HK1237383B - Method of forming a knitted component and method of assembling an article of footwear incorporating a knitted component - Google Patents

Description

Method of forming a knitted component and method of assembling an article of footwear incorporating the knitted component

Technical Field

The present application relates generally to, but is not limited to, methods of forming knitted components and methods of assembling articles of footwear incorporating knitted components.

background

Conventional articles of footwear generally include two main elements: an upper and a sole structure. The upper and sole structure at least partially define a foot-receiving chamber that is accessible by a user's foot through a foot-receiving opening.

The upper is secured to the sole structure and forms a cavity on the interior of the footwear for comfortably and securely receiving the foot. The upper member can secure the foot relative to the sole member. The upper can extend around the ankle, over the instep and toe areas of the foot. The upper can also extend along the medial and lateral sides of the foot and along the heel of the foot. The upper can be configured to protect the foot and provide ventilation, thereby cooling the foot. Additionally, the upper can include additional materials for providing additional support in certain areas.

The sole structure is fixed to the lower area of the upper, thereby being positioned between the upper and the ground. The sole structure may include a midsole and an outsole. The midsole generally includes a polymer foam material that weakens ground reaction forces to reduce the pressure acting on the foot and leg during walking, running, and other ambulatory activities. In addition, the midsole may include a fluid-filled chamber, plate, regulator, or other element that further weakens the force, enhances stability, or affects the motion of the foot. The outsole is fixed to the lower surface of the midsole and provides a portion of the sole structure that engages the ground, the portion being formed of a durable and wear-resistant material such as rubber. The sole structure may also include an insole that is positioned in the cavity and adjacent to the lower surface of the foot to enhance footwear comfort.

A variety of material elements (e.g., fabric, polymer foam, polymer sheet, leather, synthetic leather) are conventionally used to manufacture shoe uppers. For example, in athletic footwear, a shoe upper may have multiple layers, each layer comprising a variety of connected material elements. As an example, material elements may be selected to impart stretch resistance, wear resistance, flexibility, breathability, compressibility, comfort, and moisture-wicking properties to different areas of the shoe upper. In order to impart different properties to different areas of the shoe upper, material elements are typically cut into desired shapes and then typically joined together using stitching or adhesive bonding. Furthermore, material elements are typically connected in a layered configuration to impart multiple properties to the same area.

As the number and type of material elements incorporated into a shoe upper increase, the time and expense associated with transporting, storing, cutting, and connecting the material elements also increase. As the number and type of material elements incorporated into a shoe upper increase, waste generated by the cutting and stitching processes also accumulates to a significant extent. Furthermore, shoe uppers with a larger number of material elements are more difficult to reuse than shoe uppers formed from fewer types and numbers of material elements. Furthermore, the multiple pieces sewn together can cause a greater concentration of force in certain areas. The stitched joints can transfer stress at an uneven rate relative to other parts of the footwear, which can cause damage or discomfort. The additional material and stitched seams can lead to discomfort when worn. Therefore, by reducing the number of material elements used in a shoe upper, waste can be reduced while increasing the manufacturing efficiency, comfort, performance, and reusability of the shoe upper.

Overview

In one aspect, a method for forming a knitted component is provided, the method comprising the step of knitting a first portion of the knitted component with a first thread in a first course direction. Furthermore, the method comprises knitting a second portion of the knitted component with a second thread, the first thread being different from the second thread. The second portion of the knitted component has a first joining subset and a second joining subset, the first joining subset comprising a plurality of loops, the second joining subset comprising a plurality of loops, the plurality of loops of the first joining subset and the plurality of loops of the second joining subset being held by a plurality of needles. The first portion of the knitted component has a first joining side comprising a plurality of loops. The method further comprises interlooping at least one of the plurality of loops of the first joining subset with at least one of the plurality of loops of the first joining side. The method further comprises knitting a third portion of the knitted component with the first thread in the first course direction, the third portion of the knitted component comprising a second joining side, the second joining side comprising a plurality of loops. The method further comprises interlooping at least one of the plurality of loops of the second joining subset with at least one of the plurality of loops of the second joining side.

In one embodiment, the first engagement side and the second engagement side are positioned at an angle relative to each other or positioned parallel to each other.

In one embodiment, the knitted component is configured to be incorporated into an upper of an article of footwear; and the knitted component includes a base portion, the base portion including a lateral side and a medial side, the first engaging side and the second engaging side extending away from the lateral side.

In one embodiment, the knitted component is configured to be incorporated into an upper of an article of footwear; and the knitted component includes a base portion, the base portion including a lateral side and a medial side, the first engaging side and the second engaging side extending away from the medial side.

In one embodiment, the first engagement subset comprises a first ring and the second engagement subset comprises a second ring, the first ring being positioned adjacent to the second ring when positioned on the plurality of needles.

In one embodiment, the first loop is looped with respect to the first engagement side adjacent the base portion, and the second loop is looped with respect to the second engagement side adjacent the base portion.

In one embodiment, the knitted component further comprises a fourth portion comprising a third edge that is not looped with the second portion.

On the other hand, a method for assembling an article of footwear incorporating a knitted component into an upper is provided, the method comprising forming the knitted component in a planar configuration, the knitted component comprising a first edge and a second edge. The knitted component is formed by fixed horizontal rows. The method further comprises knitting a joining thread between the first edge and the second edge in a planar configuration. The joining thread comprises a first end and a second end, at least one of the first end and the second end being unfixed. The joining thread is looped with at least one loop on the first edge, and the joining thread is looped with at least one loop on the second edge. The method further comprises tensioning at least one of the first end and the second end of the joining thread so that the first edge and the second edge extend toward each other; and incorporating the knitted component into the upper of the article of footwear.

In one embodiment, the upper of the article of footwear includes a lateral side and a medial side, the first edge and the second edge being located on the lateral side.

In one embodiment, the upper of the article of footwear includes a lateral side and a medial side, the first edge and the second edge being located on the medial side.

In one embodiment, upon tensioning the connecting line, at least one loop of the first side abuts at least one loop of the second side.

In one embodiment, the upper of the article of footwear includes a base portion, a first portion, and a second portion, the first portion including at least one loop, the at least one loop of the first portion abutting at least one loop of the second portion.

In one embodiment, the first portion extends from the base portion and the second portion extends from the base portion, the first portion includes a region in fixed relation to the base portion and the second portion includes a region in fixed relation to the base portion.

In one embodiment, the first portion includes the first edge, the second portion includes the second edge, and when the connecting line is tensioned, the first portion and the second portion extend out of a plane in which the base portion is positioned.

In one embodiment, the first portion corresponds to a forefoot portion and the second portion corresponds to a midfoot portion.

In one embodiment, the upper of the footwear article further comprises a third portion and a fourth portion, the third portion and the fourth portion comprising a third edge and a fourth edge, a second connecting line extending between the third edge and the fourth edge, and when the second connecting line is tightened, at least one loop on the third edge abuts at least one loop on the fourth edge.

On the other hand, a method of assembling an article of footwear incorporating a knitted component into an upper is provided, the method comprising forming the knitted component in a planar configuration, the knitted component comprising a base portion, a first lateral portion, and a second lateral portion. The knitted component is formed by fixed horizontal rows. The method further comprises: knitting a connecting thread between the first lateral portion and the second lateral portion, the connecting thread comprising a first end and a second end. At least one of the first end and the second end is not fixed. The connecting thread is looped with at least one loop on a first edge of the first lateral portion, and the connecting thread is looped with at least one loop on a second edge of the second lateral portion. The method further comprises tensioning at least one of the first end and the second end of the connecting thread so that the first edge and the second edge extend toward each other; and incorporating the knitted component into the upper of the article of footwear.

In one embodiment, the method further comprises securing the first end and the second end of the connecting line after tensioning the connecting line.

In one embodiment, the knitted component further includes a toe portion and a first medial portion, a second connecting line extending between a third edge of the first medial portion and a fourth edge of the toe portion, and a third connecting line extending between a fifth edge of the toe portion and a sixth edge of the first medial portion.

In one embodiment, the second and third connection lines are tensioned to form a three-dimensional forefoot portion of the article of footwear.

Other systems, methods, features and advantages of the embodiments will be or will become apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily drawn to scale, but emphasis is placed on illustrating the principles of the embodiments. In addition, in the drawings, like reference numerals indicate corresponding parts throughout the different views.

Both the foregoing summary and the following detailed description will be better understood when read in conjunction with the appended drawings.

FIG1 is a representative view of an exemplary embodiment of a knit structure including connecting threads;

FIG2 is a representative view of an exemplary embodiment of a knit structure including a connecting thread subjected to tension;

FIG3 is a representative view of an exemplary embodiment of a knit structure including connecting yarns subjected to tension;

FIG4 is a representative view of an exemplary embodiment of a knit structure including a connecting thread subjected to tension;

FIG5 is a representative view of an exemplary embodiment of a connected knit structure including connecting threads;

FIG6 is a representative view of an alternative embodiment of a knit structure including connecting threads;

FIG7 is a representative view of an embodiment of multiple knit structures and connecting threads;

FIG8 is a representative view of the knitted structure of FIG7 , wherein the connecting thread is under tension;

FIG9 is a representative view of an alternative embodiment of multiple knit structures and connecting threads;

FIG10 is a representative view of the knitted structure of FIG9 , wherein the connecting thread is subjected to tension;

FIG11 is a representative view of another alternative embodiment of a plurality of knitted structures and connecting threads;

FIG12 is a representative view of the knitted structure of FIG11 with the connecting threads being subjected to tension;

FIG13 is a representative view of a connecting thread and a knitted component;

FIG14 is a representative view of a connecting yarn coupled to the knitted component of FIG13;

FIG15 is an isometric view of the knitted component of FIG13 with the connecting thread being subjected to tension;

FIG16 is an isometric view of the knitted component of FIG13 with the connecting thread being subjected to tension;

FIG17 is an isometric view of the knitted component of FIG13 as a three-dimensional article;

FIG18 is a schematic diagram of an exemplary embodiment of a knitted component during an aspect of a knitting process;

FIG19 is a schematic diagram of an exemplary embodiment of a knitted component and connecting threads during another aspect of the knitting process;

FIG20 is a schematic diagram of an exemplary embodiment of a knitted component and connecting threads during another aspect of the knitting process;

FIG21 is a schematic diagram of an exemplary embodiment of a knitted component and connecting threads during another aspect of a knitting process;

FIG22 is a schematic diagram of the knitted component and the connecting yarn of FIG18-21 being subjected to tension;

FIG23 is another schematic diagram of the knitted component and the connecting yarn of FIG18-21 being subjected to tension;

FIG24 is another schematic diagram of the knitted component and the connecting yarn of FIG18-21 being subjected to tension;

FIG25 is an isometric view of an article of footwear formed from the knitted components of FIGS. 18-24 ;

FIG26 is a top view of an embodiment of a knitted component comprising a plurality of connecting yarns;

FIG27 is an isometric view of the knitted component of FIG26 in a partially formed state; and

28 is an isometric view of an embodiment of an article of footwear formed from the knitted component of FIG. 26 .

Detailed description

The following discussion and accompanying drawings disclose a variety of concepts related to the manufacture of knitted components and knitted components. Although knitted components can be used in a variety of products, the footwear articles comprising one of the knitted components are disclosed below as an example. Except footwear, knitted components can be used for other types of clothing (e.g., shirts, trousers, socks, jackets, underwear), sports equipment (e.g., golf bags, baseball and football gloves, soccer ball restriction structures), containers (e.g., backpacks, bags) and seat covers for furniture (e.g., chairs, couches, car seats). Knitted components can also be used for bedding (e.g., sheets, blankets), tablecloths, towels, flags, tents, sails and parachutes. Knitted components can be used as technical fabrics for industrial purposes, including structures, filter materials, medical fabrics (e.g., bandages, cotton swabs, implants) for automotive and aerospace applications, geotextiles for strengthening dikes, agricultural fabrics for crop protection, and industrial clothing for protecting or isolating from the effects of heat and radiation. Therefore, knitted components disclosed herein and other concepts can be incorporated into a variety of products for both personal and industrial purposes.

For clarity, the detailed description herein describes some exemplary embodiments, but the disclosure herein can be applied to any article of footwear that includes certain features described herein and recited in the claims. In particular, although the following detailed description discusses exemplary embodiments in the form of footwear such as running shoes, jogging shoes, tennis shoes, squash or racquetball shoes, basketball shoes, sandals, and flippers, the disclosure herein can be applied to a wide range of footwear or potentially other types of articles.

For consistency and convenience, directional adjectives are used throughout this detailed description, corresponding to the illustrated embodiments. As used throughout this detailed description and in the claims, the term "longitudinal direction" refers to the direction extending from the heel toward the toe of the shoe, which can be related to the length or longest dimension of the footwear (e.g., sports shoes or casual shoes). In addition, as used throughout this detailed description and in the claims, the term "lateral direction" refers to the direction extending from one side to the other (outer side and inner side) or the direction extending along the width of the footwear. The lateral direction can generally be perpendicular to the longitudinal direction. As used throughout this detailed description and in the claims, the term "vertical direction" refers to the direction perpendicular to the plane of the sole of the footwear. In addition, the vertical direction can generally be perpendicular to both the longitudinal direction and the lateral direction.

As used herein, the terms "sole" or "sole structure" shall refer to any combination of surfaces that provide support and bearing for the wearer's foot in direct contact with the ground or playing surface, such as the sole alone; the combination of the outsole and insole; the combination of the outsole, midsole and insole; and the combination of the outer covering, outsole, midsole and insole.

In the various figures and descriptions, the articles and components of the articles are formed to accommodate a right foot. However, it should be appreciated that the same general structure can be formed to accommodate a left or right foot.

In some embodiments, the components of the article of footwear can be formed and/or tooled in a planar or two-dimensional orientation to facilitate ease of manufacture, assembly, and transport. Furthermore, using predetermined connection points between the various parts of the knitted component can further facilitate ease of manufacture and reduce waste generated by cutting. Furthermore, forming substantially invisible seams can contribute to aesthetic purposes and eliminate uncomfortable joins between the various parts of the article of footwear, providing increased comfort for the wearer.

In some embodiments, portions of a knitted component can be joined by extending a connecting thread between portions of the knitted component in a first orientation at a predetermined area. The pre-joined knitted components can be arranged in a two-dimensional orientation. Furthermore, the portions of the knitted component can be substantially independent of one another. However, when the connecting thread is subjected to tension, the knitted component can form a three-dimensional structure or a second orientation. Aspects of the connecting thread used to form a seamless abutment are described in detail below.

1-5 , a knit structure 100 is depicted in various configurations. The knit structure 100 can be formed using a knit element 102. The knit element 102 is formed from at least one yarn that is manipulated (e.g., using a knitting machine) to form a plurality of interlocking loops defining a plurality of courses and wales. That is, the knit element 102 has the structure of a knitted fabric.

Knit structure 100 includes courses and wales. As depicted, the knit structure includes three courses and three wales, course 170, course 172, and course 174, and wales 171, wale 173, and wale 175. It should be appreciated that knit structure 100 serves as a representative knit structure, and that more or fewer courses and wales may be incorporated into the knit structure. Course 170 includes loops 160, 161, and 162. Course 172 includes loops 163, 164, and 165. Course 174 includes loops 166, 167, and 168.

Each loop includes a head, legs, and a foot. With particular reference to loop 163, the head 150 interlocks with the loops 160 of row 170. In this configuration, the head 150 passes behind the loop 160, however, in other configurations, the head 150 may pass in front of the loop 160. Loop 163 also includes two legs, legs 152 and 154. Legs 152 and 154 extend from the head 150 toward loop 166. As shown, legs 152 and 154 pass in front of the head of loop 166. In other embodiments, legs 152 and 154 may pass behind the head of loop 166. As shown, feet 156 and 158 pass behind loop 166. In other embodiments, feet 156 and 158 may pass in front of the head of loop 166. Thus, loop 163 interloops with loops 160 and 166. The other loops within each of the rows may similarly be looped around each other.

The loops can be spaced at various distances along each of the wales in knit structure 100. The distance between the bases of the loops along the wale direction can be used as a proxy for the distance between the loops. Furthermore, the distance between the bases of the loops along the wale direction can determine the size of each of the loops. For example, distance 130 extends from base 146 of loop 160 to base 156 of loop 163. Distance 130 can be considered the distance between loop 160 and loop 163. Furthermore, because loop 163 extends between loop 160 and loop 166, distance 130 can be used with reference to the size of loop 163.

As shown, the loops of course 170 and the loops of course 174 can be fixed at either end. As used herein, "fixed" when referring to a course or knit structure means that the loops of the course will not be significantly deformed by pulling the strands or threads of the course within the knit structure. Moreover, if the loops do deform when subjected to a force, they will return to substantially the same shape as before the force was applied. For example, the base 146 of loop 160 can extend over another loop. Additionally, the base of loop 162 can extend over another loop. In this way, courses 170 and 174 can be fixed. Because the other loops can be held in place relative to each other and there are no free ends for courses 170 and 174, courses 170 and 174 can be fixed.

In some embodiments, a single yarn can be used to form portions of the knit structure. For example, course 170 and course 174 can be formed from a single yarn 106. In other embodiments, a separate, fixed yarn can form course 170, and a separate, fixed yarn can form course 174. In other embodiments, various courses can extend between course 170 and course 174 (not shown).

In some embodiments, course 170 and course 174 can be formed by one-piece knitting construction. As used herein, one-piece knitting construction is defined as being formed into a one-piece structure (one-piece structure) by a knitting process. One-piece knitting construction can be used to form a knitted component having a structure or element comprising one or more courses of yarn, ply or other knitted materials, the one or more courses being connected so that the structure or element comprises at least one common course (that is, sharing a common yarn) and/or is included in each of the structure or element and is substantially continuous between the courses. Utilizing this arrangement, a one-piece element of an one-piece knitting construction is provided. Therefore, except by the interaction of course 172, course 170 and course 174 can interact with each other directly or indirectly by other means. For example, in some embodiments, course 170 and course 174 can be formed by a single yarn 106.

In some embodiments, connecting line 140 can form course 172. Connecting line 140 can interact with the loops of course 170 and the loops of course 174. Connecting line 140 can be unfixed at one end of connecting line 140. For example, connecting line 140 may not be transferred to another loop of adjacent loop 163 or loop 165. In other words, connecting line 140 can have a free hanging portion, and this free hanging portion and other parts of knitted component or knitted structure do not continue to loop each other. In some embodiments, one end can be unfixed, and in other embodiments, both ends can be unfixed. As shown, end 142 can be fixed, and end 144 can be unfixed.

In some embodiments, the connecting thread can be a separate thread or a different thread from the yarn or thread used to form the other courses. For example, course 170 and course 174 can be formed by the same thread or yarn, whereas connecting thread 140 can be formed by a separate yarn.

The yarn used to form the knitted structure 100 can be made of various materials. In addition, the connecting yarn 140 can be formed by various types of yarns that impart different properties. In addition, the other rows of the knitted structure 100 can be formed by yarns or lines made of specific materials to impart specific properties to the knitted structure or knitted components. The properties that a specific type of yarn will impart to a specific area depend on the materials that form the various silks and fibers within the yarn. For example, cotton provides a soft feel, natural beauty, and biodegradability. Elastane and stretch polyester each provide a large amount of stretchability and recoverability, wherein stretch polyester also provides reusability. Rayon provides high gloss and hygroscopicity. In addition to providing thermal insulation properties and biodegradability, wool also provides high hygroscopicity. Nylon is a durable and wear-resistant material with relatively high durability. In addition to the material, other aspects of the selected yarn will also affect the properties of the connecting thread. For example, monofilament yarn or multifilament yarn can be used. The yarn can also include individual silks each formed from different materials. In addition, the yarn can include filaments each formed from two or more different materials, such as a bicomponent yarn, wherein the filaments have a sheath-core configuration or two halves formed from different materials. Different degrees of twist and curl and different deniers can also affect the properties of the yarn. In some embodiments, the yarn or thread used in the connecting line 140 can have a low coefficient of friction. This can allow the connecting line 140 to translate through the rows without stopping or snagging when the connecting line 140 is subjected to tension.

In some embodiments, knitted structure 100 may include a device for varying the distance between loops. Referring to Figures 1-5, end 142 of connecting thread 140 forming loop 163 may be secured in some manner. For example, end 142 may be held, knotted, sewn, stapled, fastened, etc., so that end 142 remains substantially stationary. In other words, end 142 may not translate along the course direction. End 144 may remain unsecured. In other words, end 144 may be free-standing and discontinuous from one course to another. A tensile force 200 may be applied to end 144 of connecting thread 140, as shown in Figure 2. As connecting thread 140 is pulled, the distance between loops along each wale decreases. For example, distance 230 may be less than distance 130. Tensile force 200 pulls connecting thread 140 through both course 170 and course 174. As connecting thread 140 is pulled, the legs of the loops in course 172 begin to contract. The threads from the legs of loops 163, 164, and 165 pass through course 172 and ultimately allow end 144 to be pulled away from knit structure 100. As connecting thread 140 is pulled, the loops within course 172 begin to flatten as the length of each loop's leg passes toward end 144. As connecting thread 140 is continuously pulled through the loops of courses 170 and 174, connecting thread 140 may eventually flatten so that connecting thread 140 may appear as a straight line.

As end 144 is pulled, the loops in course 170 and course 174 move closer together. As shown in FIG3 , distance 330 is less than distance 230. In FIG4 , the distance between course 174 and course 170 is negligible. As shown in FIG4 , the distance has been reduced such that the loops in course 174 and course 170 are adjacent to or in contact with each other.

Referring specifically to FIG. 4 , knit structure 100 can appear to have only two courses, as opposed to three. Because connecting thread 140 is pulled into a substantially straight line, the visibility of connecting thread 140 is reduced. Furthermore, before connecting thread 140 is subjected to tension, the loops of course 174 can appear to be in the same position as the loops of course 172. That is, the loops of course 174 can appear to be directly interlocked and interlooped with the loops of course 170. While the loops of course 174 may not directly interlock with the loops of course 170, the heads of each of the loops of course 174 can be located in substantially the same space as the heads of the loops of course 172. Thus, it appears as if the loops of course 174 are interlooped with the loops of course 170. By pulling course 174 toward course 170 (or vice versa), a seemingly seamless connection is formed between course 174 and course 170.

Referring to FIG. 5 , connecting line 140 has been tensioned, causing it to appear straight or unbent. As connecting line 140 continues to be pulled or tightened, the loops within row 170 and the loops in row 174 may overlap. In some embodiments, the lower portions of loops 160, 161, and 162 may extend above portions of loops 166, 167, and 168. In this configuration, tension 200 has pulled connecting line 140, causing loops 163, 164, and 165 to no longer be visible. The legs and heads of the loops in connecting line 140 have been reduced, such that, in some embodiments, the loops in connecting line 140 no longer exist. That is, the legs and heads of the loops may lie in the same plane, making the distance between the heads and the bases of the loops indistinguishable or negligible. By tightening connecting line 140 to a substantially linear orientation, the loops of course 170 and the loops of course 174 can be more tightly or securely coupled than in previous configurations. Additionally, in this configuration, connecting line 140 can be shielded by different portions of course 170 and course 174. This type of coupling can be used in other configurations as discussed in the detailed description.

Furthermore, by using connecting threads, small portions of the knit structure can overlap, which can reduce bulk compared to other configurations. In other embodiments, the knit structure can be connected or abutted without overlapping knit elements. This configuration can further reduce bulk in the area of the seam, which can increase comfort when used in an article of footwear.

With reference to Figure 6, the configuration of knitted structure is described.Knitted structure 500 comprises course 502, course 504 and course 506.In a manner similar to the knitted structure 100 of Fig. 1-5, course 502 and course 506 can be fixed, and course 504 can be unfixed at the end.In some embodiments, both ends of course 504 can be unfixed.However, in the embodiment shown in Figure 6, end 542 can be fixed, and end 544 can be unfixed.As shown, the distance 530 between the loop of course 502 and the loop of course 506 is greater than the distance 130 of Fig. 1.Knitted structure 500 shows that connecting line can span a large distance.This arrangement can allow other courses and knitted structure to be positioned away from each other.

In some embodiments, different parts of the knit structure may be able to move semi-independently of one another. For example, course 502 may be able to move toward course 506 without impacting course 506. Due to the length of the loops within course 504, course 502 may be able to move due to slack. It should be appreciated that at some point, the movement of course 502 may affect course 506. For example, by moving the course from side to side, the slack in the loops between courses may be reduced, pulling either course 506 or course 502. The distance between course 502 and course 506 may affect the distance either course can move without impacting the positioning of the other. For example, the smaller the distance between course 502 and course 506, the less each course can move without impacting the other. Furthermore, in some embodiments, the ability to move different parts of the knit structure may allow different parts of the knit structure to be positioned in a variety of orientations. For example, some parts of the knit structure may be positioned at a forty-five degree angle relative to other parts of the knit structure. In other embodiments, different parts of the knit structure may be positioned at different heights. This can allow different parts of a knitted component or knitted structure to be processed or printed thereon without interfering with another part of the knitted structure. As in Figures 1-5, the connecting thread 540 can be subjected to tension and form a structure similar to the knitted structure 100 shown in Figure 5.

In some embodiments, a connecting thread may be used to bring the loops of a course closer together along the course direction. This arrangement contrasts with the embodiment shown in Figures 1-6, which generally depict connecting threads that bring the courses closer together along the wale direction. Figure 7 depicts two knit structures, knit structure 600 and knit structure 602, separated by a distance 630. In some embodiments, knit structure 600 and knit structure 602 may be unitary knit constructions. In other embodiments, knit structure 600 and knit structure 602 may be separate knit structures. Knit structure 600 includes two fixed courses, course 604 and course 606. Similarly, knit structure 602 includes two fixed courses, course 608 and course 610. A connecting thread 640 may extend between knit structure 600 and knit structure 602. In some embodiments, connecting thread 640 may interact with the loops from course 608 as well as the loops from course 604. Additionally, a connecting line 640 can be aligned along the course direction between course 610 and course 606. As shown, connecting line 640 forms a loop 622 that is positioned adjacent to loop 620 of course 610. Additionally, loop 626 is positioned adjacent to loop 616 of course 606. Thus, connecting line 640 can appear as a course that is continuous with both course 610 and course 606.

Like connecting line 140, connecting line 640 can be unfixed on at least one end.For example, end 642 is fixed, and end 644 remains unfixed.When the end 644 of connecting line 640 is subjected to tension 700 (referring to Fig. 8), knitting structure 600 and knitting structure 602 can move toward each other.The distance 730 between knitting structure 600 and knitting structure 602 can be less than distance 630.When connecting line 640 continues to tighten, the space between knitting structure 600 and knitting structure 602 can reduce, until knitting structure 600 and knitting structure 602 can contact each other or abut each other.In this configuration, course 608 and course 604 can be presented as being formed by a continuous strand.In addition, in some embodiments, connecting line 640 can be presented as straight line and can be shielded by other loops in each of knitting structure.

Because the knitted structure 600 and the knitted structure 602 can be spaced apart before the connecting line 640 is subjected to a force, different actions or processes can be taken or performed on the knitted structure 600 and the knitted structure 602. For example, in some embodiments, the knitted structure 600 can be subjected to a dyeing or printing process while the knitted structure 602 is subjected to a finishing process. In addition, each of these processes can be completed when the knitted structure 600 and the knitted structure 602 are in a flat orientation. Compared to the actions taken by the knitted structure in a three-dimensional orientation, this configuration can allow for easier execution of actions and greater efficiency in completing processes.

Referring to Figures 9 and 10, another embodiment of a knit structure utilizing connecting threads is shown. In this embodiment, the courses of knit structures 800 and 802 are oriented substantially parallel to each other; however, knit structures 800 and 802 are separated by a distance 804. Knit structure 800 may include a fixed course 801, while knit structure 802 may include a fixed course 803. Course 801 may include loops 810, 820, and 830. Course 803 may include loops 812, 822, and 832.

As with the previous embodiments, in the embodiments shown in Figures 9 and 10, the knitted structure 800 and the knitted structure 802 can be a unitary knitted construction. In some embodiments, the knitted structure 800 and the knitted structure 802 can be formed using a single yarn. In other embodiments, the knitted structure 800 and the knitted structure 802 may not be formed of a unitary knitted construction. That is, in some embodiments, the knitted structure 800 and the knitted structure 802 can be formed of separate knitted structures.

In the configuration of Figure 9, knitted structure 800 and knitted structure 802 can be subjected to various processes, including dyeing, processing, printing or other processes. Each knitted structure can be subjected to a process independently of each other. In addition, each process can be started when each knitted structure is in a flat two-dimensional orientation. Acting on the knitted structure when the knitted structure is in a flat orientation can provide benefits compared to acting on the knitted structure when the knitted structure is in a three-dimensional orientation.

In some embodiments, a connecting thread 840 can extend between knit structure 800 and knit structure 802. Connecting thread 840 can interact with loops from the first course and loops from the second course. For example, connecting thread 840 interacts with loop 830 of course 801, and connecting thread 840 interacts with loop 832 of course 803. In some embodiments, at least one end of connecting thread 840 can be unsecured. In other embodiments, both ends of connecting thread 840 remain unsecured. As shown, end 854 can be secured, while end 852 can be unsecured.

Referring to FIG10 , end 852 of connecting thread 840 is subjected to force 900. When connecting thread 840 is pulled, the space between knitted structure 800 and knitted structure 802 decreases. Additionally, when loop 842 of connecting thread 840 aligns with loop 844 of connecting thread 840, knitted structure 800 may begin to rotate. As shown in FIG10 , loop 844 and loop 842 are positioned generally adjacent to each other. Furthermore, course 801 is positioned adjacent to course 803, however, course 801 may no longer be parallel to course 803. Due to the interacting positions of loop 842 within course 801 (at loop 830) and loop 844 within course 803 (at loop 832), course 801 may rotate when connecting thread 840 is tightened. As in another embodiment, if loop 842 interacts with loop 810, course 801 may not rotate, and instead loop 810 may be positioned adjacent to loop 832. Additionally, in such an embodiment, course 801 can be positioned adjacent to and parallel to course 803. This configuration would be similar to the knit structures shown in Figures 7 and 8. By positioning the loops of connecting thread 840 at specific locations within the knit structure, a specific rotation of each knit structure can be achieved. Similarly, a variety of shapes, designs, and course positions can be configured by specifically positioning the connecting threads in specific areas within the knit structure.

Referring to Figures 11 and 12, another embodiment of a knit structure utilizing connecting threads is depicted. Knit structure 1000 and knit structure 1002 are oriented away from each other and are separated by a distance 1080. That is, along a dividing line parallel to course 1001 and course 1003, knit structure 1000 and knit structure 1002 are essentially mirror images of each other. Furthermore, in some embodiments, knit structure 1000 and knit structure 1002 can be formed of a unitary knit construction.

Knit structure 1000 includes course 1001, which includes loops 1010, 1020, and 1030. Knit structure 1002 includes course 1003, which includes loops 1012, 1022, and 1032. Each course can be secured in a manner similar to that discussed with respect to the previous embodiments. As shown, connecting thread 1040 extends between course 1001 and course 1003. Loop 1042 interacts with loop 1010 of course 1001, and loop 1046 interacts with loop 1030 of course 1001. Additionally, loop 1044 interacts with loop 1022 of course 1003. Thus, the loops of connecting thread 1040 extend in different directions. In some embodiments, at least one end of connecting thread 1040 may be unsecured.

In some embodiments, both ends of the connecting line 1040 can be free. As shown in Figures 11 and 12, end 1050 is fixed, while end 1052 remains free.

12 , a pulling force 1100 can act on end 1052, causing connecting thread 1040 to pull knitted structures 1000 and 1002 together. The distance between knitted structures 1000 and 1002 can be reduced so that knitted structures 1000 and 1002 can appear to be directly bonded to each other. In a manner similar to the embodiment shown in FIGS. 1-5 , connecting thread 1040 can be substantially straight so that when tightened, connecting thread 1040 can be substantially obscured. The legs of the loops in connecting thread 1040 translate through the loops of courses 1001 and 1003. The length of the legs and heads of the loops in connecting thread 1040 can be transferred toward end 1052, allowing end 1052 to extend away from knitted structures 1000 and 10002. This configuration can allow knitted structures in different orientations to be easily connected together. Additionally, the configurations of Figures 11 and 12 may allow each knit structure to be machined, dyed, printed, or subjected to other processes substantially independently of the other knit structures.

In each of the embodiments discussed above, it should be appreciated that different knit structures may be used. For example, each knit structure need not utilize a plain jersey knit structure. Furthermore, each connecting thread may connect a particular loop of a knit structure to other loops of the knit structure that are spaced apart. For example, some loops of the knit structure may not be looped with the connecting thread. For example, loop 1020 does not loop with connecting thread 1040. In other embodiments, the various loops of the knit structure may not interact with the connecting thread.

In each of the previously discussed embodiments, the knitted structure can be secured after the connecting threads have been subjected to a force. In some embodiments, after the desired amount of tension has been applied, the free ends of the connecting threads can be sewn, knitted, bonded, stapled, or otherwise secured. This can lock the knitted structure in place so that the connecting threads can resist forces that would otherwise separate the knitted structure from one another.

With reference to Figures 13-17, a knitted component using a connecting thread is depicted. As depicted, knitted component 1200 is formed in a substantially rectangular shape. Knitted component 1200 includes a first side 1201 and a second side 1202 substantially perpendicular to first side 1201. In addition, knitted component 1200 includes a third side 1203, which is substantially perpendicular to second side 1202 and parallel to first side 1201. In addition, knitted component 1200 includes a fourth side 1204, which is substantially parallel to second side 1202 and substantially perpendicular to first side 1201 and third side 1203. Therefore, knitted component 1200 is substantially rectangular. In other embodiments, various shapes can be used.

In some embodiments, the connecting line can be pre-positioned to interact with the knitted component 1200 in a predetermined manner. As shown, the connecting line 1240 can be pre-positioned so as to interact with the specific loop in the knitted component 1200 in a predetermined manner. In some embodiments, the connecting line 1240 can be located on the knitting machine. That is, in some embodiments, the knitting machine can be programmed so that the connecting line 1240 automatically interacts with the knitted component 1200 during the knitting process. In other embodiments, when the knitted component is formed, the connecting line 1240 can be placed on the knitting machine. For example, the connecting line 1240 can be located in a specific needle in the knitting machine. As the knitted component 1200 is formed on the needle bed, the connecting line 1240 can then interact with the knitted component 1200.

Connecting line 1240 can be arranged to interact with specific loops and specific points within knitted component 1200 in a predetermined manner. As shown, loop 1211 can be arranged to interact with loop 1210 at point A. Loop 1213 can be arranged to interact with loop 1212 at point A'. In some embodiments, loops 1210 and 1212 can be positioned substantially the same distance from third side 1203. That is, loops 1210 and 1212 can be positioned directly across knitted component 1200. Loop 1221 can be oriented to interact with loop 1220 at point B. Loop 1223 can be oriented to interact with loop 1222 at point B'. In some embodiments, loops 1220 and 1222 can be positioned substantially the same distance from third side 1203. Loop 1231 can be oriented to interact with loop 1230 at point C. Loop 1233 can be oriented to interact with loop 1232 at point C'. In some embodiments, ring 1230 and ring 1232 can be positioned substantially the same distance from third side 1203. Ring 1251 can be oriented to interact with ring 1250 at point D. Ring 1253 can be oriented to interact with ring 1252 at point D'. In some embodiments, ring 1250 and ring 1252 can be positioned substantially the same distance from third side 1203.

In some embodiments, the points of connection can be arranged in various ways. In some embodiments, the points may not be directly positioned across the knitted component. For example, in some embodiments, the points may be positioned diagonally to each other. In addition, the loops of connecting line 1240 can interact with different loops. For example, loop 1213 can interact with loop 1222.

In some embodiments, connecting line 1240 can be configured as a knitted structure. In some embodiments, such as shown in Figure 13, connecting line 1240 can utilize floating loops to extend from one loop to another. For example, between loop 1211 and loop 1213, a floating loop can be used. In other embodiments, auxiliary elements can be used to maintain connecting line 1240 in a specific orientation and form an auxiliary knitted component. Auxiliary elements can be used to maintain the shape of connecting line 1240 so that the parts of connecting line 1240 do not tangle with each other. The auxiliary elements can be removed before or during the tensioning of connecting line 1240. The embodiments described herein can use the device, structure or method described in U.S. Publication No. 2014/0237861 entitled "Method of Knitting a Knitted Component with a Vertically Inlaid Tensile Element" published by Podhajny on August 28, 2014, the entire contents of which are hereby incorporated herein by reference. In the US publication of Podhajny, auxiliary elements are used during the manufacture of the knitted components.

In some embodiments, the loops of connecting line 1240 can be specifically positioned. In some embodiments, the loops of connecting line 1240 can be arranged so that adjacent loops can be placed across the knitted component. For example, loop 1211 can interact with loop 1210 of knitted component 1200, and loop 1213 can interact with loop 1212 of knitted component 1200. As discussed above, loop 1210 and loop 1212 can be positioned roughly relative to each other. In addition, connecting line 1240 can extend directly from loop 1211 to loop 1213. That is to say, between loop 1211 and loop 1213, there may not be other loops configured to interact with knitted component 1200. In this sense, when connecting line 1240 is tightened, loop 1211 and loop 1213 can be positioned next to each other.

14 , each of the loops of connecting thread 1240 is shown interacting with a previously discussed loop at a predetermined point in knitted component 1200. Although connecting thread 1240 is shown extending beneath and around knitted component 1200, it should be appreciated that in some embodiments, connecting thread 1240 may extend across knitted component 1200.

In some embodiments, the ends of connecting thread 1240 may be secured after the loops of connecting thread 1240 are inter-looped with the loops of knitted component 1200. In other embodiments, both ends of connecting thread 1240 may be unsecured. In other embodiments, end 1272 may be unsecured while end 1270 remains secured.

In the configuration shown in FIG. 14 , the second side 1202 and the fourth side 1204 can be physically coupled to each other via a connecting thread 1240. Although loosely coupled, loops in the connecting thread 1240 interlock with loops on the second side 1202 and the fourth side 1204. Furthermore, machining, dyeing, or other processes can be performed in this configuration. The knitted component 1200 and connecting thread 1240 can also be moved to different positions while in a two-dimensional orientation to perform additional processes.

With reference to Figure 15, the isometric view of knitted component 1200 is shown.In the figure, the end 1272 of connecting line 1240 is subjected to tension 1400.When connecting line 1240 was subjected to tension 1400, knitted component 1200 can begin to bend.Tensioning force can be transmitted by connecting line, and makes the loop of connecting line 1240 move toward each other.When connecting line 1240 continues to be pulled, the loop of connecting line 1240 is pulled closer to each other, and therefore the corresponding loop (connecting line 1240 and its mutual looping) at the point of knitted component 1200 is also pulled closer to each other.As shown in Figure 15, knitted component 1200 becomes the three-dimensional structure with semi-cylindrical shape from flat, basically two-dimensional structure.

Referring to Figure 16, end 1272 continues to be subjected to tension. Tension 1400 pulls connecting thread 1240 through the loop of knitted component 1200. This action extends end 1272 away from knitted component 1200 and brings predetermined points of knitted component 1200 closer together because the loop of connecting thread 1240 also moves closer together. Knitted component 1200 transforms into a shape similar to a cylinder. First side 1201 and third side 1203 bend in a generally circular manner, while second side 1202 and fourth side 1204 remain generally linear and parallel.

Referring to FIG17 , connecting line 1240 has been pulled so that second side 1202 and fourth side 1204 are adjacent to and positioned adjacent to each other. In this configuration, ring 1210 can be positioned adjacent to ring 1212; ring 1220 can be positioned adjacent to ring 1222; ring 1230 can be positioned adjacent to ring 1232; and ring 1250 can be positioned adjacent to ring 1252. Rings 1211 and 1213 can be positioned adjacent to each other in a manner similar to that depicted in FIG1-12 . Additionally, rings 1221 and 1223 can be positioned adjacent to each other. Rings 1231 and 1233 can be positioned adjacent to each other. Rings 1251 and 1253 can be positioned adjacent to each other.

In some embodiments, corresponding points from either side of the knitted component can abut each other. As shown, point A abuts point A', point B abuts point B', point C abuts point C', and point D abuts point D'. In other embodiments, the interaction of the loops can be changed so that different points abut each other. For example, by rearranging the interaction of the different loops of the connecting line 1240 and the knitted component 1200, point A can abut point C'. This arrangement can allow different shapes and designs of the knitted component to be completed while allowing the knitted component to be attached in a predetermined manner with a two-dimensional configuration.

1-12 , when connecting thread 1240 is tightened, the loops of connecting thread 1240 can flatten or decrease, allowing connecting thread 1240 to appear straight or linear. That is, connecting thread 1240 can appear as if it does not include loops. Furthermore, as previously discussed, in some embodiments, since connecting thread 1240 is ultimately tightened, connecting thread 1240 can be obscured from view by the loops of knitted component 1200. Thus, after connecting thread 1240 is fully tightened, knitted component 1200 can take on the shape of a seamless cylinder.

In some embodiments, the free end of connecting thread 1240 can be secured after being fully tightened. The free end can be secured by knitting, sewing, gluing, thermoplastic melting, or other techniques. By securing the free end of connecting thread 1240, second side 1202 and fourth side 1204 can be securely positioned. In other words, connecting thread 1240 can prevent second side 1202 and fourth side 1204 from being pulled apart or separated from each other.

Figures 13-17 show an embodiment utilizing connecting lines, which facilitate converting a two-dimensional knitted component into a three-dimensional knitted component. Additionally, the connecting lines can be pre-positioned to connect predetermined areas of the knitted component in a two-dimensional orientation. Since the second side 1202 and the fourth side 1204 can be physically connected by connecting lines 1240 when in a two-dimensional state, no additional knitting, threading, or stitching is required to form a three-dimensional structure. Instead, the connecting lines 1240 are simply pulled to form the three-dimensional knitted component. Since the sides of the knitted component 1200 are pre-configured and attached in a predetermined manner, processing can be performed while the sides of the knitted component 1200 are already physically attached to each other. This arrangement can improve the efficiency of the construction and processing of the knitted component. For example, when the knitted component 1200 is in a two-dimensional configuration, a printed design can be formed that extends across the junction of the second side 1202 and the fourth side 1204. Since the sides are pre-configured to connect at a predetermined desired location, the sides can be printed when in a flat orientation, forming a three-dimensional representation of the printed material. Because the knitted component 1200 can be in a two-dimensional orientation that is completely different from a three-dimensional orientation, this arrangement allows printed material to be more accurately or easily placed on the knitted component 1200.

In addition, various shapes and orientations can be formed by changing the position of the predetermined connection point. For example, in some embodiments, the connection point on the second side 1202 can be positioned closer to the center portion along the second side 1202. When the fourth side 1204 is connected to the second side 1202 by tightening the connecting line, the fourth side 1204 can be tightened or gathered (scrunch or bunch). This is because the points along the fourth side 1204 are positioned farther away from each other than the points along the second side 1202. Due to the difference in distance, the points along the fourth side 1204 can be forced to occupy a smaller distance, and therefore when each of these points is connected along the point of the second side 1202, the points along the fourth side 1204 are gathered together. By pre-configuring the connecting line and interacting with a specific loop in a predetermined manner, a consistent and accurate joint can be formed along each of the side portions of the knitted component. In addition, compared with other technologies, using this pre-configured arrangement can require less labor.

18-25, the use of connecting thread to form a portion of an article of footwear is depicted. As shown, portions of the knitted component are formed on a knitting machine.

Although knitting can be done by hand, the commercial manufacture of knitted components is typically done by knitting machines. Examples of knitting machines capable of producing knitted components (including any embodiments of knitted components described herein) are depicted in Figures 18-25. In addition, the embodiments herein may use any of the devices or structures described in U.S. Publication No. 2014/0237861, entitled "Method of Knitting a Knitted Component with a Vertically Inlaid Tensile Element," published on August 28, 2014 by Podhajny, the entire contents of which are hereby incorporated by reference herein. In this U.S. Publication by Podhajny, knitting machines and techniques that can be used to form knitted components as discussed in this detailed description are described.

In some embodiments, knitting machine 1764 may include two needle beds. In some embodiments, the needle beds may be angled to form a V-shaped bed. Each needle bed includes multiple independent needles located on a common plane. A track extends above and parallel to the intersection of the needle beds. The track may provide an attachment point for a feeder. The feeder can supply yarn to the needles so that the needles manipulate the yarn. Due to the action of the carriage, the feeder can move along the track and the needle bed, thereby supplying yarn to the needles. The needles can then extend and retract, forming a knitted structure. In some embodiments, a second track may be provided that can feed a second supply of yarn to the needles. In this embodiment, the first yarn can interact with the second yarn.

Referring to Figure 18, a tongue portion of a knitted component is formed using first yarn 1760. Tongue portion 1700 can be formed using a first set of needles. A first feeder 1762 delivers first yarn 1760 to a needle bed. The first set of needles interacts with first yarn 1760 to form tongue portion 1700. Tongue portion 1700 can be secured to the needles along edge 1702. In other words, a portion of tongue portion 1700 can remain attached to the first set of needles.

As discussed throughout the specification and claims, knitting direction refers to the orientation of the yarns or strands that are looped together to form rows of courses or loops, which are connected to continuous courses by the knitting process. The knitting direction can be roughly defined relative to the direction of the knitted material being formed during the knitting process. For example, in a flat knitting process, by manipulating the yarn to knit courses or rows in a generally horizontal direction, continuous courses of yarns that are looped together are connected together to increase the size of the knitted component in a generally vertical direction. The course direction can be used to refer to the orientation of the courses within a knitted component compared to the base orientation of the courses within the knitted component. For example, the base orientation of the courses can be horizontal or zero degrees. Some courses can be oriented at an angle of forty-five degrees relative to the base orientation. Other courses can be oriented at various angles relative to the base orientation. Changes in orientation can be formed using gores and other methods. As shown in Figure 18, the course direction of the tongue portion 1700 is substantially horizontal or parallel to the knitting direction of the first feeder 1762.

Referring to FIG19 , the connecting portion is formed separately from the tongue portion 1700. Connecting portion 1800 can be formed using a different track and feeder than the one used to form tongue portion 1700. As shown, connecting portion 1800 is formed when second feeder 1862 delivers second yarn 1860 to the second set of needles. Second yarn 1860 can be a separate yarn from first yarn 1760. Furthermore, in some embodiments, second yarn 1860 can be formed from a different material than first yarn 1760. For example, in FIG19 , knitting machine 1764 forms two different, separate knitted structures using strands of at least two different yarns. Therefore, during manufacturing, tongue portion 1700 and connecting portion 1800 may not interact with each other at this point.

In some embodiments, connecting portion 1800 can be formed as a knitted structure. As shown, connecting portion 1800 is described as extending between various needles. In other words, connecting portion 1800 is formed in a generally linear manner. For example, each of the loops of connecting portion 1800 is located in the needle of knitting machine 1764. In other words, as described, during manufacture, the loops of connecting portion 1800 do not disengage from the needle at this time. In other embodiments, connecting portion 1800 can be formed as a knitted structure comprising a plurality of rows. In some embodiments, connecting portion 1800 can be formed as a knitted component in a triangular shape. In other embodiments, connecting portion 1800 can be formed as other shapes.

In some embodiments, connecting portion 1800 may include a plurality of loops. As shown, connecting portion 1800 includes a first subset and a second subset. First subset 1870 may be used to refer to loop 1811, loop 1821, loop 1831, and loop 1851. Second subset 1872 may be used to refer to loop 1813, loop 1823, loop 1833, and loop 1853. First subset 1870 and second subset 1872 may abut each other between loop 1853 and loop 1851. Each loop of each subset extends outward from the abutment between first subset 1870 and second subset 1872. For example, as shown, connecting portion 1800 includes loop 1811 positioned opposite loop 1813. Both loop 1811 and loop 1813 are positioned furthest from the junction of first subset 1870 and second subset 1872. In a similar manner, ring 1821 is positioned opposite ring 1823; ring 1831 is positioned opposite ring 1833; and ring 1851 is positioned opposite ring 1853. In other embodiments, a greater number of rings may be used to form connecting portion 1800.

As shown, the connecting portion 1800 can include floating rings between each of the rings of the connecting portion 1800. In other embodiments, the connecting portion 1800 can include auxiliary elements that can take up the space of the floating rings or can reduce the length of the sinkers between the rings of the connecting portion 1800. The auxiliary elements can be used to orient the connecting line 1840 so that portions of the connecting line 1840 can not be entangled with each other, as previously discussed in this detailed description. In other embodiments, different configurations of the connecting portion 1800 can utilize auxiliary elements.

In some embodiments, knitting of tongue portion 1700 may be suspended while forming connecting portion 1800. In other embodiments, tongue portion 1700 and connecting portion 1800 may be formed simultaneously. In still other embodiments, connecting portion 1800 may be formed before forming other portions.

At this point during manufacturing, as shown in FIG. 19 , the knitting machine may include two knitting structures: tongue portion 1700 and connecting portion 1800. Each of the loops (loop 1811, loop 1813, loop 1821, loop 1823, loop 1831, loop 1833, loop 1851, and loop 1853) of connecting portion 1800 may be located within a needle. In other words, each of the loops of connecting portion 1800 may not be disengaged from the needle. Additionally, the loops along edge 1702 of tongue portion 1700 may also be located within a needle. However, the loops along edge 1702 may be located within a different needle than the loops of connecting portion 1800.

Referring to Figure 20 , a portion of the vamp portion and the lower portion are knitted. As shown, vamp portion 1900 is knitted continuously from tongue portion 1700. That is, in some embodiments, vamp portion 1900 and tongue portion 1700 are formed of a unitary knitted construction. Although edge 1702 is depicted in Figure 20 , edge 1702 may not be visible and is labeled for convenience and reference. Furthermore, a portion of lower portion 1950 may also be knitted. In some embodiments, lower portion 1950 and vamp portion 1900 may be of unitary knitted construction. The course direction of lower portion 1950 and vamp portion 1900 may be substantially parallel to the course direction of tongue portion 1700. In some embodiments, lower portion 1950 and vamp portion 1900 may be coupled along region 1910. Zone 1910 is not meant to delineate a specific exact area, but rather zone 1910 is intended to represent the area of unitary knit construction bridging vamp portion 1900 and lower portion 1950 .

When vamp portion 1900 is knitted, the needle holding the loops of connecting portion 1800 can interact with first yarn 1760 used to form vamp portion 1900. Thus, connecting thread 1840 can interact with and loop first yarn 1760 used to form vamp portion 1900. The loops of first subset 1870 can interact with loops of vamp portion 1900 along side 1902. As shown, loop 1811 can interact with loop 1810 of vamp portion 1900 at point A, loop 1821 with loop 1820 of vamp portion 1900, loop 1831 with loop 1830 of vamp portion 1900, and loop 1851 with loop 1850 of vamp portion 1900 at point B. In this configuration, the physical connection between connecting thread 1840 and the loops within vamp portion 1900 can appear as depicted in FIG. 1-12. That is, the connecting line 1840 can be looped with the fixed horizontal rows or fixed loops of the vamp portion 1900.

In some embodiments, connecting portion 1800 can be positioned at a predetermined location on the needles of knitting machine 1764. That is, connecting thread 1840 can be held on the needles of knitting machine 1764 so that when forming vamp portion 1900, specific loops of vamp portion 1900 can interact with specific loops of connecting portion 1800. Knitting machine 1764 can be programmed to form a joint between side portion 1902 and first subset 1870. In other words, the joint can be formed automatically during the knitting process. As a first feeder forms vamp portion 1900, the feeder moves back and forth along the needle bed. The feeder can be moved to the side portion including connecting portion 1800. When the feeder reaches the needle holding the loop of connecting portion 1800, first thread 1760 and connecting portion 1800 can interact and loop each other.

As depicted, vamp portion 1900 can be associated with the forefoot area of the article of footwear. Furthermore, vamp portion 1900 can be associated with the toe box and phalangeal area of the article of footwear. Furthermore, lower portion 1950 can be associated with the underside of the foot. That is, when completed, lower portion 1950 can be positioned adjacent to the underside of the foot in the completed article of footwear. In other embodiments, various portions of the article of footwear and other knitted items can be formed.

As shown in Figure 20, the loops of first subset 1870 of connecting portion 1800 can be looped with vamp portion 1900 along side 1902. Loops 1813, 1823, 1833, and 1853 can be retained within their respective needles. When the needle is disengaged from loops 1811, 1821, 1831, and 1851 formed by second yarn 1860 of connecting thread 1840, the needle can interact with first yarn 1760 and further form additional portions of vamp portion 1900 and a portion of lower portion 1950. Loop 1811 can be looped with loop 1810, loop 1821 can be looped with loop 1820, loop 1831 can be looped with loop 1830, and loop 1851 can be looped with loop 1850. First subset 1870 of connecting portions 1800 may now be interengaged with the loops of vamp portion 1900 .

21 , the unattached loops of the second subset 1872 along the connecting portion 1800 can be aligned and attached to the loops along the side 1952 of the lower portion 1950 at specific and predetermined locations, and can be looped with each other. The first feeder 1762 of the knitting machine 1764 moves back and forth along the track, and the loops of the knitted component can eventually be aligned with the needles holding the loops of the second subset 1872 of the connecting thread 1840. When the first feeder 1762 passes to the needles holding the loops of the connecting thread 1840, the needles extend to receive the first yarn 1760 used to form the lower portion 1950. As the needles extend, the loops of the second subset 1872 of the connecting thread 1840 disengage and become looped with the loops along the side 1952 of the lower portion 1950. In this state, the loops of connecting line 1840 are looped with the loops along side 1902 of vamp portion 1900 and with the loops along side 1952 of lower portion 1950 .

In some embodiments, connecting portion 1800 can be positioned at a predetermined location within the needle of knitting machine 1764. That is, connecting thread 1840 can be placed within the needle of knitting machine 1764 so that when forming lower portion 1950, specific loops of lower portion 1950 can interact with specific loops of connecting portion 1800. Knitting machine 1764 can be programmed to form a joint between side portion 1952 and second subset 1872. In other words, the joint can be automatically formed during the knitting process. Thus, different areas of knitted component 2000 can be physically connected in an automated manner.

In some embodiments, the angle of the wires within the connecting portion 1800 can vary. When the second subset 1872 of the connecting wires 1840 are looped with the side 1952 of the lower portion 1950, the loops of the second subset 1872 can interact with loops from a different row of the lower portion 1950. By interacting with different rows of the lower portion 1950, the second subset 1872 can be positioned at an angle relative to the rows within the lower portion 1950. Additionally, in this orientation, the second subset 1872 can be oriented at an angle relative to the first subset 1870.

In some embodiments, the loops of second subset 1872 can interact with and loop each other at lower portion 1950. Loop 1853 can interact with loop 1852 at point B' of lower portion 1950; loop 1833 can interact with loop 1832 of lower portion 1950; loop 1823 can interact with loop 1822 of lower portion 1950, and loop 1813 can interact with loop 1812 at point A' of lower portion 1950. The interactions between these loops can be similar to the interactions previously discussed between knitted component and connecting thread 1840 or other embodiments of connecting thread as discussed with respect to Figures 1-12.

In some embodiments, the entirety of the knitted component can be completed and removed from knitting machine 1764. In some embodiments, the knitted component can include lower portion 1950 and vamp portion 1900. In other embodiments, other portions can be included to form the knitted component.

As shown in FIG21 , knitted component 2000 includes lower portion 1950, vamp portion 1900, and tongue portion 1700. Once removed from knitting machine 1764, knitted component 2000 may appear as knitted component 2000 as shown in FIG21 . That is, knitted component 2000 may be generally two-dimensional, with connecting threads 1840 extending between various loops of knitted component 2000. Additionally, vamp portion 1900 may be attached to lower portion 1950 via connecting threads 1840.

In this two-dimensional or planar configuration, processing and dyeing of the knitted component 2000 can be performed while the knitted component 2000 is in a two-dimensional orientation. This arrangement can provide ease of assembly over processing and dyeing when the knitted component 2000 is in a three-dimensional state. In addition, because the positions of the connecting threads 1840 can be pre-planned to connect at certain predetermined locations, the amount of labor required to connect the components of the knitted component 2000 can be less than in other methods of connecting parts of a knitted component to form a three-dimensional object.

22-24, knitted component 2000 is removed from the knitting machine. As shown, connecting line 1840 can be subjected to tension 2100 at end 2102 of connecting line 1840. When end 2102 is tightened, side 1902 of vamp portion 1900 can be pulled toward side 1952 of lower portion 1950. Because vamp portion 1900 and lower portion 1950 can be limited to rotation in the same two-dimensional plane due to the connection at district 1910, these two parts can be rotated into different planes, thereby forming a three-dimensional shape. In other embodiments, due to the specific layout and geometry of knitted component, the part of knitted component can form a two-dimensional article after tightening.

When the end 2102 is continuously pulled or tightened, the side portion 1902 and the side portion 1952 can eventually abut each other. The abutment can appear as discussed with respect to Figures 1-12. In other words, the connecting line 1840 can appear as a straight line passing through the rows of knitted component 2000. In addition, the connecting line 1840 can be obscured from view by the loops of the vamp portion 1900 and the lower portion 1950. Furthermore, the rows of the vamp portion 1900 and the lower portion 1950 can appear as if each directly loops with the other and is joined to each other. In this sense, a seamless abutment can be formed between the side portion 1902 and the side portion 1952.

As shown, connecting portion 1800 can be specifically positioned so as to connect a specific point of side portion 1902 toward a point on side portion 1952. For example, connecting portion 1800 can be arranged so that loop 1852 of side portion 1952 can be aligned with loop 1850 of side portion 1902. As shown, loop 1851 is positioned adjacent to loop 1850 of side portion 1902 so that when vamp portion 1900 is knitted, loop 1850 can interloop with loop 1851 at point B. Similarly, loop 1853 is positioned so that when lower portion 1950 is formed, loop 1853 can interact with the loop at point B'. In this particular embodiment, when connecting thread 1840 is tightened, loop 1853 and loop 1851 will move toward each other. Because loop 1853 is directly coupled to loop 1851 (i.e., connecting thread 1840 extends between loop 1853 and loop 1851), when connecting thread 1840 is tightened, loop 1853 will move toward loop 1851. Thus, the loops of connecting portion 1800 can be positioned along with the knitted portion to achieve a specific coupling point. By moving the position of the loops of connecting portion 1800, different coupling points and shapes can be formed.

26-28, alternative embodiments of knitted components utilizing connecting threads are depicted.In some embodiments, multiple connecting threads may be used to connect multiple areas or portions of a knitted component together.

As shown, knitted component 2500 uses multiple connecting lines. Knitted component 2500 can be formed by a one-piece knitted construction. Knitted component 2500 can include various parts. In the depicted embodiment, knitted component 2500 includes lower portion 2502, lateral rear portion 2504, lateral forward portion 2506, medial rear portion 2514, medial forward portion 2512, heel portion 2508 and vamp portion 2510. Each part can be attached to an adjacent part by a connecting line. As shown, the side 2530 of vamp portion 2510 can be attached to the side 2526 of the lateral forward portion 2506 by a connecting line 2501. The side 2546 of the lateral forward portion 2506 can be attached to the side 2544 of the lateral rear portion 2504 by a connecting line 2503. 2505. Side 2524 of lateral rearward portion 2504 may be attached to side 2528 of heel portion 2508 via connecting line 2505. Side 2548 of heel portion 2508 may be attached to side 2554 of medial rearward portion 2514 via connecting line 2507. Side 2534 of medial rearward portion 2514 may be connected to side 2532 of medial forward portion 2512 via connecting line 2509. Side 2552 of medial forward portion 2512 may be attached to side 2550 of vamp portion 2510 via connecting line 2511.

As discussed with respect to the previous embodiments, the connecting line can include at least one unfixed end. That is, at least one end can be tightened or pulled and the rest of the connecting line is passed through a loop (such as depicted in Figures 1-12) with which the connecting line is interwoven. In addition, in some embodiments, the connecting line and the knitted component can be formed on the knitting machine so that the connecting line can be interwoven at a predetermined position and interact with the loop of the knitted component 2500. By attaching the different parts of the knitted component 2500 to each other while the knitted component 2500 is still on the knitting machine, there is no need for an additional step of attaching these parts after the knitted component is removed from the knitting machine.

Additionally, in a loosely coupled state, as shown in Figure 26, knitted component 2500 can be processed and dyed while in a two-dimensional orientation. This allows for easy customization of an article of footwear.

With reference to Figure 27, the isometric view of the knitted component 2500 in the partially conforming state is depicted. At least one end in connecting line 2501, connecting line 2503, connecting line 2505, connecting line 2507, connecting line 2509 and connecting line 2511 is subjected to force. In some embodiments, each end can be subjected to force at the same time. In other embodiments, each end can be subjected to force at different times. When each in the connecting line is subjected to force, each in the side portion that is mutually looped with the connecting line can begin to move toward each other (as seen in Figure 27). Due to the shape and relative spacing of the parts of knitted component 2500, these parts can extend from the two-dimensional shape of the plane or be folded into a three-dimensional shape.

28, connecting line is tightened so that each in the side portion is adjacent to another.For example, side portion 2548 is adjacent to side portion 2554, thereby forms seamless connection portion between heel portion 2508 and medial rear portion 2514.When each connecting line is tightened, knitted component 2500 can form the shape of article of footwear.In some embodiments, article of footwear can also include sole structure 2710.In some embodiments, sole structure 2710 can adhere to lower portion 2502 before connecting line is tightened.In this embodiment, sole structure 2710 can adhere to by any known means.By sole structure 2710 being fixed to lower portion 2502 when knitted component 2500 is in two-dimensional state, sole structure 2710 is positioned and attached to lower portion 2502, sole structure 2710 is attached to the required labor amount of lower portion 2502 and can be less than the labor amount that needs sole structure 2710 to be attached to the method for three-dimensional knitted component.

Although various embodiments have been described, the description is intended to be illustrative rather than restrictive, and it will be apparent to those skilled in the art that many embodiments and implementations are possible within the scope of the embodiments. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the appended claims. As used in the claims, "any of..." when referencing a preceding claim is intended to mean (i) any one claim, or (ii) any combination of two or more of the cited claims.

Claims (41)

1. A method for forming a knitted part, the method comprising the following steps: The first part of the knitted component is knitted using the first thread along the first horizontal direction; The second part of the knitted component is knitted with a second thread, the first thread being different from the second thread; The second portion of the knitted component has a first engagement subset and a second engagement subset, the first engagement subset including a plurality of loops, the second engagement subset including a plurality of loops, and the plurality of loops of the first engagement subset and the plurality of loops of the second engagement subset being held by a plurality of needles. The first portion of the knitted component has a first joining side, the first joining side including a plurality of loops; At least one of the plurality of rings in the first junction subset is interlocked with at least one of the plurality of rings on the first junction side; The third portion of the knitted component is knitted along the first transverse direction using the first yarn, the third portion of the knitted component including a second joining side, the second joining side including a plurality of loops; At least one of the plurality of rings in the second joining subset is interlocked with at least one of the plurality of rings on the second joining side. The knitted component is configured to be incorporated into the upper of the footwear article; and the knitted component includes a base portion comprising an outer side and an inner side, wherein the first joining side and the second joining side extend away from the outer side. 2. The method of claim 1, wherein the first engagement side and the second engagement side are positioned at an angle relative to each other or positioned parallel to each other. 3. The method according to any one of claims 1 to 2, wherein the first engagement subset includes a first ring, the second engagement subset includes a second ring, and the first ring is positioned adjacent to the second ring when located on the plurality of needles. 4. The method of claim 3, wherein the first ring interlocks with the first engagement side adjacent to the base portion, and the second ring interlocks with the second engagement side adjacent to the base portion. 5. The method according to any one of claims 1, 2 and 4, wherein the knitted part further comprises a fourth portion, the fourth portion including a third edge that does not loop with the second portion. 6. The method of claim 3, wherein the knitted component further comprises a fourth portion, the fourth portion including a third edge, the third edge not interlocking with the second portion. 7. A method for forming a knitted part, the method comprising the following steps: The first part of the knitted component is knitted using the first thread along the first horizontal direction; The second part of the knitted component is knitted with a second thread, the first thread being different from the second thread; The second portion of the knitted component has a first engagement subset and a second engagement subset, the first engagement subset including a plurality of loops, the second engagement subset including a plurality of loops, and the plurality of loops of the first engagement subset and the plurality of loops of the second engagement subset being held by a plurality of needles. The first portion of the knitted component has a first joining side, the first joining side including a plurality of loops; At least one of the plurality of rings in the first junction subset is interlocked with at least one of the plurality of rings on the first junction side; The third portion of the knitted component is knitted along the first transverse direction using the first yarn, the third portion of the knitted component including a second joining side, the second joining side including a plurality of loops; At least one of the plurality of rings in the second joining subset is interlocked with at least one of the plurality of rings on the second joining side. The knitted component is configured to be incorporated into the upper of the footwear article; and the knitted component includes a base portion comprising an outer side and an inner side, wherein the first joining side and the second joining side extend away from the inner side. 8. A method for assembling footwear articles by incorporating knitted components into a shoe upper, the method comprising: The method of claim 7 forms the knitted part in a planar configuration, wherein the second thread is a connecting thread, the connecting thread including a first end and a second end, at least one of the first end and the second end being non-fixed; Tighten at least one of the first and second ends of the connecting wire, such that the first and second engagement sides extend toward each other; and The knitted component is incorporated into the upper of the footwear article. 9. The method of claim 8, wherein the upper of the footwear article includes an outer side and an inner side, and the first joint side and the second joint side are located on the outer side. 10. The method of claim 8, wherein the upper of the footwear article includes an outer side and an inner side, and the first joint side and the second joint side are located on the inner side. 11. The method according to any one of claims 8 to 9, wherein, when the connecting line is tightened, at least one loop on the first engagement side is adjacent to at least one loop on the second engagement side. 12. The method of claim 10, wherein, when the connecting line is tightened, at least one loop on the first engagement side is adjacent to at least one loop on the second engagement side. 13. The method according to any one of claims 8, 9 and 12, wherein the first portion comprises at least one loop, the at least one loop of the first portion being adjacent to at least one loop of the third portion when the connecting line is tightened. 14. The method of claim 10, wherein the first portion comprises at least one loop, the at least one loop of the first portion being adjacent to at least one loop of the third portion when the connecting line is tightened. 15. The method of claim 11, wherein the first portion comprises at least one loop, the at least one loop of the first portion being adjacent to at least one loop of the third portion when the connecting line is tightened. 16. The method according to any one of claims 8, 9, 12, 14 and 15, wherein the first portion extends from the base portion and the third portion extends from the base portion, the first portion including a region fixedly related to the base portion, and the third portion including a region fixedly related to the base portion. 17. The method of claim 10, wherein the first portion extends from the base portion and the third portion extends from the base portion, the first portion including a region fixedly related to the base portion, and the third portion including a region fixedly related to the base portion. 18. The method of claim 11, wherein the first portion extends from the base portion and the third portion extends from the base portion, the first portion including a region fixedly related to the base portion, and the third portion including a region fixedly related to the base portion. 19. The method of claim 13, wherein the first portion extends from the base portion and the third portion extends from the base portion, the first portion including a region fixedly related to the base portion, and the third portion including a region fixedly related to the base portion. 20. The method according to any one of claims 8, 9, 12, 14, 15 and 17-19, wherein, when the connecting line is taut, the first portion and the third portion extend from the plane where the base portion is positioned. 21. The method of claim 10, wherein, when the connecting line is taut, the first portion and the third portion extend from the plane where the base portion is positioned. 22. The method of claim 11, wherein, when the connecting line is taut, the first portion and the third portion extend from the plane where the base portion is positioned. 23. The method of claim 13, wherein, when the connecting line is taut, the first portion and the third portion extend from the plane where the base portion is positioned. 24. The method of claim 16, wherein, when the connecting line is taut, the first portion and the third portion extend from the plane where the base portion is positioned. 25. The method according to any one of claims 8, 9, 12, 14, 15, 17-19 and 21-24, wherein the first portion corresponds to the forefoot portion of the shoe, and wherein the third portion corresponds to the midfoot portion of the shoe. 26. The method of claim 10, wherein the first portion corresponds to the forefoot portion of the shoe, and wherein the third portion corresponds to the midfoot portion of the shoe. 27. The method of claim 11, wherein the first portion corresponds to the forefoot portion of the shoe, and wherein the third portion corresponds to the midfoot portion of the shoe. 28. The method of claim 13, wherein the first portion corresponds to the forefoot portion of the shoe, and wherein the third portion corresponds to the midfoot portion of the shoe. 29. The method of claim 16, wherein the first portion corresponds to the forefoot portion of the shoe, and wherein the third portion corresponds to the midfoot portion of the shoe. 30. The method of claim 20, wherein the first portion corresponds to the forefoot portion of the shoe, and wherein the third portion corresponds to the midfoot portion of the shoe. 31. The method according to any one of claims 8, 9, 12, 14, 15, 17-19, 21-24 and 26-30, wherein the upper of the footwear article further includes a fourth portion and a fifth portion, the fourth portion and the fifth portion including a third joint side and a fourth joint side, the second connecting line extending between the third joint side and the fourth joint side, wherein when the second connecting line is taut, at least one loop located on the third joint side is adjacent to at least one loop located on the fourth joint side. 32. The method of claim 10, wherein the upper of the footwear article further comprises a fourth portion and a fifth portion, the fourth portion and the fifth portion comprising a third joint side and a fourth joint side, the second connecting line extending between the third joint side and the fourth joint side, wherein, when the second connecting line is taut, at least one loop located on the third joint side is adjacent to at least one loop located on the fourth joint side. 33. The method of claim 11, wherein the upper of the footwear article further comprises a fourth portion and a fifth portion, the fourth portion and the fifth portion comprising a third joint side and a fourth joint side, the second connecting line extending between the third joint side and the fourth joint side, wherein, when the second connecting line is taut, at least one loop located on the third joint side is adjacent to at least one loop located on the fourth joint side. 34. The method of claim 13, wherein the upper of the footwear article further comprises a fourth portion and a fifth portion, the fourth portion and the fifth portion comprising a third joint side and a fourth joint side, the second connecting line extending between the third joint side and the fourth joint side, wherein, when the second connecting line is taut, at least one loop located on the third joint side is adjacent to at least one loop located on the fourth joint side. 35. The method of claim 16, wherein the upper of the footwear article further comprises a fourth portion and a fifth portion, the fourth portion and the fifth portion comprising a third joint side and a fourth joint side, the second connecting line extending between the third joint side and the fourth joint side, wherein, when the second connecting line is taut, at least one loop located on the third joint side is adjacent to at least one loop located on the fourth joint side. 36. The method of claim 20, wherein the upper of the footwear article further comprises a fourth portion and a fifth portion, the fourth portion and the fifth portion comprising a third joint side and a fourth joint side, the second connecting line extending between the third joint side and the fourth joint side, wherein, when the second connecting line is taut, at least one loop located on the third joint side is adjacent to at least one loop located on the fourth joint side. 37. The method of claim 25, wherein the upper of the footwear article further comprises a fourth portion and a fifth portion, the fourth portion and the fifth portion comprising a third joint side and a fourth joint side, the second connecting line extending between the third joint side and the fourth joint side, wherein, when the second connecting line is taut, at least one loop located on the third joint side is adjacent to at least one loop located on the fourth joint side. 38. A method for assembling footwear articles by incorporating knitted components into a shoe upper, the method comprising: The method of claim 1 forms the knitted part in a planar configuration, wherein the second thread is a connecting thread, the first portion is a first outer portion, and the third portion is a second outer portion, the connecting thread includes a first end and a second end, at least one of the first end and the second end being non-fixed; Tighten at least one of the first and second ends of the connecting wire, such that the first and second engagement sides extend toward each other; and The knitted component is incorporated into the upper of the footwear article. 39. The method of claim 38, further comprising securing the first end and the second end of the connecting wire after tightening the connecting wire. 40. The method according to any one of claims 38 to 39, wherein the knitted component further comprises a toe portion and a first inner portion, a second connecting line and a third connecting line, the second connecting line extending between a third engagement side of the first outer portion and a fourth engagement side of the toe portion, and the third connecting line extending between a fifth engagement side of the toe portion and a sixth engagement side of the first inner portion. 41. The method of claim 40, wherein the second connecting line and the third connecting line are taut to form a three-dimensional forefoot portion of the footwear article.