Upper for an article of footwear with at least one molded thermoplastic polymer element

• US 10,524,530 B2
• Filed: 02/14/2017
• Issued: 01/07/2020
• Est. Priority Date: 02/16/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: McFarland, II, William C., Resneck, Leah
• Primary Examiner(s): Kavanaugh, Ted
• Application Number:
  US15/431,940
• Publication Number:
  US 20170245581A1
• Time in Patent Office: 1,057 Days
• Field of Search: 36 45
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: D04B 1/16 synthetic threads
• CPC Class Codes: D04B 1/24 wearing apparel
• CPC Class Codes: D10B 2401/041 thermoplastic; thermosetting
• CPC Class Codes: D10B 2403/0114 with one or more yarns appearing predominantly on one face, e.g. plated or paralleled yarns for pile fabrics D03D27/00, D04B1/02, D04B21/02; for intarsia fabrics D04B1/126
• CPC Class Codes: D10B 2403/023 Fabric with at least two, predominantly unlinked, knitted or woven plies interlaced with each other at spaced locations or linked to a common internal co-extensive yarn system
• 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
• CPC Class Codes: D10B 2501/061 Piped openings (pockets)

Abstract

The present disclosure relates to uppers for articles of footwear. The uppers may be formed by knitting one or more yarns together. After formation of the upper, the one or more yarns may be manipulated to change a property of the knitted upper. For example, one or more of the yarns may be at least partially melted and subsequently cooled to form a molded thermoplastic polymer element.

Claims

1. An upper for an article of footwear, the upper comprising:

a plurality of molded thermoplastic polymer elements linked together by a knit element, each of the plurality of molded thermoplastic polymer elements being substantially discrete,

wherein each of the plurality of molded thermoplastic polymer elements comprises a border, the border being substantially surrounded by the knit element,

wherein the knit element includes a first layer forming a first side and a second layer forming a second side facing opposite the first side, wherein the first layer is secured to the second layer via a plurality of intermeshed loops of the knit element located in an area coextensive with at least one of the molded thermoplastic polymer elements,

wherein the first side includes the plurality of molded thermoplastic polymer elements,

wherein the second side faces a void of the upper such that the second layer is located between the void and the plurality of molded thermoplastic polymer elements, and

wherein a single yarn extends through the first layer and the second layer.

2. The upper of claim 1, wherein the second side comprises a polyester yarn.

3. The upper of claim 1, wherein the second side comprises an elastomeric filament that comprises spandex.

4. The upper of claim 1, wherein the plurality of molded thermoplastic polymer elements comprises a thermoplastic polyurethane.

5. The upper of claim 1, wherein the first layer comprises a first outer-edge and the second layer comprises a second outer-edge, at least a portion of the first outer-edge being secured to at least a portion of the second outer-edge with the single yarn.

6. The upper of claim 1, wherein each of the plurality of molded thermoplastic polymer elements independently comprises a shape selected from the group consisting of a triangle, a quadrilateral, a regular polygon, an irregular polygon, a circle, an ellipse, and a crescent.

7. An upper for an article of footwear, the upper comprising:

a plurality of molded thermoplastic polymer elements linked together by a knit element, each of the plurality of molded thermoplastic polymer elements being substantially discrete,

wherein each of the plurality of molded thermoplastic polymer elements comprises a border, the border being substantially surrounded by the knit element,

wherein the knit element includes a first layer forming a first side and a second layer forming a second side facing opposite the first side,

wherein the first side includes the plurality of molded thermoplastic polymer elements,

wherein the second side faces a void of the upper such that the second layer is located between the void and the plurality of molded thermoplastic polymer elements, and

wherein the first layer and the second layer are formed together on a knitting machine such that the first layer is substantially fixed to the second layer via a plurality of intermeshed loops of the knit element located in an area coextensive with at least one of the molded thermoplastic polymer elements.

8. The upper of claim 7, wherein the second side comprises a polyester yarn.

9. The upper of claim 7, wherein the second side comprises an elastomeric filament that comprises spandex.

10. The upper of claim 7, wherein the plurality of molded thermoplastic polymer elements comprises a thermoplastic polyurethane.

11. The upper of claim 7, wherein each of the plurality of molded thermoplastic polymer elements independently comprises a shape selected from the group consisting of a triangle, a quadrilateral, a regular polygon, an irregular polygon, a circle, an ellipse, and a crescent.

12. An upper for an article of footwear, the upper comprising:

a molded thermoplastic polymer element surrounded by a knit element,

wherein the knit element includes a first layer forming a first side and a second layer forming a second side facing opposite the first side, the first layer and the second layer being coextensive and secured via interlooped knit loops that form at least a portion of the molded thermoplastic polymer element,

wherein the first side includes the molded thermoplastic polymer element, and

wherein the second side faces a void of the upper such that the second layer is located between the void and the molded thermoplastic polymer element.

13. The upper of claim 12, wherein the second side comprises a polyester yarn.

14. The upper of claim 12, wherein the second side comprises an elastomeric filament that comprises spandex.

15. The upper of claim 12, wherein molded thermoplastic polymer element comprises a thermoplastic polyurethane.