Packaged dyed knitted component

• US 10,194,711 B2
• Filed: 05/06/2014
• Issued: 02/05/2019
• Est. Priority Date: 05/06/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh, Hawkinson, Karen
• Primary Examiner(s): Worrell, Danny
• Application Number:
  US14/270,521
• Publication Number:
  US 20150320136A1
• Time in Patent Office: 1,736 Days
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/02 Uppers; Boot legs
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: D02G 3/328 containing elastane
• CPC Class Codes: D02G 3/36 Cored or coated yarns or threads D02G3/34, D02G3/40 take precedence; elastic yarns or threads D02G3/32
• CPC Class Codes: D04B 1/12 characterised by thread material
• CPC Class Codes: D04B 1/16 synthetic threads
• CPC Class Codes: D04B 1/24 wearing apparel
• CPC Class Codes: D10B 2401/14 Dyeability
• CPC Class Codes: D10B 2501/043 Footwear

Abstract

A method of manufacturing an article of footwear includes providing a yarn that is at least partially package dyed. The method also includes flat knitting a knitted component at least partially from the yarn. The knitted component has an area with a density of at least twenty-eight courses per inch (28 CPI). Moreover, the method includes forming at least a portion of an upper of the article of footwear with the knitted component.

Claims

1. An article of footwear comprising:

a sole assembly; and

an upper that is attached to the sole assembly, the upper including a flat knitted component, the flat knitted component formed of unitary knit construction, the flat knitted component including an area that is formed from a yarn, the yarn being at least partially package dyed, and the area having a density of at least twenty-eight courses per inch (28 CPI), and

wherein the yarn has a first cross-sectional thickness before being at least partially package dyed and has a second cross-sectional thickness after being at least partially package dyed that is less than the first cross-sectional thickness, and

wherein the yarn that is at least partially package dyed is texturized to a third cross-sectional thickness that is greater than the second cross-sectional thickness prior to knitting the yarn into the flat knitted component.

2. The article of footwear of claim 1, wherein the area has a stitch density of at least four hundred stitches per square inch (400 stitches/in²).

3. The article of footwear of claim 2, wherein the area has a stitch density of at least four hundred fifty stitches per square inch (450 stitches/in²).

4. The article of footwear of claim 3, wherein the area has a stitch density of at least four hundred eighty stitches per square inch (480 stitches/in²).

5. The article of footwear of claim 1, wherein the yarn is a composite yarn including a covering strand,

wherein the composite strand further includes a core strand, and

wherein the covering strand at least partially covers the core strand.

6. The article of footwear of claim 5, wherein the core strand is resiliently elastic, and wherein the composite yarn is resiliently stretchable between a first length and a second length.

7. The article of footwear of claim 1, wherein the package dyed yarn is incorporated within the area in a tuck stitch.