Method for forming a seamless knitted abutment

• US 10,294,591 B2
• Filed: 01/28/2016
• Issued: 05/21/2019
• Est. Priority Date: 01/30/2015
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Podhajny, Daniel A., Cross, Tory M.
• Primary Examiner(s): Worrell, Danny
• Application Number:
  US15/008,544
• Publication Number:
  US 20160219966A1
• Time in Patent Office: 1,209 Days
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: D04B 1/108 Gussets, e.g. pouches or heel or toe portions
• CPC Class Codes: D04B 1/22 specially adapted for knitting goods of particular configuration
• CPC Class Codes: D10B 2403/032 Flat fabric of variable width, e.g. including one or more fashioned panels
• CPC Class Codes: D10B 2501/043 Footwear

Abstract

A method for forming a seamless knitted abutment may include a joining thread. The joining thread may extend between a first portion and a second portion in a first orientation. The joining thread may be tensioned and bring the first portion and the second portion together. The first portion and the second portion may be then oriented in a second orientation.

Claims

1. A method of forming a knitted component, the method comprising the steps of:

knitting a first portion of the knitted component with a first thread along a first course direction;

knitting a second portion of the knitted component with a second thread, the first thread being distinct from the second thread;

the second portion of the knitted component having a first engaging subset including a plurality of loops and a second engaging subset including a plurality of loops, the plurality of loops being held by a plurality of needles;

the first portion of the knitted component having a first engaging side including a plurality of loops;

interlooping at least one of the plurality of loops of the first engaging subset with at least one of the plurality of loops of the first engaging side;

knitting a third portion of the knitted component with the first thread along the first course direction, the third portion of the knitted component including a second engaging side including a plurality of loops;

wherein the first engaging side and the second engaging side are located at an angle greater than 0 degrees with respect to one another; and

interlooping at least one of the plurality of loops of the second engaging subset with at least one of the plurality of loops of the second engaging side.

2. The method according to claim 1, wherein the knitted component is configured to be incorporated into an upper of an article of footwear;

and wherein 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.

3. The method according to claim 1, wherein the knitted component is configured to be incorporated into an upper of an article of footwear;

and wherein 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.

4. The method according to claim 1, wherein the first engaging subset includes a first loop, the second engaging subset includes a second loop, while located on the plurality of needles, the first loop being located adjacent to the second loop.

5. The method according to claim 1, wherein the first loop interloops with the first engaging side adjacent to a base portion, the second loop interloops with the second engaging side adjacent to the base portion.

6. The method according to claim 1, wherein the knitted component further comprises a fourth portion including a third edge, the third edge not being interlooped with the second portion.

7. A method of assembling an article of footwear incorporating a knitted component into an upper, the method comprising:

forming the knitted component in a planar configuration including a first edge and a second edge;

wherein the first edge and the second edge are oblique with respect to each other;

the knitted component being formed of courses which are secured;

knitting a joining thread between the first edge and the second edge in a planar configuration, the joining thread including a first end and a second end, at least one of the first end and the second end being unsecured, the joining thread interlooping with at least one loop on the first edge and the joining thread interlooping with at least one loop on the second edge;

tensioning at least one of the first end and the second end of the joining thread such that the first edge and the second edge extend toward one another; and

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

8. The method according to claim 7, wherein 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.

9. The method according to claim 7, wherein 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.

10. The method according to claim 7, wherein at least one loop of the first side abuts at least one loop of the second side upon tensioning of the joining thread.

11. The method according to claim 7, wherein 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 that abuts at least one loop of the second portion.

12. The method according to claim 7, wherein the first portion extends from the base portion and the second portion extends from the base portion, the first portion including an area that is in a fixed relationship to the base portion, the second portion including an area that is in a fixed relationship to the base portion.

13. The method according to claim 7, wherein the first portion includes the first edge, the second portion includes the second edge, and wherein as the joining thread is tensioned the first portion and the second portion extend out of a plane in which the base portion is located.

14. The method according to claim 7, wherein the first portion corresponds to a forefoot portion and wherein the second portion corresponds to a midfoot portion.

15. The method according to claim 7, wherein the upper of the article of footwear further comprises a third portion and a fourth portion, the third portion and the fourth portion including a third edge and a fourth edge, a second joining thread extending between the third edge to the fourth edge, wherein as the second joining thread is tensioned, at least one loop located on the third edge abuts at least one loop located on the fourth edge.