HK1239474B - Article of footwear incorporating a knitted component with integrally knit contoured portion - Google Patents

Description

Articles of footwear containing knitted components with integral knitted outline portions

This application is a divisional application of an application filed on February 28, 2014, with application number 201480025172.2, and invention name “Footwear comprising a woven component with an integral woven contour portion”.

field

The present disclosure relates to an article of footwear, and more particularly to an article of footwear including a knitted component with an integral knitted contour portion.

background

This section provides background information related to the present disclosure which is not necessarily prior art.

Conventional footwear typically includes two main components: an upper and a sole structure. The upper is fixed to the sole structure and forms a cavity on the interior of the footwear for comfortably and securely accommodating the foot. The sole structure is fixed to the lower area of the upper, thereby being positioned between the upper and the ground. In athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole typically includes a polymer foam material that weakens ground reaction forces to reduce pressure on the foot and leg during walking, running, and other ambulatory activities. In addition, the midsole may include a fluid-filled chamber, a plate, a regulator, or other elements that further weaken the force, enhance stability, or affect the movement of the foot. The outsole is fixed to the lower surface of the midsole and provides a ground-engaging portion of the sole structure formed of a durable and wear-resistant material, such as rubber. The sole structure may also include an insole positioned within the cavity and positioned adjacent to the lower surface of the foot to enhance footwear comfort.

The shoe upper generally extends above the instep and toe area of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some footwear articles such as basketball shoes and boots, the shoe upper can extend upward and around the ankle to provide support or protection to the ankle. Generally, an entrance to the cavity inside the shoe upper is provided by an ankle opening in the heel area of the footwear. A lacing system is generally incorporated into the shoe upper to adjust the suitability of the shoe upper, thereby allowing the foot to enter the cavity in the shoe upper and to be removed from the cavity in the shoe upper. The lacing system also allows the wearer to change certain dimensions of the shoe upper, particularly girth, to accommodate feet of different sizes. In addition, the shoe upper may include a tongue that extends under the lacing system to enhance the adjustability of the footwear, and the shoe upper may include a heel stabilizer to limit the movement of the heel.

In the manufacture of shoe uppers, a variety of material elements (e.g., fabric, polymer foam, polymer sheet, leather, synthetic leather) are typically utilized. For example, in sports 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 regions of the shoe upper. In order to impart different properties to different regions of the shoe upper, material elements are typically cut into desired shapes and then typically stitched or glued together. In addition, material elements are typically connected in a layered configuration to impart multiple properties to the same region. As the number and type of material elements incorporated into the shoe upper increase, the time and expense associated with transporting, storing, cutting, and connecting material elements may also increase. As the number and type of material elements incorporated into the shoe upper increase, waste from the cutting and stitching process also accumulates to a greater extent. In addition, shoe uppers with a larger number of material elements may be more difficult to recycle than shoe uppers formed from fewer types and numbers of material elements. Therefore, by reducing the number of material elements used in the upper, waste can be reduced while increasing production efficiency and the recyclability of the upper.

Overview

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

1) Disclosed is an upper for an article of footwear, which is configured to be connected to a sole structure and configured to accommodate a foot. The upper includes a woven component having an integral woven construction. The woven component has a base portion configured to be disposed adjacent to the sole structure. The woven component also includes a heel portion and a forefoot portion extending from opposite ends of the base portion. In addition, the woven component includes a medial portion and a lateral portion extending from opposite sides of the base portion. The medial portion and the lateral portion cooperate to define a throat area between the medial portion and the lateral portion. In addition, the woven component includes a tongue portion configured to be disposed in the throat area. The tongue portion is detached from at least one of the medial portion and the lateral portion. Furthermore, the upper includes a first edge of the woven component and a second edge of the woven component. The second edge is configured to be coupled to the first edge at a seam, resulting in the base portion, the heel portion, the forefoot portion, the medial portion, and the lateral portion cooperatively defining a cavity configured to accommodate a foot.

2) The upper according to 1), wherein the heel portion and the base portion cooperate to define a surface of a heel cavity having a three-dimensional curvature.

3) The upper of 1), wherein the forefoot portion and the base portion cooperate to define a surface of a forefoot cavity having a three-dimensional curvature.

4) The shoe upper according to 1), wherein the tongue portion extends from the base portion.

5) The shoe upper according to 4), wherein a gap is defined between the forefoot portion and one of the medial portion and the lateral portion, and the tongue portion extends from the base portion and is disposed within the gap.

6) The upper according to 1), wherein the woven component includes a first conical area having a first conical boundary and a second conical area having a second conical boundary, the first conical boundary being connected to the second conical boundary to provide a three-dimensional contour surface for the woven component.

7) The upper of 1), wherein the tongue portion includes a curved zone having a plurality of knitted rows radiating from a common area to provide curvature to the curved zone.

8) The shoe upper according to 1), further comprising a tensile cord incorporated into the unitary braided structure, the tensile cord extending across at least one of the base portion, the medial portion, and the lateral portion.

9) The shoe upper according to 8), wherein the tensile cord extends continuously between the base portion and one of the medial portion and the lateral portion.

10) The shoe upper according to 9), wherein the tensile cord extends continuously from the medial portion, through the base portion, to the lateral portion.

11) The shoe upper according to 10), wherein the tensile cords extend alternately between the medial portion and the lateral portion, the tensile cords extending through the base portion as the cords alternate between the medial portion and the lateral portion.

12) The upper of 8), wherein the tensile cord includes a turn configured to receive and support a closure element that selectively secures the upper to a foot.

13) The upper according to 12), wherein one of the medial portion and the lateral portion includes an opening, and the turn portion extends at least partially around the opening, and the opening and the turn portion are configured to cooperatively accommodate and support the closure element.

14) The shoe upper according to 13), wherein the turn portion is exposed from one of the medial portion and the lateral portion.

15) The shoe upper according to 13), wherein the turn portion is enclosed between the outer surface and the inner surface of the one of the medial portion and the lateral portion.

16) The upper of 8), wherein the base portion defines an inner surface of the knitted component and an outer surface of the knitted component, a channel is defined between the inner surface and the outer surface, and wherein the tensile cord extends through the channel.

17) The shoe upper according to 16), wherein a first longitudinal portion of the tensile cord is disposed inside the channel, and a second longitudinal portion of the tensile cord is exposed from the channel.

18) The upper according to 1), wherein the first edge and the second edge are connected by the seam.

19) The upper of 18), wherein the first edge and the second edge are adjacent at the seam.

20) The upper of 19), wherein the seam comprises stitches independent of stitches of the integral knit construction.

21) The upper according to 20), wherein the seam extends continuously from the base portion to at least one of the medial portion, the lateral portion, and the forefoot portion.

22) The upper according to 21), wherein the seam is spaced apart from the heel portion such that the heel portion is seamless.

23) The upper according to 19), wherein the seam is the only seam of the upper.

24) In addition, a method for manufacturing a woven component for an article of footwear is disclosed, the woven component being configured to be connected to a sole structure. The method includes weaving the woven component to have: a base portion configured to be disposed adjacent to a sole, a heel portion and a forefoot portion extending from opposite ends of the base portion, and a medial portion and a lateral portion extending from opposite sides of the base portion. The medial portion and the lateral portion cooperate to define a throat area between the medial portion and the lateral portion. In addition, weaving the woven component includes weaving a tongue portion configured to be disposed in the throat area. The tongue portion is disengaged from at least one of the medial portion and the lateral portion. In addition, the method includes coupling a first edge of the woven component and a second edge of the woven component at a seam, resulting in the base portion, the heel portion, the forefoot portion, the medial portion, and the lateral portion collectively defining a cavity configured to accommodate a foot.

25) The method according to 24), wherein weaving the woven component includes forming a surface of a cavity having a three-dimensional curvature.

26) The method according to 24), wherein coupling the first edge and the second edge together comprises sewing the first edge and the second edge together using stitches.

27) The method according to 24), further comprising extending a tensile cord across at least one of the base portion, the inner portion, and the outer portion.

28) The method according to 27), wherein extending the tensile cord comprises continuously extending the tensile cord from the inner portion, through the base portion, to the outer portion.

29) The method according to 28), wherein extending the rope includes extending the rope alternately between the inner portion and the outer portion.

30) The method of 27), wherein the base portion defines an inner surface of the woven component and an outer surface of the woven component, a channel is defined between the inner surface and the outer surface, and wherein extending the tensile cord comprises extending the cord through the channel.

31) The method according to 24), wherein knitting the woven component includes knitting a first conical region having a first conical boundary and a second conical region having a second conical boundary, the first conical boundary being connected to the second conical boundary to provide the woven component with a three-dimensional contour surface.

32) The method of 24), wherein knitting the knitted component includes knitting the tongue portion to include a curved region having a plurality of knit rows radiating from a common area to provide curvature to the curved region.

33) Furthermore, an upper for an article of footwear is disclosed that is configured to be connected to a sole structure and configured to accommodate a foot. The upper includes a woven component having a base portion configured to be positioned adjacent to the sole structure. The base portion defines an inner surface and an outer surface of the woven component. The base portion defines a base portion channel between the inner surface and the outer surface. Furthermore, the upper includes a tensile cord extending through the base portion channel.

34) An upper according to 33), wherein the woven component further includes a side portion, the side portion further defining the inner surface and the outer surface of the woven component, the side portion defining a side channel between the inner surface and the outer surface, the tensile cord extending continuously between the base portion channel and the side channel and being accommodated in both the base portion channel and the side channel.

35) The upper according to 34), wherein the base portion channel and the side channel are connected to each other so that the tensile cord is embedded in the base portion channel and the side channel as the cord extends continuously between the base portion channel and the side channel.

36) The shoe upper according to 34), wherein the side portion includes a medial portion and a lateral portion extending from opposite sides of the base portion, and the tensile cord extends continuously from the medial portion, through the base portion, to the lateral portion.

37) The upper according to 36), wherein the tensile cord extends alternately between the medial portion and the lateral portion.

38) The upper of 34), wherein the tensile cord includes a turn configured to accommodate and support a closure element that selectively secures the upper to the foot.

39) The upper of claim 38), wherein the side portion includes an opening and the turn extends at least partially around the opening, the opening and the turn being configured to cooperatively accommodate and support the closure element.

40) The upper according to 34), wherein the side portion and the base portion are formed of an integral woven structure.

41) The upper according to 33), wherein the tensile cord is slidably received within the base portion channel.

42) The upper according to 33), wherein the tensile cord is fixedly attached to the base portion.

43) The upper of 42), wherein the tensile cord is a fusible cord configured to be fused to the base portion.

44) The upper of 33), wherein the base portion includes an arch support area configured to extend beneath the arch of a foot, and wherein the tensile cord extends across the arch support area.

45) Additionally, a method of manufacturing a shoe upper configured to be attached to a sole structure and configured to be worn on a foot is disclosed. The method includes knitting a woven component having a base portion configured to be positioned adjacent to the sole structure. The base portion defines an inner surface and an outer surface of the woven component. The base portion defines a base portion channel between the inner surface and the outer surface. The method further includes extending a tensile cord through the base portion channel.

46) The method according to 45), wherein knitting the knitted component further comprises knitting side portions, wherein the side portions further define the inner surface and the outer surface of the knitted component, wherein the side portions define side channels between the inner surface and the outer surface, and wherein extending the tensile cord comprises continuously extending the cord through both the base portion channel and the side channel.

47) A method according to 46), wherein the base portion channel and the side channel are connected to each other, and wherein extending the tensile cord comprises embedding the tensile cord into the base portion channel and the side channel as the tensile cord continuously extends through both the base portion channel and the side channel.

48) The method of claim 46), wherein the side portion comprises an inner portion and an outer portion extending from opposite sides of the base portion, and wherein extending the tensile cord comprises continuously extending the tensile cord from the inner portion, through the base portion, to the outer portion.

49) The method according to 48), wherein extending the tensile cord comprises extending the tensile cord alternately between the inner portion and the outer portion.

50) The method of 49) further comprising forming a turn in the tensile cord, the turn configured to accommodate and support a closure element that selectively secures the upper to the foot.

51) The method of 50), wherein the side portion includes an opening, and wherein forming the bend includes extending the tensile cord at least partially around the opening, the opening and the bend being configured to cooperatively accommodate and support the closure element.

52) The method according to 45), wherein knitting the knitted component includes providing the side portions to have an integral knitted construction with the base portion.

53) The method according to 45) further includes sliding the tensile cord longitudinally through the base portion channel.

54) The method according to 45) further comprises fixedly attaching the tensile cord to the base portion.

55) Additionally, an article of footwear is disclosed, comprising a sole structure and an upper. The upper comprises a woven component having an integral woven construction. The woven component further comprises a base portion configured to be positioned adjacent to the sole structure. The base portion defines an inner surface and an outer surface of the woven component. The base portion defines a base portion channel between the inner surface and the outer surface. Furthermore, the article of footwear comprises a tensile cord extending through the base portion channel.

56) The article of footwear according to 55), wherein the woven component further comprises a side portion extending from the base portion, the side portion further defining at least one of the inner surface and the outer surface, at least one of the inner surface and the outer surface having a three-dimensional contour so as to define a cavity in the woven component.

57) The article of footwear according to 56), wherein the side portion defines a side channel between the inner surface and the outer surface, and the tensile cord extends continuously between and is accommodated in both the base portion channel and the side channel.

58) The article of footwear according to 57), wherein the side portion includes a medial portion and a lateral portion, and wherein the tensile cord extends continuously between the base portion, the medial portion and the lateral portion.

59) The article of footwear according to 56), wherein the woven component further comprises a first edge and a second edge, the second edge being configured to be connected to the first edge at a seam, causing the base portion and the side portion to cooperatively define a cavity configured to accommodate a foot.

60) The article of footwear according to 59), wherein the side portion includes a heel portion and a forefoot portion extending from opposite ends of the base portion, a medial portion and a lateral portion extending from opposite sides of the base portion, and a tongue portion configured to be disposed in a throat defined between the medial side and the lateral side.

Further areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Attached photos

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG1 is a perspective view of an article of footwear according to an exemplary embodiment of the present disclosure;

FIG2 is a perspective view of the article of footwear of FIG1 with the closure member removed;

FIG3 is an exploded perspective view of the article of footwear of FIG2 ;

FIG4 is a perspective view of a knitted component having an inlaid cord of the article of footwear of FIG1 ;

FIG5 is a top plan view of the knitted component of FIG4;

FIG6 is a bottom plan view of the knitted component of FIG4 , with the footprint shown in phantom;

FIG7 is a cross-sectional view of the knitted component taken along line 7-7 of FIG6;

FIG8 is a schematic diagram of the heel portion of the knitted component taken from the perspective of line 8-8 of FIG5;

FIG9 is a detailed view of a portion of the knitted component taken from FIG6;

10 and 11 are bottom plan views of the knitted component, wherein FIG. 10 shows the closure member in an unsecured position and FIG. 11 shows the closure member in a secured position;

12 is a bottom view of a knitted component having inlaid cord according to additional embodiments of the present disclosure;

13 and 14 are schematic diagrams of an integral braided construction with inlaid cord; and

15-23 are perspective schematic illustrations of portions of a flat knitting machine shown during the formation of an integral knit construction with inlaid cord.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

Details

Example embodiments will now be described more fully with reference to the accompanying drawings.

General discussion of footwear

1-3 , an article of footwear 100 is shown according to an exemplary embodiment. Generally, article of footwear 100 may include a sole structure 110 and an upper 120.

The sole structure 110 is fixed to the upper 120 and extends between the foot and the ground when the footwear 100 is worn. The sole structure 110 may include a midsole 112 and an outsole 114 layered on top of each other. The midsole 112 may include an elastically compressible material, a fluid-filled bladder, and the like. Thus, when running, jumping, etc., the midsole 112 can cushion the wearer's foot and attenuate impact and other forces. The outsole 114 may be fixed to the midsole 112 and may include a wear-resistant material, such as rubber or the like. The outsole 114 may also include a tread and other traction-enhancing features.

Furthermore, upper 120 may define a cavity 122 for receiving a wearer's foot. In other words, upper 120 may define an inner surface 121 that defines cavity 122, and upper 120 may define an outer surface 123 that faces in an opposite direction from inner surface 121. When a wearer's foot is received within cavity 122, upper 120 may at least partially surround and encase the wearer's foot.

Many conventional footwear uppers are formed from multiple material elements (e.g., fabric, polymer foam, polymer sheet, leather, synthetic leather) connected, for example, by stitching or bonding. In contrast, at least a portion of upper 120 is formed from a woven component 116 having an integrally woven construction. The outer boundary of woven component 116 can be defined by a peripheral edge 199 shown in Figures 5 and 6. As will be discussed, woven component 116 can define at least a portion of a cavity within upper 120. Additionally, woven component 116 can define at least a portion of an exterior surface 123 and/or interior surface 121 of upper 120.

In some embodiments, knitted component 116 may define a majority of upper 120. Reducing the number of material elements used to form upper 120 can reduce waste while also increasing manufacturing efficiency and recyclability of upper 120. As discussed in more detail below, knitted component 116 of upper 120 of the present disclosure can reduce waste and increase manufacturing efficiency and recyclability. Additionally, knitted component 116 of upper 120 can include a smaller number of seams or other discontinuities, thereby enhancing the overall comfort of footwear 100.

Braided component 116 can also have common properties when formed from the same rope, yarn (or type of yarn) or having a similar braid structure. For example, using the same rope in various parts of braided component 116 can impart similar durability, strength, stretchability, abrasion resistance, biodegradability, thermal and hydrophobic properties. In addition to physical properties, using the same rope in multiple parts of braided component 116 can impart common aesthetic or tactile properties, such as color, sheen and texture. Using the same braid structure across different parts of braided component 116 can also impart common physical and aesthetic properties.

Braided component construction

Figures 4-6 illustrate various embodiments of knitted component 116 that can be incorporated into an article of footwear in a manner similar to the exemplary embodiment of Figures 1 to 3. Knitted component 116 shown in Figures 4-6 is depicted as being separated from the remainder of footwear 100. However, it should be understood that each of the embodiments of knitted component 116 described herein can be combined with the elements of footwear 100 described above to form an article of footwear 100 that includes knitted component 116.

Knitted component 116 can be of "unitary knit construction". As defined herein and used in the claims, the term "unitary knit construction" means that knitted component 116 is formed as a one-piece element by a knitting process. That is, the knitting process generally forms the various features and structures of knitted component 116 without requiring significant additional manufacturing steps or processes. Unitary knit construction can be used to form a knitted component having a structure or element that includes one or more courses of yarn or other knitted material that are connected so that the structure or element includes at least one common course (i.e., shares a common strand or common yarn) and/or includes a course that is generally continuous between each portion of knitted component 116. Using this arrangement, a one-piece element of unitary knit construction is provided.

Although portions of knitted component 116 may be connected to one another after the knitting process, knitted component 116 remains formed of unitary knit construction because it is formed as a one-piece knit element. Furthermore, when other elements (e.g., inlay cord, closure elements, logos, trademarks, labels with instructions for use and material information, and other structural elements) are added after the knitting process, knitted component 116 remains formed of unitary knit construction.

4-6 illustrate exemplary embodiments of a woven component 116 defining a majority of an upper 120 of an article of footwear 100. As shown, the woven component 116 of the upper 120 can include a base portion 124 or a strobel portion or an underfoot portion. In addition, the woven component 116 can include one or more side portions 126. The base portion 124 can be configured to be disposed adjacent to the sole structure 110. For example, the base portion 124 can be attached directly or indirectly to the sole structure 110 so that the base portion 124 is located above the sole structure 110. In another embodiment, one or more portions of the base portion 124 (such as the periphery of the base portion 124) can be attached to the sole structure 110 when other portions remain separated or disengaged. Furthermore, the base portion 124 can be configured to extend under the wearer's foot. The side portions 126 can extend from the base portion 124 and can be configured to at least partially cover the wearer's foot. Furthermore, the base portion 124 and the side portions 126 can jointly define a cavity 122 for accommodating the wearer's foot. Furthermore, the base portion 124 and the side portions 126 may be formed of a unitary woven construction as discussed above.

As shown in the illustrated embodiment, side portion 126 of knitted component 116 may include a heel portion 128, a lateral portion 130, a medial portion 132, a forefoot portion 134, and a tongue portion 136, each of which is formed from the same unitary knit construction as base portion 124. Thus, knitted component 116 can fit snugly and conform to the wearer's foot. Moreover, due to this construction, knitted component 116 can be formed relatively quickly to increase manufacturing efficiency.

6 and as will be discussed in detail, knitted component 116 may include one or more tensile cords 158 integrated with the overall knit construction of knitted component 116. For example, cords 158 may be inlaid within the courses and/or wales of knitted component 116, as will be discussed. Furthermore, cords 158 may be attached to the interior and/or exterior surfaces of knitted component 116.

Cord 158 may be disposed within the shoe upper to extend across the sides and/or under the wearer's foot. Furthermore, cord 158 may be operatively coupled to closure member 154, such as shoelace 155. Thus, tightening shoelace 155 may in turn tighten cord 158. As a result, cord 158 may provide support for the wearer's foot for increased comfort and a better fit.

The illustrated embodiment of upper 120 and footwear 100 is configured to be worn on a wearer's left foot. However, it should be understood that footwear 100 can be configured to be worn on a right foot and can include similar features to the illustrated embodiment.

Footwear 100 can also be configured as a running shoe. However, footwear 100 can also be applied to a variety of other athletic shoe types, including, for example, baseball shoes, basketball shoes, cycling shoes, rugby shoes, tennis shoes, soccer shoes, training shoes, walking shoes, and hiking boots. The concepts can also be applied to types of footwear typically considered non-athletic, including dress shoes, loafers, sandals, and work boots. Thus, the concepts disclosed with respect to footwear 100 are applicable to a variety of footwear types.

Exemplary Features of Knitted Components

13 , the primary elements of knitted component 116 can be formed from at least one yarn 1138 or other strand that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshing loops defining a plurality of courses and wales. While yarn 1138 forms each of the courses and wales in this configuration, additional yarns may form one or more of the courses and/or wales.

The characteristic that a particular type of yarn will impart to the region of a woven component depends in part on the material forming the multiple filaments and fibers in 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 recyclability. Rayon provides high gloss and hygroscopicity. Wool, in addition to providing thermal insulation properties and biodegradability, also provides high hygroscopicity. Nylon is a durable and wear-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability.

Another example of a suitable structure for a portion of knitted component 116 is depicted in Figure 14. In this structure, knitted component 116 includes yarn 1138 and another yarn 1139 (i.e., multiple ropes). Yarns 1138 and 1139 are plated and together form a plurality of intermeshing loops defining multiple horizontal rows and vertical wales. In other words, yarns 1138 and 1139 extend parallel to each other. The advantage of this structure is that the performance of each of yarns 1138 and 1139 can be presented in this area of knitted component 1130. For example, yarns 1138 and 1139 can have different colors, wherein the color of yarn 1138 is mainly presented on the front of the different stitches in knitted element 1131, while the color of yarn 1139 is mainly presented on the back of the different stitches in knitted element 1131. As another example, yarn 1139 can be formed from a yarn that is softer and more comfortable against the foot than yarn 1138, where yarn 1138 is primarily present on first surface 1136 and yarn 1139 is primarily present on second surface 1137.

Moreover, as shown in Figures 13 and 14, rope 1132 can be incorporated into the overall braided construction of woven component 116. Rope 1132 can be a tensile rope element that provides support for woven component 116. In other words, the tension in rope 1132 can allow woven component 116 to resist deformation, stretching, or otherwise provide support for the wearer's foot during running, jumping, or other movements of the wearer's foot. Moreover, it should be understood that rope 158 of Figure 6 (mentioned above and described in detail below) can be incorporated into woven component 116 similar to rope 1132 of Figures 13 and 14.

As will be discussed, cord 1132 can be incorporated or inlaid into the overall knit construction of knitted component 116 such that cord 1132 can be incorporated during the knitting process on a knitting machine. For example, cord 1132 can be inlaid within the overall knit construction such that cord 1132 extends along one of the courses and/or wales of knitted component 116 as shown in Figures 13 and 14. As shown in Figures 13 and 14, cord 1132 can alternate between being (a) behind the loop formed by yarn 1138 and (b) in front of the loop formed by yarn 1138. In effect, inlaid strand 1132 is woven through the overall knit construction of knit element 1131.

The woven component can also include one or more ropes or yarns formed by at least one of a thermosetting polyester material and a natural fiber (e.g., cotton, wool, silk). Other yarns or ropes can be formed by thermoplastic polymer materials. Generally speaking, thermoplastic polymer materials melt when heated and return to a solid state when cooled. More specifically, thermoplastic polymer materials transition from a solid state to a softened state or liquid state when subjected to sufficient heat, and then the thermoplastic polymer materials transition from a softened state or liquid state to a solid state when sufficiently cooled. In this way, thermoplastic polymer materials are often used to combine two objects or elements together. In this case, the yarn can be used for example, (a) connecting a part of the yarn to another part of the yarn, (b) connecting the yarn and the inlaid thread to each other, or (c) connecting another element (e.g., a logo, a trademark, and a label with instructions and material information) to the woven component. In this way, the yarn can be considered as a fusible yarn, assuming that it can be used to fuse the parts of the woven component or otherwise connect the parts of the woven component to each other. Moreover, a yarn may be considered to be a non-fusible yarn if it is not formed of a material that would normally allow portions of a knitted component to fuse or otherwise connect portions of the knitted component to one another. That is, a yarn may be a non-fusible yarn while other yarns may be fusible yarns. In some configurations of knitted components, the yarn (i.e., the non-fusible yarn) may be substantially formed of a thermosetting polyester material, and the yarn (i.e., the fusible yarn) may be at least partially formed of a thermoplastic polymer material.

The use of binding yarns gives the braided component advantages. When the yarn is heated and fused to the yarn and inlaid yarn, this process can have the effect of hardening or solidifying the structure of the braided component. Moreover, (a) connecting one part of the yarn to another part of the yarn or (b) connecting the yarn and the inlaid yarn to each other has the effect of fixing or locking the relative positions of the yarn and the inlaid yarn, thereby imparting tensile resistance and hardness. That is, the parts of the yarn can not slide relative to each other when fused to the yarn, thereby preventing bending or permanent stretching of the braided element caused by the relative movement of the braided structure. Another benefit relates to limiting unraveling if a part of the braided component becomes damaged or one of the yarns is disconnected. Therefore, areas of the braided component can benefit from the use of fusible yarns and non-fusible yarns within the braided element.

In addition, it should be understood that the woven component can have different areas that together form an integral woven structure. For example, the woven component can include a combination of at least two of the following: a flat woven area, a tubular woven area, a 1×1 mesh woven area, a 2×2 mesh woven area, a 3×2 mesh woven area, a 1×1 simulated mesh woven area, a 2×2 simulated mesh woven area, a 2×2 hybrid woven area, a full gauge knit zone, a 1/2 gauge knit zone, etc. Therefore, the woven component 116 and the upper 120 can be constructed according to the teachings of U.S. Patent Application No. 2012/0233882 published on September 20, 2012, and the application is incorporated herein by reference in its entirety.

Implementation of upper and knitted components

Various embodiments for forming upper 120 and knitted component 116 will now be discussed in greater detail.As shown, upper 120 may define longitudinal direction 125, lateral direction 127, and vertical direction 129 for reference to various features of upper 120 in the following discussion.

As mentioned above, the woven component 116 of the upper 120 can include a base portion 124 configured to be arranged below the wearer's foot. The outline of the wearer's foot is shown in Figure 6 so that the base portion 124 is at least generally limited relative to the wearer's foot. Thus, the base portion 124 can extend continuously below one or more parts of the heel, sole, toe, arch of the foot and/or other lower surfaces of the wearer's foot. In other embodiments, the base portion 124 can include an opening to partially or discontinuously extend below the wearer's foot.

Knitted component 116 may also include various side portions 126 that extend circumferentially from base portion 124. Side portions 126 may be configured to overlie and rest against at least a portion of a wearer's foot. In the illustrated embodiment, side portions 126 of knitted component 116 may generally surround base portion 124. Moreover, it should be understood that base portion 124 and side portions 126 may collectively define an interior surface 121 of knitted component 116 and an exterior surface 123 of knitted component 116.

For example, side portion 126 may include a heel portion 128 disposed on one end of base portion 124. As shown in Figure 4, heel portion 128 may also extend upward from base portion 124 in a vertical direction 129. Heel portion 128 may be configured to overlie the heel and/or ankle area of a wearer's foot.

4 , side portion 126 of knitted component 116 may also include a lateral portion 130 that is disposed forwardly relative to heel portion 128 and may extend upwardly from a lateral side of base portion 124. Lateral portion 130 may be configured to overlie and rest against at least a portion of a wearer's foot.

Additionally, lateral portion 126 of knitted component 116 may include medial portion 132 disposed on an opposite side of base portion 124 relative to lateral portion 130 and forward of heel portion 128. As shown in FIG4 , medial portion 132 may also extend upward from base portion 124 in vertical direction 129. Medial portion 132 may be disposed on an opposite side of base portion 124 in lateral direction 127. Medial portion 132 may be configured to overlie and rest against a medial area or instep of a wearer's foot.

Heel portion 128, lateral portion 130, and medial portion 132 may collectively define a horseshoe-shaped collar 133 of upper 120. Collar 133 may provide access to and exit from cavity 122 of upper 120. Furthermore, lateral edge 135 of lateral portion 130 and medial edge 137 of medial portion 132 may collectively define a throat 131 of upper 120. Throat 131 may extend generally parallel to longitudinal direction 125, or throat 131 may be angled relative to longitudinal direction 125. Furthermore, while throat 131 is generally centered above base portion 124 in the embodiment of FIG. 4 , throat 131 may be positioned to one side relative to base portion 124 in lateral direction 127. As will be discussed, the width of throat 131 can be selectively varied by closure member 154 to move lateral edge 135 and medial edge 137 toward and away from each other. As a result, footwear 100 can be selectively tightened and loosened about the wearer's foot.

In addition, the side portion 126 of the knitted component 116 may include a forefoot portion 134. As shown in FIG1 , the forefoot portion 134 may be disposed on the opposite end of the base portion 124 relative to the heel portion 128 and in front of the lateral portion 130 and the medial portion 132 in the longitudinal direction 125. Moreover, the forefoot portion 134 may be integrally connected to the lateral portion 130 or the medial portion 132, and the forefoot portion 134 may be spaced apart from the other. In the illustrated embodiment, for example, the forefoot portion 134 is integrally connected to the lateral portion 130 and spaced apart from the medial portion 132. Therefore, when the upper 120 is in the disassembled state as shown in FIG4 , a gap 139 may be defined between the forefoot portion 134 and the medial portion 132.

Furthermore, side portion 126 of knitted component 116 may include tongue portion 136. As shown in FIG. 4 , tongue portion 136 may include a curved zone 143 and a longitudinal zone 145. When upper 120 is disassembled as shown in FIG. 4 , tongue portion 136 may extend generally forward from base portion 124, and curved zone 143 may be positioned within gap 139 between medial portion 124 and forefoot portion 139. As shown in FIG. 4 , curved zone 143 may also be curved such that longitudinal zone 145 extends generally rearward and at angle 143 relative to medial portion 132. As shown in FIG. 5 , the curvature of curved zone 143 may be achieved by having knitting courses that generally radiate from a common region 151. Common region 151 may be a virtual point spaced from the perimeter of curved zone 143 between tongue portion 136 and medial portion 132, as shown, or common region 151 may be positioned elsewhere. Furthermore, when upper 120 is assembled, flexure region 143 can wrap upward to at least partially fill gap 139, and longitudinal region 145 of tongue portion 136 can be positioned within throat 131 of upper to overlie the wearer's foot between lateral portion 130 and medial portion 132. Furthermore, as shown in FIG3 , longitudinal region 145 of tongue portion 136 can be separated and disengaged from lateral portion 130 and/or medial portion 132 when upper 120 is assembled.

As shown in Figures 4, 5 and 6, the base portion 124 and the heel portion 128 can define a heel cavity 148 (see Figure 6) configured to accommodate the heel of the wearer's foot. The heel cavity 148 can have an inner surface and/or an outer surface with a three-dimensional curvature. Moreover, the heel cavity 148 can have a convex outer surface. Thus, when the heel portion 128 extends from the base portion 124 in the vertical direction 129, the heel portion 128 can be slightly bent forward in the longitudinal direction 125. Moreover, when the heel portion 128 extends in the lateral direction 127, the two sides of the heel portion 128 can be bent forward in the longitudinal direction 125 to connect to the lateral portion 130 and the medial portion 132. Therefore, the heel cavity 148 can conform to and approximately correspond to the shape of the wearer's heel and ankle.

In addition, as shown in Figures 4, 5 and 6, the base portion 124 and the forefoot portion 134 can define a forefoot cavity 150 (see Figure 6) configured to accommodate the toes and other forefoot areas of the wearer's foot. The forefoot cavity 150 can have an inner surface and/or outer surface with a three-dimensional curvature. Moreover, the forefoot cavity 150 can have a convex outer surface. Thus, when the forefoot portion 134 extends from the base portion 124 in the vertical direction 129, the forefoot portion 134 can bend backward in the longitudinal direction 125. Moreover, when the forefoot portion 134 extends in the lateral direction 127, the forefoot portion 134 can bend backward in the longitudinal direction 125 to connect to the lateral portion 130.

The three-dimensional curvature of heel cavity 148 and/or forefoot cavity 150 may be formed due to the unitary knit construction of knitted component 116. For example, as shown in FIG8 , heel portion 128 may include at least two tapered areas 170, 171. Tapered areas 170, 171 may have a generally tapered boundary 173 in lateral direction 127, as indicated by the dashed lines. Each of tapered areas 170, 171 may have a plurality of courses or rows of stitches; however, consecutive courses may have different lengths to provide the tapered shape of boundary 173. Thus, tapered areas 170, 171 may have an eye shape, a two-dot ellipse shape, a biconvex shape, or a crescent shape.

Furthermore, boundary 173 of tapered zone 170 is connected to boundary 173 of tapered zone 171 in a unitary knit construction to provide knitted component 116 with a three-dimensional curvature. This can create a visually apparent distortion along joint boundary 173. The distortion can be a so-called fully formed marker extending along joint boundary 173 of knitted component 116.

In the embodiment of FIG8 , there are multiple tapered areas that are connected along their respective boundaries so that the tapered areas extend from the shoe collar 133 to the base portion 124, and a majority of the heel portion 128 includes these tapered areas. Thus, a majority of the heel portion 128 can have a three-dimensional curvature. However, it should be understood that the woven component 116 can include any number of tapered areas 170, 171 on any portion of the woven component 116 to provide the woven component 116 with a three-dimensional curvature. Moreover, the tapered areas 170, 171 can be oriented in any suitable direction on the woven component 116. For example, the forefoot portion 134 can similarly include tapered areas; however, in an exemplary embodiment, these tapered areas can be tapered in the vertical direction 129.

Flex zone 143 of tongue portion 136 may also include multiple tapered regions that provide flex zone 143 with a curvature. For example, flex zone 143 may include tapered regions 193, 195 that are integrally knitted together and connected along boundary 197. This may create a visually noticeable distortion along joint boundary 197. The distortion may be a so-called fully formed marker extending along joint boundary 197 in knitted component 116. Thus, as mentioned above, the courses within flex zone 143 may radiate from common area 151 to provide a two-dimensional curvature.

Furthermore, in some embodiments, forefoot portion 134 can include a plurality of openings 152 arranged to assist in increasing the curvature of forefoot portion 134. In the illustrated embodiment, plurality of openings 152 can include one or more rows of through holes. Because openings 152 reduce the amount of braided material in these areas of forefoot portion 134, forefoot portion 134 can more easily bend rearward toward heel portion 128.

Knitted component 116 may further include at least two edge portions 140, 142 configured to be connected together when upper 120 is assembled. It should be understood that first edge portion 140 may be a first longitudinal segment of larger peripheral edge 199 of knitted component 116 shown in Figures 5 and 6. It should be understood that second edge portion 142 may be a second longitudinal segment of peripheral edge 199. Edge portions 140, 142 may be defined at any suitable location along peripheral edge 199 and/or at any location on knitted component 116. As shown in Figures 5 and 6, first edge portion 140 may extend along a bend 143 of tongue portion 136 and may also extend partially through base portion 124 in a lateral direction 127, proximate to forefoot portion 134. Second edge portion 142 may bend along forefoot portion 134 in a generally lateral direction 127 and may extend downwardly along forefoot portion 134 in a vertical direction 129 to partially define gap 139. As shown in FIG. 4 , the first edge 140 and the second edge 142 may also meet at a notch 141 defined within the base portion 124 .

As mentioned above, footwear 100 may further include closure member 154, shown in Figure 1. Closure member 154 may selectively secure upper 120 to the wearer's foot and selectively release upper 120 from the wearer's foot.

1 , closure member 154 may be a lace 155. Thus, lateral portion 130 may include one or more lateral closure openings 156, such as through-holes, arranged in a row extending along lateral edge 135. Medial portion 132 may include similar medial closure openings 157 arranged in a row extending along medial edge 137. Openings 156, 157 may accommodate lace 155 such that lace 155 may crisscross, zigzag, and alternate between lateral portion 130 and medial portion 132.

It should be understood that openings 156, 157 may be configured differently than as through-holes as shown in Figure 1. For example, openings 156, 157 may be defined by loops, eyelets, hooks, and other suitable features configured to receive closure members and either integrated into knitted component 116 or removably attached thereto.

Moreover, it should be understood that the closure member 154 may include structures other than the lace 155 without departing from the scope of the present disclosure. For example, the closure member 154 may be a strap, a spring band, a velvet strap, or other closure member.

Furthermore, as shown in FIG6 , upper 120 may include at least one tensile cord 158 coupled to base portion 124 and/or side portion 126. Cord 158 may be coupled to any portion of base portion 124 and/or side portion 126. Furthermore, cord 158 may be coupled to base portion 124 and/or side portion 126 in any suitable manner. For example, as will be discussed, cord 158 may be embedded within the courses and/or wales of the integral braided construction of base portion 124 and side portion 126. Thus, cord 153 may correspond to cord 1132 described above and shown in FIG13 and FIG14 . Cord 158 may also be bonded, fastened, pierced, or otherwise coupled to inner surface 121 or outer surface 123 of base portion 124 and/or side portion 126.

The cord 158, knitted component 116, and upper 120 may incorporate one or more of the teachings of commonly owned U.S. patent application serial number 12/338,726, entitled “Article of Footwear Having An Upper Incorporating A Knitted Component,” filed on December 18, 2008, and published as U.S. patent application publication number 2010/0154256 on June 24, 2010, to Dua et al., and U.S. patent application serial number 13/048,514, entitled “Article Of Footwear Incorporating A Knitted Component,” filed on March 15, 2011, and published as U.S. patent application publication number 2012/0233882 on September 20, 2012, to Huffa et al., both of which are incorporated herein by reference in their entirety (collectively referred to herein as the “Inlaid Cord Case”).

Rope 158 can be elongated and flexible. Moreover, rope 158 can include at least one yarn, cable, wire, string, rope, silk, fiber, line, rope and the like. Moreover, rope 158 can be formed by rayon, nylon, polyester, polyacrylic acid, silk, cotton, carbon, glass, aramid (for example, para-aramid fiber and meta-aramid fiber), ultra-high molecular weight polyethylene, liquid crystal polymer, copper, aluminum, steel or other suitable materials. The single filament utilized in rope 158 can be formed by a single material (that is, single component filament) or by multiple materials (that is, bicomponent filament). Similarly, different filaments can be formed by different materials. As an example, the yarn used as rope 158 can include the filament formed by a common material respectively, can include the filament formed by two or more different materials respectively, or can include the filament formed by two or more different materials respectively. Similar concepts can also be applied to lines, cables, ropes, etc. The thickness (diameter) of rope 158 can be, for example, in the range of from about 0.03 mm to 5 mm. Furthermore, the cord 158 may have a generally circular cross-section, an oval cross-section, or any other shaped cross-section.

As an example, the rope 158 can be formed from a bonded nylon 6.6 having a breaking strength or tensile strength of 3.1 kg and a weight of 45 tex. The rope 158 can also be formed from a bonded nylon 6.6 having a breaking strength or tensile strength of 6.2 kg and a weight of 45 tex. As another example, the rope 158 can have an outer sheath that surrounds and protects the inner core.

In some embodiments, the cord 158 can have a fixed length (eg, can be inextensible). Also, in some embodiments, the cord 158 can be resiliently extensible.

Additionally, in some embodiments, cord 158 can include a thermoplastic material configured to be bonded, joined, or fused to base portion 124 and/or side portion 126 of upper 120. For example, selective application of heat can cause the material in cord 158 to fuse to the material of base portion 124 and/or side portion 126. Thus, cord 158 can be included in accordance with the teachings of U.S. Patent Application No. 2012/0233882, published on September 20, 2012, and incorporated herein by reference in its entirety.

As shown in the embodiment of Fig. 6, upper 120 can include a single strand rope 158 extending continuously between medial portion 132, base portion 124 and lateral portion 130. In addition, rope 158 can include one or more turns 159, 160. Turns 159, 160 can be one hundred and eighty degree turns or larger. Specifically, rope 158 can include a plurality of lateral turns 159 arranged in a row along lateral edge 135, and rope 158 can include a plurality of medial turns arranged in a row along medial edge 137. Rope 158 can also extend straightly between pairs of turns 159, 160. In addition, rope 158 can include a first end 164 provided by adjacent heel portion 128, and rope 158 can include a second end 166 provided by adjacent forefoot portion 134. Rope 158 can also extend and zigzag alternately between lateral portion 130 and medial portion 132.

In addition, as shown in Figures 6 and 7, woven component 116 can define channel 162 between inner surface 121 and outer surface 123. Channel 162 can be defined in any suitable manner. For example, in the embodiment in which rope 158 is embedded in woven component 116, channel 162 can be defined by one or more rows or wales of woven component 116. Moreover, in some embodiments, inner surface 121 can be defined by a woven material layer, and outer surface 123 can be defined by a separated woven material layer, and multiple ropes, silk or monofilaments can extend between these layers and provide intervals (for example, so-called "spacer woven material") between these layers. In these embodiments, channel 162 can be defined between the woven material layers and among multiple spacer ropes. In other embodiments, inner surface 121 and outer surface 123 can be interconnected suture surfaces, and channel 162 can be defined between these surfaces.

6 , upper 120 may define a plurality of channels 162, and each channel 162 may extend continuously between lateral portion 130, base portion 124, and medial portion 132. In the illustrated embodiment, each channel 162 extends partially through lateral portion 130 (lateral channel), partially through base portion 124 (base portion channel), and partially through medial portion 132 (medial channel), such that channel 162 is continuous between lateral portion 130, base portion 124, and medial portion 132. However, it should be understood that one or more channels 162 may be located on any portion of upper 120 and isolated on any portion of upper 120.

7 , the cord 158 may be housed within and may extend longitudinally within the one or more channels 162 so as to extend between the lateral portion 130, the base portion 124, and the medial portion 132. Furthermore, the turns 159, 160 of the cord 158 may be exposed from the channels 162.

Lateral turn 159 can extend at least partially around a corresponding one of lateral closed openings 156, and medial turn 160 can extend at least partially around a corresponding one of medial closed openings 157. Furthermore, as shown in FIG1 , shoelace 155 can be accommodated within corresponding pairs of lateral closed openings 156 and lateral turn 159, and shoelace 155 can be accommodated within corresponding pairs of medial closed openings 157 and medial turn 160. In other words, each pair of lateral turn 159 and lateral closed opening 156 can collectively accommodate and support shoelace 155, and each pair of medial turn 160 and medial closed opening 157 can also accommodate and support shoelace 155.

In some embodiments, the cord 158 can be loosely and movably received within the corresponding channel 162. For example, the cord 158 can slide longitudinally through the channel 162. Thus, as shown in Figure 9, the turns 159, 160 can be pulled closer to the corresponding closed openings 156, 157. In other embodiments, the first end 164 and/or the second end 166 of the cord 158 can be fixed (e.g., fused) to the base portion 124, while the remainder of the cord 158 can remain movable relative to the base portion 124, the outer portion 130, and the inner portion 132. In still other embodiments, the portion of the cord 158 between the ends 164, 166 can be fused or otherwise fixed to the base portion 124, the outer portion 130, and the inner portion 132.

Additionally, tightening the lace 155 can further increase the tension in the cord 158. For example, as shown in FIG10 , when the lace 155 is loose and in an unsecured position, the tension in the cord 158 can be relatively low, allowing the upper 120 to fit loosely around the wearer's foot. However, when the lace 155 is pulled and tightened as indicated by arrows 174 and 175, the lace 155 can pull on the turns 159 and 160 to increase the tension in the cord 158. As a result, the cord 158 can be pulled closer to the wearer's foot and conform to the upper 120 as indicated by arrows 176, 177, 178, and 179 in FIG11 .

It should be understood that in the embodiments shown in Figures 10 and 11, the cord 158 can provide support for various areas on the bottom of the wearer's foot. For example, the cord 158 can be disposed on the arch area 164, which is configured to be disposed under the arch of the wearer's foot. Thus, the cord 158 within the arch area 164 can support the wearer's arch, particularly when the cord 158 is tightened by the shoelace 155.

It should also be understood that, in the illustrated embodiment, upper 120 may include only one continuous cord 158 for providing such support to the foot. Thus, the number of parts of upper 120 may be relatively low, and upper 120 may be constructed in an efficient manner.

Footwear assembly

The assembly of footwear 100, knitted component 116, and upper 120 will now be discussed according to an exemplary embodiment. For clarity, it will be assumed that knitted component 116 and cord 158 have been formed into the disassembled state shown in Figures 5 and 6.

To begin assembling the exemplary embodiment of upper 120, lateral portion 130 and medial portion 132 can be moved (folded) upward to the position shown in FIG4 . Tongue portion 136 can then be rolled upward so that curved region 143 substantially fills gap 139 and longitudinal region 145 substantially fills throat 131 . Thus, first edge portion 140 and second edge portion 142 can be positioned directly adjacent to one another. First edge portion 140 and second edge portion 142 can then be joined at seam 144 .

The first edge portion 140 and the second edge portion 142 can be joined in any suitable manner at the seam 144. For example, the first edge portion 140 and the second edge portion 142 can be joined using stitching, adhesives, tapes, bonding, welding, fasteners, or other suitable attachment devices.

In some embodiments, seam 144 can be formed by sewing edge portions 140, 142 together using stitches 146, as shown in Figures 1-3. As mentioned above, upper 120 can be a woven element having multiple stitches; however, it should be understood that stitches 146 can be independent of the stitches of woven component 116. In other words, stitches 146 can be formed using one or more threads, yarns, cables, or other cords that are attached after woven component 116 has been woven. Stitches 146 can also be zigzag stitches or other suitable stitches. In addition, edge portions 140, 142 can abut at seam 144. For example, edge portions 140, 142 can form a butt joint, or edge portions 140, 142 can partially overlap to form seam 144. In addition, edge portions 140, 142 can be slightly spaced apart at seam 144 by using a bead of adhesive or other material between edge portions 140, 142 at seam 144.

Moreover, seam 144 can extend through any suitable portion of knitted component 116. For example, in the embodiment of FIG. 3 , seam 144 can include a first end 147 disposed in base portion 124 proximate to forefoot portion 134. Seam 144 can also include a second end 149 at the junction of lateral edge 135, forefoot portion 134, and tongue portion 136. Moreover, in some embodiments, seam 144 can extend continuously between first end 147 and second end 149. For example, seam 144 can include a first portion 181 extending in a generally lateral direction 127 from first end 147 through base portion 124 toward medial portion 132. Seam 144 can also include a second portion 183 extending in a generally vertical direction 129 through medial portion 132 and proximate to forefoot portion 134. Seam 144 may further include a third portion 185 that extends in a generally lateral direction toward lateral portion 130 and that curves rearwardly toward second end 149. Thus, seam 144 may extend continuously between ends 147, 149 to extend from an area beneath the wearer's foot, around the medial side of the wearer's foot, to an area above the wearer's foot.

Furthermore, there may be any number of seams 144 of knitted component 116. As shown in the embodiment of Figure 3 , for example, there may be only one, single seam 144 necessary to impart the three-dimensional shape of Figures 1-3 to knitted component 116 of upper 120. This may facilitate manufacturing and shorten assembly time of upper 120.

Moreover, seam 144 can be spaced apart from heel portion 128 so that heel portion 128 is seamless. Thus, even if heel portion 128 shifts on the wearer's heel, the relatively smooth and seamless heel portion 128 is unlikely to rub against the wearer's heel and provide discomfort to the wearer.

Subsequently, lace 155 can be passed through lateral opening 156 and medial opening 157 as well as lateral turn 159 and medial turn 160 as discussed above. Next, sole structure 110 can be attached to upper 120. Specifically, midsole 112 can be attached to outer surface 123 of base portion 124, and outsole 114 can be attached to midsole 112. In further embodiments, an additional sockliner can be inserted over and/or attached to inner surface 121 of base portion 124.

Additional Embodiments of Knitted Components and Uppers

12 illustrates an additional embodiment of knitted component 116 of upper 220. Except as discussed, knitted component 116 and upper 220 may be substantially similar to knitted component 116 and upper 120 described above.

Similar to the above-described embodiments, upper 220 may include cords 258 that extend alternately through medial portion 232, base portion 224, and lateral portion 230. Cords 258 may also extend through one or more channels 262. However, channels 262 may be defined on medial portion 132 and lateral portion 130, and channels 262 may be spaced apart from base portion 224.

Thus, the longitudinal portions of cord 258 extending through base portion 224 may be exposed from channel 262. Moreover, these portions of cord 258 may be separated and detached from base portion 224. Thus, in some embodiments, these portions of cord 258 may be free to attach directly to sole structure 110.

12, in some embodiments, the channel 262 can be V-shaped such that the turns of the cord 258 are embedded and enclosed within the channel 262, unlike the exposed turns 159, 160 shown above in FIGs. 1-6.

Exemplary Knitting Processes for Forming Knitted Components and Uppers

Woven component 116 can be woven in any suitable direction. For example, woven component 116 can be formed from heel portion 128 at collar 133, and woven component 116 can be formed so as to expand generally in longitudinal direction 125 toward forefoot portion 134. Forefoot cavity 150 can be formed in front of tongue portion 136. Then, tongue portion 136 is subsequently formed. It should be understood that the three-dimensional curved cavity and two-dimensional curved portion (such as heel cavity 148, forefoot cavity 150, curved area 143 and/or other areas) of woven component 116 can be formed as a whole during the weaving process. Specifically, when subsequent stitch courses are added, the stitches at boundaries 173 and 197 can be maintained by corresponding needles, and the stitches maintained at boundaries 173 and 197 can be woven into the corresponding stitches passing through boundaries 173 and 197. Moreover, rope 158 can be inlaid during this weaving process. Moreover, this process can be completed on any suitable machine, such as a flat knitting machine.

15-23 , an exemplary automated knitting process for forming knitted component 116 using cord 158 will be discussed. For purposes of this discussion, a flat knitting process and a flat knitting machine will be discussed; however, knitted component 116 and cord 158 may be formed in other ways without departing from the scope of this disclosure. Thus, knitted component 116 and cord 158 may be formed in accordance with the teachings of U.S. Patent Application No. 2012/0233882, published on September 20, 2012, and incorporated herein by reference in its entirety.

15 , a portion of a knitting machine 1200 is depicted, including various needles 1202, a track 1203, a standard feeder 1204, and a combination feeder 1220. Combination feeder 1220 is secured to the front side of track 1203, while standard feeder 1204 is secured to the back side of track 1203. Yarn 1206 passes through combination feeder 1220, with one end of yarn 1206 extending outward from dispensing tip 1246. Although yarn 1206 is depicted, any other cord (e.g., a wire, thread, cord, webbing, cable, chain, or yarn) may pass through combination feeder 1220. Another yarn 1211 passes through standard feeder 1204 and forms part of a knitted component 1260, with the loops of yarn 1211 forming the topmost course in knitted component 1260 being held by hooks located on the ends of needles 1202.

The braiding process discussed herein relates to the formation of braided component 1260 or portions of braided component 1260. Thus, portions of braided component 1260 may correspond to base portion 124, heel portion 128, lateral portion 130, medial portion 132, forefoot portion 134, and/or tongue portion 136 discussed above with respect to Figures 1-6. For purposes of discussion, only a relatively small portion of braided component 1260 is shown in the figures to allow for illustration of the braided structure. Additionally, the scale or proportions of the various elements of braiding machine 1200 and braided component 1260 may be exaggerated to better illustrate the braiding process.

16 , standard feeder 1204 moves along track 1203 and a new course is formed in knitted component 1260 from yarn 1211. More specifically, needle 1202 pulls a segment of yarn 1211 through the loops of an existing course, thereby forming a new course. Thus, courses can be added to knitted component 1260 by moving standard feeder 1204 along needle 1202, thereby allowing needle 1202 to manipulate yarn 1211 and form additional loops with yarn 1211.

Continuing the knitting process, the feed arm 1240 is now translated from the retracted position to the extended position, as depicted in Figure 17. In the extended position, the feed arm 1240 extends downward from the carrier 1230 to position the dispensing tip 1246 (a) centered between the needles 1202 and (b) below the intersection of the needle beds.

Referring now to FIG. 18 , combination feeder 1220 moves along track 1203 and yarn 1206 is positioned between the loops of knitted component 1260. That is, yarn 1206 is positioned in front of some loops and behind others in an alternating manner. Furthermore, yarn 1206 is positioned in front of the loops held by needles 1202 from one needle bed 1201, and behind the loops held by needles 1202 from another needle bed. It should be noted that feeder arm 1240 remains in an extended position so that yarn 1206 is positioned in the area below the intersection of the needle beds. This effectively places yarn 1206 within the course recently formed by standard feeder 1204 in FIG. 16 .

To complete the inlaying of yarn 1206 into knitted component 1260, standard feeder 1204 moves along track 1203 to form a new course from yarn 1211, as depicted in Figure 19. By forming the new course, yarn 1206 is effectively knitted or otherwise integrated into the structure of knitted component 1260. At this stage, feeder arm 1240 may also translate from an extended position to a retracted position.

Figures 18 and 19 illustrate the independent movement of feeders 1204 and 1220 along track 1203. That is, Figure 18 illustrates a first movement of combination feeder 1220 along track 1203, and Figure 19 illustrates a second movement of standard feeder 1204 along track 1203. In many knitting processes, feeders 1204 and 1220 can effectively move simultaneously to inlay yarn 1206 and form a new course from yarn 1211. However, combination feeder 1220 moves ahead of or in front of standard feeder 1204 to position yarn 1206 before forming a new course from yarn 1211.

1-6 may be positioned within base portion 124, lateral portion 130, and/or medial portion 132 of upper 120. More specifically, due to the reciprocating action of feeder arm 1240, cord 158 may be positioned within a previously formed course before a new course is formed.

Continuing the knitting process, feeder arm 1240 is now translated from the retracted position to the extended position, as depicted in FIG20 . Combination feeder 1220 then moves along track 1203 and yarn 1206 is positioned between the loops of knitted component 1260, as depicted in FIG21 . This effectively places yarn 1206 within the course formed by standard feeder 1204 in FIG19 . To complete the inlaying of yarn 1206 into knitted component 1260, standard feeder 1204 moves along track 1203 to form a new course from yarn 1211, as depicted in FIG22 . By forming the new course, yarn 1206 is effectively knitted or otherwise integrated into the structure of knitted component 1260. At this stage, feeder arm 1240 may also be translated from the extended position to the retracted position.

22 , yarn 1206 forms loop 1214 between two inlaid segments. In the discussion of turns 159 and 160 in FIGS. 1-6 , it is noteworthy that cord 158 exits channel 162 and then enters another channel 162, thereby forming turns 159 and 160. Loop 1214 can be formed in a similar manner. That is, loop 1214 can be formed at a location where yarn 1206 exits the knit structure of knitted component 1260 and then reenters the knit structure.

23 , combination feeder 1220 moves along track 1203 while in a retracted position and forms a course of knitted component 1260 while in the retracted position. Thus, by reciprocating feeder arm 1240 between the retracted and extended positions, combination feeder 1220 can supply yarn 1206 for knitting, tucking, floating, and inlaying purposes.

The following discussion and accompanying figures disclose various concepts related to knitted components and the manufacture of knitted components. Although knitted components can be used in a variety of products, an article of footwear incorporating one of the knitted components is disclosed below as an example.

The foregoing description of the embodiments has been provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable and can be used in selected embodiments where applicable, even if not explicitly shown or described. They may also be varied in many ways. These variations should not be considered as departing from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims (42)

1. An upper for footwear articles, the upper configured to be attached to a sole structure and configured to accommodate a foot, the upper comprising: A woven component having an integral woven construction and having a base portion and side portions, the base portion being configured adjacent to the sole structure, the base portion defining a portion of an inner surface and an outer surface of the woven component, the base portion defining a base portion channel between the inner surface and the outer surface, the side portions including an inner portion and an outer portion extending from opposite sides of the base portion and a tongue portion extending from the base portion, the tongue portion being partially disposed in a throat defined between the inner portion and the outer portion, and disengaging from at least one of the inner portion and the outer portion; and A tensile rope extends through the channel of the foundation portion. 2. The upper of claim 1, wherein the side portion further defines a portion of the inner surface and the outer surface of the woven component, the side portion defining a side channel between the inner surface and the outer surface, and the tensile cord extending continuously between the base portion channel and the side channel and being accommodated in both the base portion channel and the side channel. 3. The upper according to claim 2, wherein the base portion channel and the side channel are in communication with each other, such that as the tensile cord extends continuously between the base portion channel and the side channel, the tensile cord is embedded in the base portion channel and the side channel. 4. The upper according to claim 2, wherein the tensile cord extends continuously from the inner portion, through the base portion, to the outer portion. 5. The upper of claim 4, wherein the tensile cord extends alternately between the inner portion and the outer portion. 6. The upper of claim 2, wherein the anti-tension cord includes a bend configured to receive and support a closure element that selectively secures the upper to the foot. 7. The upper of claim 6, wherein the side portion includes an opening, and the bend extends at least partially around the opening, the opening and the bend being configured to cooperatively receive and support the closure element. 8. The upper according to claim 1, wherein the tensile cord is slidably accommodated within the channel of the base portion. 9. The upper according to claim 1, wherein the tensile cord is fixedly attached to the base portion. 10. The upper of claim 9, wherein the tensile cord is a fusible cord configured to be fused to the base portion. 11. The upper of claim 1, wherein the base portion includes an arch support area configured to extend below the arch of the foot, and wherein the tensile cord extends across the arch support area. 12. The upper of claim 2, wherein the tensile cord is exposed at least partially from at least one of the side channel and the base portion channel. 13. The upper of claim 6, wherein at least a portion of the tensile cord, including the bend, is exposed from the side passage. 14. A method of manufacturing a shoe upper, the shoe upper being configured to be attached to a sole structure and configured to be worn on a foot, the method comprising: A knitted component is constructed having an integral knitted structure and having a base portion and side portions. The base portion is configured adjacent to the sole structure and defines a portion of an inner surface and an outer surface of the knitted component. The base portion defines a base portion channel between the inner surface and the outer surface. The side portions include an inner portion and an outer portion extending from opposite sides of the base portion, and a tongue portion extending from the base portion. The tongue portion is partially disposed in a throat defined between the inner portion and the outer portion, and is detached from at least one of the inner portion and the outer portion. Extend the tensile rope through the channel of the foundation section. 15. The method of claim 14, wherein the side portion further defines a portion of the inner surface and the outer surface of the braided member, the side portion defining a side channel between the inner surface and the outer surface, and wherein extending the tensile cord includes continuously extending the tensile cord through both the base portion channel and the side channel. 16. The method of claim 15, wherein the base portion channel and the side channel are in communication with each other, and wherein extending the tensile rope comprises embedding the tensile rope within the base portion channel and the side channel as the tensile rope extends continuously through both the base portion channel and the side channel. 17. The method of claim 15, wherein extending the tensile rope comprises extending the tensile rope continuously from the inner portion, through the base portion, to the outer portion. 18. The method of claim 17, wherein extending the tensile rope comprises alternately extending the tensile rope between the inner portion and the outer portion. 19. The method of claim 18, further comprising forming a bend in the tensile cord, the bend being configured to receive and support a closure element that selectively secures the upper to the foot. 20. The method of claim 19, wherein the side portion includes an opening, and wherein forming the bend includes extending the tensile rope at least partially around the opening, the opening and the bend being configured to cooperatively receive and support the closure element. 21. The method of claim 14, further comprising sliding the tensile rope longitudinally through the channel of the foundation portion. 22. The method of claim 14, further comprising securingly attaching the tensile rope to the foundation portion. 23. The method of claim 15, wherein extending the tensile rope comprises exposing the tensile rope at least partially from at least one of the side channel and the base portion channel. 24. The method of claim 15, wherein weaving the braided component comprises weaving the side channels and base portion channels that are in communication with each other, and wherein extending the tensile cord comprises extending the tensile cord continuously from the inner portion, through the base portion, to the outer portion. 25. The method of claim 24, wherein extending the tensile rope comprises extending the tensile rope alternately between the inner portion and the outer portion. 26. The method of claim 25, further comprising forming a bend in the tensile cord, the bend being configured to receive and support a closure element that selectively secures the upper to the foot. 27. The method of claim 26, wherein the side portion includes an opening, and wherein forming the bend includes extending the tensile rope at least partially around the opening, the opening and the bend being configured to cooperatively receive and support the closure element. 28. The method of claim 27, wherein extending the tensile rope includes exposing at least a portion of the tensile rope, including the bend surrounding the opening, from the side passage. 29. A type of footwear, comprising: Sole structure; and The upper, comprising: A woven component having an integral woven construction and having a base portion and side portions, the base portion being configured adjacent to the sole structure, the base portion defining a portion of an inner surface and an outer surface of the woven component, the base portion defining a base portion channel between the inner surface and the outer surface, the side portions including an inner portion and an outer portion extending from opposite sides of the base portion and a tongue portion extending from the base portion, the tongue portion being partially disposed in a throat defined between the inner portion and the outer portion, and disengaging from at least one of the inner portion and the outer portion; and A tensile rope extends through the channel of the foundation portion. 30. The footwear article of claim 29, wherein the side portion further defines at least one of the inner surface and the outer surface, the at least one of the inner surface and the outer surface having a three-dimensional profile to define a cavity in the woven component. 31. The footwear article of claim 30, wherein the side portion defines a side channel between the inner surface and the outer surface, and the tensile cord extends continuously between the base portion channel and the side channel and is accommodated in both the base portion channel and the side channel. 32. The footwear article of claim 31, wherein the anti-tension cord extends continuously between the base portion, the inner portion, and the outer portion. 33. The footwear article of claim 30, wherein the woven component further comprises a first edge and a second edge, the second edge being configured to be joined to the first edge at a seam, such that the base portion and the side portion cooperate to define a cavity configured to receive a foot. 34. The footwear article of claim 33, wherein the side portion includes a heel portion and a forefoot portion extending from opposite ends of the base portion. 35. The footwear article of claim 31, wherein the anti-tension cord is exposed at least partially from at least one of the side channel and the base portion channel. 36. The footwear article of claim 35, wherein the side portion includes a heel portion and a forefoot portion extending from opposite ends of the base portion. 37. The footwear article of claim 31, wherein the tensile cord includes a bend configured to receive a closure element and wherein at least a portion of the tensile cord including the bend is exposed from the side passage. 38. The footwear article of claim 31, wherein the inner surface is defined by a woven material layer and the outer surface is defined by separate woven material layers. 39. The footwear article of claim 38, wherein the base portion channel and the side channel are defined between the woven material layers. 40. The footwear article of claim 39, wherein a plurality of spacer cords are located in the base portion channel or the side channel between the layers of the woven material. 41. The footwear article of claim 40, wherein the plurality of spacer cords comprises monofilament cords. 42. The footwear article of claim 31, wherein the woven component includes a plurality of openings that expose different longitudinal areas of at least one of the side channels and the base portion channels.