot relative to sole structure 110. Cavity 121 is shaped to receive a foot. Accordingly, when the foot is located within void 121, upper 120 extends along the lateral side of the foot, along the medial side of the foot, over the foot, around the heel, and under the foot. A collar 122 is located in at least heel region 103 and forms an ankle opening 123 that provides access to void 121 for the foot. When the foot is positioned within void 121, collar 122 and ankle opening 123 extend around or otherwise enclose the ankle. Upper 120 also has a lacing system located in a throat area 124 of upper 120, primarily in midfoot area 102 and corresponding with an instep area or upper surface of the foot. The lacing system includes a lace 125, the lace 125(a) extending through various apertures 126 in the upper 120 and (b) extending repeatedly across the throat area 124. The lacing system facilitates tightening upper 120 around the foot and loosening portions of upper 120 to allow the foot to enter void 121 and be removed from void 121. As an alternative to apertures 126, the lacing system may include other lace receiving elements, such as D-rings, hooks, or various looped tensile cords. Additional configurations of upper 120 may also include one or more of the following: (a) a heel counter in heel region 103 for improved stability, (b) a toe guard (toe guard) formed of a wear resistant material in forefoot region 101, and (c) logos, trademarks, and placards with instructions for use and material information. Accordingly, upper 120 may incorporate various features and elements in addition to those discussed herein and shown in the accompanying figures.

A majority of upper 120 is formed from a knitted component 130 and a cover component 140. Knitted component 130 has a knitted structure and is formed of unitary knit construction (i.e., as a one-piece element) through a knitting process. When incorporated into upper 120, knitted component 130 extends through each of regions 101-103 and between sides 104 and 105. Although primarily located within upper 120, portions of knitted component 130 are exposed in heel region 103 and throat region 124. In addition to forming collar 122 and ankle opening 123, knitted component 130 defines most or all of cavity 121. As such, a foot (or sock covering the foot) located in void 121 will contact knitted component 130 and lie against knitted component 130. Cover component 140 is secured to sole structure 110 and is located exterior to knitted component 130, covering various areas of knitted component 130. When cover component 140 is incorporated into footwear 100, cover component 140 extends through each of areas 101-103, extends between side 104 and side 105, and extends between knitted component 130 and sole structure 110. That is, a portion of cover member 140 may extend between throat area 124 and an area where upper 120 is secured to sole structure 110. Although the structure of the cover part 140 may vary significantly, the cover part 140 may be formed of a plurality of material elements (e.g., fabric, polymer foam, polymer sheet, leather, synthetic leather) that are connected, for example, by stitching or bonding. Further, the cover part 140 may have a layered structure including a plurality of overlapping material elements.

Knitted component 130 is separable and may be removed from the remainder of footwear 100, as depicted in figure 5. That is, knitted component 130 is not secured to other portions of upper 120 and may be repeatedly removed from cover component 140 and inserted into cover component 140. To place footwear 100 on the foot, the wearer may first place knitted component 130 on the foot and then position the foot and knitted component 130 within cover component 140. Alternatively, the wearer may first place knitted component 130 within cover component 140 and then position the foot within knitted component 130. Although elements 130 and 140 are separable, in some configurations of footwear 100, knitted element 130 may be secured (e.g., by stitching, adhesively bonding, thermal bonding) to other portions of upper 120 or to cover element 140.

Upper 120 includes an exterior surface 127 and an opposite interior surface 128. Outer surface 127 is a portion of an exterior surface of footwear 100 and is primarily formed from both knitted component 130 and cover component 140. Knitted component 130 is exposed in heel region 103 and throat region 124, forming portions of outer surface 127 in these areas. Similarly, cover component 140 forms a portion of outer surface 127 between throat area 124 and sole structure 110. The outer surface 127 is formed by each of the braided component 130 and the cover component 140 together, with the braided component 130 forming most or all of the inner surface 128, the inner surface 128 also defining a portion of the cavity 121. As such, a foot located within knitted component 130 will contact portions of interior surface 128.

Advantages of knitted component 130 include stretch and recovery properties, as well as improved fit and comfort. When the foot is positioned within void 121, collar 122 may stretch to allow the foot to enter void 121 through ankle opening 123. As the foot continues into upper 120, the portion of knitted component 130 located in throat area 124 may also stretch to allow the foot to fully enter void 121. In addition to stretching, the knitted component may recover or contract to secure the foot within upper 120. More particularly, collar 122 may be restored to extend securely around the ankle and other portions of knitted component 130 may be restored to pull cover component 140 against the foot to tighten upper 120 around the foot. Various features of knitted component 130, including materials and knit structures, may be utilized to impart specific stretch and recovery characteristics to knitted component 130. That is, the degree of stretch and recovery may be designed into knitted component 130. As a result, knitted component 130 may be designed to extend around the ankle and tighten upper 120 around the foot in a manner that improves the overall fit of footwear 100. In addition, knitted component 130 may be designed with additional layers or padding portions in throat area 124 to separate the foot from lace 125 and cushion the foot. In addition, knitted component 130 rests against the foot and improves the overall comfort of footwear 100.

Knitted component configuration

In fig. 6-11D, knitted component 130 is depicted individually and separated from the remainder of footwear 100. Although the knitting process used to manufacture knitted component 130 will be discussed in greater detail below, knitted component 130 is formed from at least one yarn that is manipulated (e.g., using a knitting machine) to form a plurality of intermeshing rings that define a plurality of courses and wales. That is, knitted component 130 has the structure of a knitted fabric. Furthermore, knitted component 130 is formed of unitary knit construction. As used herein, a knitted component (e.g., knitted component 130) is defined as being formed from a "unitary knit structure" when formed as a one-piece element by a knitting process. That is, the knitting process generally forms the various features and structures of knitted component 130 without requiring significant additional manufacturing steps or processes. Although portions of knitted component 130 may be connected to one another after the knitting process (e.g., edges of knitted component 130 are connected together), knitted component 130 remains formed of unitary knit construction because it is formed as a one-piece knit element. Moreover, knitted component 130 remains formed of unitary knit construction when other elements (e.g., stabilizers, stretch limiting elements, straps, aesthetic features, logos, trademarks, and placards) are added after the knitting process.

Although the configuration of knitted component 130 may vary considerably, knitted component 130 is depicted as including a sock portion 131 and a tongue portion 132. The cover portion 131 has the general configuration of a sock and, as such, forms a generally cylindrical and hollow structure for receiving a foot. Tongue portion 132 is located within sock portion 131 and has an elongate structure that extends along a majority of the length of sock portion 131. When sock portion 131 is incorporated into footwear 100, sock portion 131 forms collar 122, defines ankle opening 123, and extends throughout the length and width of footwear 100. Tongue portion 132 is located in throat area 124 or at least a portion of throat area 124 and extends through throat area 124 or at least a portion of throat area 124. In addition, tongue portion 132 is positioned to extend between the foot and lace 125 to separate the foot from lace 125 and cushion the foot.

The sock portion 131 generally includes a collar region 151, a foot region 152, and a toe region 153. Collar region 151 forms an opening that provides access to the interior of knitted component 130. As such, collar region 151 forms collar 122 and defines ankle opening 123 in footwear 100. Although collar region 151 is depicted as having a two-layer configuration, portions of collar region 151 may also be formed from a single knit layer. Foot region 152 forms a majority of the sock portion 131 and provides a generally cylindrical and hollow structure of the sock portion 131 in which the foot is located. Toe region 153 is located opposite collar region 151 and forms a closed end of sock portion 131 that receives the toes of the wearer. Based on this discussion, and as noted above, the sheath portion 131 has the general configuration of a sock and may have the general configuration of a variety of conventional socks. That is, sock portion 131 may incorporate various features and knit structures commonly utilized in socks intended to cover the foot. In view of the unique use for knitted component 130, jacket portion 131 may also comprise a variety of unconventional structures that differ from those found in conventional socks.

Tongue portion 132 extends longitudinally through foot region 152 and is secured to opposite sides of foot region 152. More particularly, a collar end 154 of the tongue portion 132 is secured to the sock portion 131 adjacent the collar region 151, and an opposite toe end 155 of the tongue portion 132 is secured to the sock portion 131 adjacent the toe region 153. Although the area between ends 154 and 155 may be secured to sheath portion 131, this area is depicted as being unsecured. As discussed in more detail below, tongue portion 132 may be formed of unitary knit construction with sock portion 131. As such, one or both of the ends 154 and 155 may be formed of unitary braided construction with the sheath portion 131. However, in the exemplary configuration depicted in the figures, toe end 155 is connected to sheath portion 131 with stitching 133, whereas collar end 154 is formed of unitary knit construction with sheath portion 131.

Although tongue portion 132 may be formed from a single layer of textile material, tongue portion 132 is depicted as including first knit layer 156 and second knit layer 157 that are substantially coextensive and lie against one another. First braid 156 also rests against jacket portion 131. The braided layers 156 and 157 are formed in a braiding process and are connected to each other by the braiding process, thereby being formed of an integral braided structure. Although the specific location at which knit layers 156 and 157 are joined may vary, the edge regions and peripheral regions of knit layers 156 and 157 are described as being joined to one another, whereas the central regions of knit layers 156 and 157 are described as not being joined to one another. Thus, in practice, braids 156 and 157 are separate layers of braided material, but are joined at their outer peripheries. An advantage of connecting knit layers 156 and 157 relates to maintaining the relative position of knit layers 156 and 157 after the knitting process and while knitted component 130 or footwear 100 is being worn. In other configurations of knitted component 130, however, the peripheral regions of knitted layers 156 and 157 may be unconnected or both peripheral and central regions may be connected.

Knitted component 130 is formed of unitary knit construction, but knitted component 130 may include stitching 133 connecting toe end 155 to sheath portion 131. During a knitting process for knitted component 130, discussed in more detail below, each of sock portion 131 and tongue portion 132 are formed and joined together. More particularly, this knitting process connects collar end 154 to sock portion 131. Once the knitting process is complete, the toe end 155 is connected to the sheath portion 131 with stitching 133. In further configurations, the braiding process may connect toe end 155 to sheath portion 131, and stitching 133 may be positioned at collar end 154. It may also be possible to connect both ends 154 and 155 during the weaving process, thereby eliminating the need for stitching 133.

An advantage of forming tongue portion 132 to include both knit layers 156 and 157 involves providing additional separation and cushioning between the foot and lace 125. When incorporated into footwear 100, both knit layers 156 and 157 are positioned between the foot and lace 125. In addition, a portion of sheath portion 131 also extends between the foot and lace 125. Thus, in practice, three layers of knitted material separate the foot from lace 125 in throat area 124, although other portions of the knitted component (e.g., sock portion 131) may have a single layer that separates the foot from other portions of upper 120. Each of the knit layers imparts some degree of cushioning that protects the foot from lace 125. In combination, however, the three knit layers provide greater separation and cushioning, thereby increasing the overall comfort of footwear 100. In some configurations, tongue portion 132 may include only one knit layer or may include three or more knit layers. In other configurations, foam or other elements may be utilized to provide even further separation and cushioning between the foot and lace 125.

Knitted component 130 may be formed from a single type of yarn that imparts common characteristics to each of sock portion 131 and tongue portion 132. However, to change the characteristics of knitted component 130, different yarns may be used in different areas of knitted component 130. That is, portions 131 and 132 or different areas of portions 131 and 132 may be formed from different yarns to vary the properties between areas of knitted component 130. Further, one region of knitted component 130 may be formed from a first type of yarn or combination of yarns that imparts a first set of properties, and another region of knitted component 130 may be formed from a second type of yarn or combination of yarns that imparts a second set of properties. Accordingly, by selecting particular yarns for different regions of knitted component 130, properties may be varied throughout knitted component 130. Examples of properties that may be altered by the selection of yarn include color, pattern, gloss, stretchability, recovery, softness (loft), hand, moisture absorption, biodegradability, abrasion resistance, durability, and thermal conductivity. It should also be noted that two or more yarns may be used in combination to take advantage of properties from both yarns, for example when the yarns are plated or form different courses in the same area.

The properties that a particular type of yarn will impart to the areas of knitted component 130 depend, in part, on the materials that form the various filaments and fibers within the yarn. For example, cotton provides a soft hand, natural aesthetics, and biodegradability. Spandex (elastane) and stretched polyester each provide substantial stretch and recovery, and stretched polyester also provides recycling capability. Rayon provides high luster and moisture absorption. In addition to thermal insulation properties and biodegradability, wool also provides high moisture absorption. Nylon is durable, abrasion resistant and has relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. Yarns comprising thermoplastic materials may also allow regions of knitted component 130 to be melted or stabilized by the application of heat. In addition to materials, other aspects of the selection of yarns for knitted component 130 may affect properties. For example, the yarns forming knitted component 130 may be monofilament or multifilament yarns. The yarns may also include separate filaments each formed of a different material. Further, the yarn may include filaments that are each formed of two or more different materials, for example, a bicomponent yarn having filaments with a sheath-core configuration or two halves formed of different materials. Different degrees of twist and curl, as well as different deniers, may also affect the characteristics of knitted component 130. Accordingly, the materials forming the yarns and other aspects of the yarns may be selected to impart a variety of properties to separate regions of knitted component 130.

The knit structure in knitted component 130 imparts specific characteristics in addition to the type of yarn selected for knitted component 130. As depicted, a majority of knitted component 130 is formed to have a common or unitary knit structure that is relatively untextured and may be referred to as a tubular knit (tubular knit) or a weft flat knit (plain knit). However, in other configurations, knitted component 130 may have a rib knit structure (rib knit structure) or a mesh knit structure (mesh knit structure), or knitted component 130 may have a hybrid knit structure in which multiple types of knit structures are used in a region. To alter the characteristics of knitted component 130, different knit structures may be used in different areas of knitted component 130. That is, portions 131 and 132 or different areas of portions 131 and 132 may be formed of different knit structures to vary the properties between areas of knitted component 130. Further, one region of knitted component 130 may be formed from a first knit structure or combination of knit structures that impart a first set of properties, and another region of knitted component 130 may be formed from a second knit structure or combination of knit structures that impart a second set of properties. Accordingly, by selecting particular knit structures for different regions of knitted component 130, properties may be varied throughout knitted component 130. Examples of properties that may be altered by the selection of yarns include pattern, gloss, stretch, recovery, softness, hand, moisture absorption, abrasion resistance, durability, and thermal conductivity.

Properties may be further varied by selecting the type of yarn and weave structure utilized in knitted component 130 or regions of knitted component 130. Additional combinations of properties may be imparted to knitted component 130 by combining multiple types of yarns with multiple knit structures. For example, a first type of yarn and a first knit structure may be used in one region of knitted component 130 to provide a set of properties, and a second type of yarn and a second knit structure may be used in a different region of knitted component 130 to provide a different set of properties. As an example, sheath portion 131 may include a yarn type and knit structure that imparts high stretchability, and tongue portion 132 may include a yarn type and knit structure that imparts softness and low stretchability. Given the two-layer configuration in collar region 151, the outer layer may include a yarn type and knit structure that imparts durability and wear resistance, and the inner layer may include a yarn type and knit structure that imparts stretchability and recovery. Additionally, some portions of foot region 152 may have a rib knit structure with higher denier yarns and other portions of foot region 152 may have a weft flat knit structure with lower denier yarns. Portions of the cover portion 131 may also include yarn types and woven structures that wick moisture away from the foot. Accordingly, selecting a particular combination of yarn types and weave configurations for each area of knitted component 130 allows each area to have a particular combination of beneficial properties.

An advantage of footwear 100 relates to the separability of knitted component 130 from the remainder of footwear 100. Different individuals have different foot shapes and proportions, as well as different preferences regarding various aspects of the footwear. Accordingly, each individual may select the configuration of knitted component 130 that is most appropriate for their proportions and preferences. In addition, an individual may replace one knitted component 130 with another knitted component 130 based on the intended activity that footwear 100 is intended to wear during that period. The ability to replace knitted component 130 also allows footwear 100 to have various aesthetics, depending on which knitted component 130 is worn. Accordingly, various aspects of footwear 100 may vary depending on the particular configuration of knitted component 130 with which footwear 100 is used.

While separability offers advantages, inseparable configurations also have advantages. For example, knitted component 130 provides a substantially seamless surface for resting on the foot, thereby enhancing the comfort of footwear 100. In addition, the use of knitted component 130 increases the efficiency of manufacturing footwear 100 and reduces the number of separate elements that must be joined in making upper 120.

Based on the above discussion, a portion of upper 120 incorporates knitted component 130 formed of unitary knit construction. Knitted component 130 may include both a sock portion 131 and a tongue portion 132. Cuff portion 131 has a generally cylindrical and hollow structure that forms ankle opening 123, extending between regions 101 and 103 to define cavity 121. Tongue portion 132 has an elongate configuration that (a) extends across at least a portion of the length of throat area 124, and (b) includes two knit layers 156 and 157 that rest adjacent to one another. One of knit layers 156 and 157 may also lie against sock portion 131 in throat area 124. With this construction in mind, a majority of knitted component 130 is formed from a sheathed portion 131, with sheathed portion 131 typically being a single knit layer. In throat area 124, however, upper 120 has a layered structure that includes a knit layer of sock portion 131 and each of knit layers 156 and 157. Further, each of portions 131 and 132 and the three braided layers are formed of unitary braided construction.

Additional configurations

The configurations of footwear 100 and knitted component 130 discussed above and depicted in the figures provide one example of structure for footwear 100 and knitted component 130. In other configurations, a number of features of footwear 100 and knitted component 130 may vary considerably. For example, referring to FIG. 12A, a plurality of looped cords 161 form lace receiving elements and replace apertures 126. Looped strand 161 extends upward from a lower area of upper 120 and forms a loop through which lace 125 extends. Additional information regarding the structure of Looped-like cords 161 can be found in U.S. patent application No. 13/529,381, filed on day 21/6/2012 by the united states patent and trademark office, and entitled "Footwear Incorporating Looped Tensile cord structures" which is incorporated herein by reference in its entirety. Although knitted component 130 may be detachable and replaceable, fig. 12B depicts a configuration in which stitching 162 connects knitted component 130 to cover component 140. Although footwear 100 may have the configuration of a running shoe, another configuration of footwear 100 is depicted in fig. 12C as having the configuration of a basketball shoe.

In addition to variations in other areas of footwear 100, a number of characteristics of knitted component 130 may vary considerably. Referring to fig. 13A, knitted component 130 includes a rib knit structure. More particularly, substantially all of the upper surface of foot region 152 has a rib knit structure. In addition, a portion of the lower surface of foot region 152 that corresponds with the location of the arch of the foot has a rib knit structure. Rib knit structures may be used to impart significant stretch to knitted component 130 as compared to other knit structures. In another configuration depicted in fig. 13B, a side region of foot region 152 has a mesh knitted structure that forms a plurality of holes or apertures in knitted component 130. Another advantage of the mesh woven structure relates to breathability. Although tongue portion 132 may be located within sock portion 131, FIG. 13C depicts a configuration in which tongue portion 132 is located on the exterior of sock portion 131.

In some variations, the proportions of knitted component 130 may vary. As an example, fig. 13D depicts collar region 151 as having a greater height, which will cover more of the wearer's ankle. Referring to FIG. 14A, the tongue portion 132 exhibits a reduced length that will extend through the less throat area 124. FIG. 15A depicts a configuration in which the tongue portion 132 has a greater width. Similarly, the width of tongue portion 132 is also larger in FIG. 15B and extends to the side areas of the sock portion 131. As a further variation, fig. 15C depicts second knit layer 157 as having an increased thickness, which may be formed by varying the knit structure or yarn type.

Numerous other aspects of knitted component 130 may also vary. Referring to fig. 14B, toe end 155 is stitched to sheath portion 131, and collar end 154 is formed of unitary knit construction with sheath portion 131. In fig. 14C, both ends 154 and 155 are formed of unitary braided construction with sheath portion 131. To provide more cushioning and separation between the foot and lace 125, the thickness of one of knit layers 156 and 157 may be increased, as in fig. 15C. As a further example, FIG. 14D depicts foam element 162 positioned between knit layers 156 and 157, and FIG. 15D depicts tongue portion 132 as having an additional knit layer 163. Referring to fig. 14E, tongue portion 132 is formed with a spacer material configuration in which drop yarns (drop yarns) extend between sheath portion 131 and tongue portion 132 to provide cushioning. As a final example, FIG. 14F depicts a configuration in which tongue portion 132 is positioned to extend under the foot and may provide cushioning similar to an insole.

Knitting process

The knitting process may be used to form knitted component 130 and many or all of the various features discussed above for knitted component 130. It should be noted, however, that the weaving process may also be used to form textile elements having many or all of the various features discussed above for knitted component 130. While the knitting process to form knitted component 130 may be performed manually, commercial manufacture of multiple knitted components 130 will typically be performed by a knitting machine. Generally, knitting involves courses and wales forming intermeshed loops of a yarn or yarns. During the production process, the knitting machine may be programmed to mechanically manipulate one or more yarns into the configuration of knitted component 130. That is, knitted component 130 may be formed by mechanically manipulating one or more yarns to form a single piece textile element having the shape and characteristics of knitted component 130. As such, the knitted component may be formed from a unitary knit structure using a knitting machine.

Although knitted component 130 may be formed by a variety of different knitting processes and using a variety of different knitting machines, circular knitting (i.e., using a circular knitting machine) has the ability to form knitted component 130 to have the various features discussed above. Generally, circular knitting involves the formation of a plurality of courses and wales. By way of example, the course is a circular column of loops extending completely around the sock portion 131 and extending across the width of the tongue portion 132. Wales are rows of loops that extend perpendicular to the courses and extend from (a) collar region 151 to toe region 153 and (b) toe end 154 to toe end 155. While a conventional or conventional circular knitting process may be used to form knitted component 130, specific examples of knitting processes that may be utilized include, for example, wide tube circular knitting (wide tube circular knitting), narrow tube circular knitting (narrow tube circular knitting), single side knitting (single knit circular knitting), double side knitting (double knit circular knitting), warp knitting (warp knitting), and flat knitting (flat knitting).

The knitting process used to form knitted component 130 will now be discussed in more detail. As noted above, the sheath portion 131 has the general configuration of a sock. That is, sock portion 131 may incorporate various features and knit structures commonly utilized in socks intended to cover the foot. Accordingly, the portion of the knitting process that forms the sheath portion 131 is well known in the knitting art. In contrast with conventional socks, however, knitted component 130 includes a tongue portion 132. To knit tongue portion 132 with sock portion 131, the general knitting process may proceed as follows: initially, the knitting machine knits a first circular course forming a portion of collar region 151 and transfers the first circular course to a dial that holds the first circular course throughout the remainder of the knitting process. Various other circular courses of portions forming collar region 151 may be formed. In knitting tongue portion 132, the knitting machine may reciprocate to form each of knit layers 156 and 157. Once the reciprocating motion is complete and tongue portion 132 is formed, knitting machine may continue to form one or more additional circular courses forming part of collar region 151, and one of these additional circular courses may be connected with the first circular course held on the dial. At this point, portions of collar region 151 and tongue portion 132 are formed, and the knitting process may continue to form the remainder of sock portion 131 in a well-known manner. Thus, in practice, the knitting process for knitted component 130 is similar to conventional processes for forming a sock, but includes additional reciprocating steps to form tongue portion 132.

Many aspects of the knitting process discussed above may be performed by using a conventional circular knitting machine. However, to facilitate portions of the knitting process, the circular knitting machine may be modified to raise and lower the dial that holds the first course formed in knitted component 130. Additionally, air blowers may be utilized to ensure that knitted component 130 remains properly positioned within the circular knitting machine during the knitting process.

Based on the above discussion, a circular knitting process forms knitted component 130. Once the knitting process is complete, knitted component 130 may be incorporated into upper 120. More particularly, knitted component 130 is positioned within cover component 140 and extends from forefoot region 101 to heel region 103. In addition, knitted component 130 is oriented such that tongue portion 132 is positioned to extend through at least a portion of the length of throat area 124. In configurations where the knitted component is secured to cover component 140, stitching, adhesive bonding, or thermal bonding may be used.

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

Claims (14)

1. An article of footwear having an upper and a sole structure secured to the upper, the upper including a knitted component formed of unitary knit construction, and the knitted component including a sock portion and a tongue portion, the sock portion having a hollow structure and a toe region, the hollow structure (a) forming an ankle opening in a heel region of the footwear and (b) extending between the heel region and a forefoot region of the footwear to define a void within the footwear for receiving a foot, the knitted component having only a first knit layer in the toe region, and the tongue portion having an elongate configuration, that (a) extends through at least a portion of a length of a throat area of the upper and (b) includes second and third knit layers positioned adjacent to one another, the second and third knit layers extending only in the throat area.

2. The article of footwear recited in claim 1, wherein one of the second knit layer and the third knit layer is against the sock portion in the throat area.

3. The article of footwear recited in claim 1, wherein the tongue portion is located within the cavity.

4. The article of footwear recited in claim 1, wherein a first end of the tongue portion is formed of unitary knit construction with the sock portion, and a second end of the tongue portion is stitched to the sock portion, the first end being opposite the second end.

5. The article of footwear recited in claim 1, wherein (a) peripheral areas of the second knit layer and the third knit layer are joined to each other, and (b) central areas of the second knit layer and the third knit layer are not joined to each other.

6. The article of footwear recited in claim 1, wherein the upper includes a cover component that extends (a) between the heel region and the forefoot region and (b) between the throat region and the sole structure, the knitted component being located at least partially within the cover component.

7. The article of footwear recited in claim 6, wherein the cover component is secured to the knitted component.

8. The article of footwear recited in claim 6, wherein the knitted component is removable from within the cover component.

9. The article of footwear recited in claim 6, wherein the cover component is absent from the throat area to expose an area of the sheath portion located in the throat area.

10. The article of footwear recited in claim 9, wherein a lace extends through the throat area and between opposite sides of the cover component.

11. The article of footwear recited in claim 9, wherein the upper includes: (a) a plurality of tensile cords extending through an area between the throat area and the sole structure, and (b) a lace coupled to the tensile cords and repeatedly extending through the throat area.

12. A method for manufacturing an article of footwear, the method comprising:

forming a knitted component using a circular knitting process by knitting a jacket and two substantially coextensive layers within the jacket and extending along at least a portion of the length of the jacket; and

incorporating the knitted component into an upper of the article of footwear.

13. The method recited in claim 12, wherein the step of utilizing the circular knitting process includes forming the jacket to have a hollow structure.

14. The method recited in claim 12, wherein the step of incorporating the knitted component includes (a) positioning the sock to extend from a forefoot region to a heel region of the article of footwear, and (b) positioning the two substantially coextensive layers to extend through at least a portion of a length of a throat area of the upper.