Article Of Footwear Having An Upper Incorporating A Knitted Component

• US 20100154256A1
• Filed: 12/18/2008
• Published: 06/24/2010
• Est. Priority Date: 12/18/2008
• Status: Active Grant

• Current Assignee: Fabdesigns, Inc., Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh
• Granted Patent: US 8,490,299 B2
• Time in Patent Office: Days
• US Class Current: 36/25.R
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0205 characterised by the material material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08
• CPC Class Codes: A43B 7/20 Ankle-joint supports or holders
• CPC Class Codes: A43C 1/04 with rings or loops
• CPC Class Codes: D04B 1/106 at a selvedge, e.g. hems or turned welts
• CPC Class Codes: D04B 1/123 with laid-in unlooped yarn, e.g. fleece fabrics with elastic weft yarn D04B1/18
• 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 2403/0113 One surface including hollow piping or integrated straps, e.g. for inserts or mountings
• CPC Class Codes: D10B 2403/022 Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics
• 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

An article of footwear has an upper that includes a knitted component and a sole structure secured to the upper. The knitted component may define a tube formed of unitary knit construction, and a strand may extend through a length of the tube. As another example, the knitted component may have a pair of at least partially coextensive knitted layers formed of unitary knit construction, and a plurality of floating yarns may extend between the knitted layers. In some configurations, the knit type or yarn type may vary in different regions of the knitted component to impart different properties. Additionally, the knitted component may incorporate a thermoplastic yarn that is fused in different regions of the knitted component to impart different properties. A flat knitting process or a variety of other knitting processes may be utilized to form the knitted component.

Claims

1. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component defining a tubular structure formed of unitary knit construction; and

a yarn having a configuration of a one-dimensional material, the yarn extending through at least a portion of a length of the tube.

2. The article of footwear recited in claim 1, wherein the knitted component extends along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper.

3. The article of footwear recited in claim 2, wherein the tubular structure is located on the lateral side of the upper and is oriented to extend upward from an area proximal the sole structure, and the yarn extends outward from an end of the tubular structure to form a loop that receives a lace.

4. The article of footwear recited in claim 2, wherein the tubular structure is located in the heel region and around at least a portion of an ankle opening of the upper, and the yarn and a plurality of additional yarns are located within the tubular structure.

5. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a first knitted layer that forms at least a portion of an exterior surface of the upper;

a second knitted layer formed of unitary knit construction with the first knitted layer, the second knitted layer being positioned adjacent to the first knitted layer and at least partially coextensive with the first knitted layer to define a tube between the first knitted layer and the second knitted layer; and

a strand having a configuration of a one-dimensional material, the strand extending through the tube and between the first knitted layer and the second knitted layer.

6. The article of footwear recited in claim 5, wherein the first knitted layer extends along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper.

7. The article of footwear recited in claim 5, wherein the tube is oriented to extend upward from an area proximal the sole structure, a portion of the strand extending outward from an end of the tube and forming a loop that receives a lace.

8. The article of footwear recited in claim 7, wherein the first knitted layer defines an aperture adjacent to the end of the tube, and the lace extends through the aperture.

9. The article of footwear recited in claim 7, wherein the strand extends into another tube formed by the first knitted layer and the second knitted layer.

10. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component defining a first tube and a second tube each formed of unitary knit construction, the first tube and the second tube extending in an upward direction from an area proximal the sole structure, and ends of the first tube and the second tube being located in an upper area of the upper;

a strand extending through the first tube and the second tube, a portion of the strand extending outward from the ends of the first tube and the second tube to form a loop; and

a lace extending through the loop.

11. The article of footwear recited in claim 10, wherein the first tube and the second tube are adjacent and parallel to each other.

12. The article of footwear recited in claim 10, wherein the knitted component defines an aperture adjacent to the ends of the first tube and the second tube, and the lace extends through the aperture.

13. The article of footwear recited in claim 10, wherein the knitted component includes:

a pair of at least partially coextensive knitted layers formed of unitary knit construction; and

a plurality of floating yarns extending between the knitted layers.

14. The article of footwear recited in claim 13, wherein the knitted layers and the floating yarns are located adjacent to an ankle opening of the upper.

15. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component defining a plurality of tubes formed of unitary knit construction, a first portion of the tubes being located on a lateral side of the footwear, and a second portion of the tubes being located on a medial side of the footwear;

at least one strand extending through the tubes and extending outward from ends of tubes to form a plurality of loops, the strand having a configuration of a one-dimensional material; and

a lace extending through the loops.

16. The article of footwear recited in claim 15, wherein the knitted component defines apertures adjacent to the ends of the tubes, and the lace extends through the apertures.

17. The article of footwear recited in claim 15, wherein at least two of the tubes are adjacent and parallel to each other.

18. The article of footwear recited in claim 15, wherein the knitted component forms a majority of an exterior surface of the upper.

19. The article of footwear recited in claim 15, wherein the knitted component includes:

a pair of at least partially coextensive knitted layers formed of unitary knit construction; and

a plurality of floating yarns located between the knitted layers and extending in a direction that is substantially parallel to the knitted layers,

the knitted layers and the floating yarns being located adjacent to an ankle opening of the upper.

20. The article of footwear recited in claim 15, wherein a first area of the knitted component has a first knit type and a second area of the knitted component has a second knit type, the first knit type being different than the second knit type.

21. The article of footwear recited in claim 15, wherein a first area of the knitted component has a first yarn type and a second area of the knitted component has a second yarn type, the first yarn type being different than the second yarn type.

22. An article of footwear having an upper that includes a lacing system, the lacing system comprising:

a knitted component that defines (a) a tube formed of unitary knit construction and (b) an aperture positioned adjacent to an end of the tube;

a strand extending through the tube and forming a loop; and

a lace extending through the loop and the aperture.

23. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising a knitted component that includes:

a first knitted layer and a second knitted layer that are at least partially coextensive with each other and formed of unitary knit construction; and

a plurality of floating yarns located between the first knitted layer and the second knitted layer and extending in a direction that is substantially parallel to the first knitted layer and the second knitted layer.

24. The article of footwear recited in claim 23, wherein the upper defines an interior void for receiving a foot and an ankle opening providing access to the void, the first knitted layer, the second knitted layer, and the floating yarns being positioned adjacent to the ankle opening.

25. The article of footwear recited in claim 24, wherein the first knitted layer, the second knitted layer, and the floating yarns are located on a medial side of the upper and a lateral side of the upper.

26. The article of footwear recited in claim 23, wherein the knitted component defines a tube formed of unitary knit construction, and a strand extends through a length of the tube.

27. The article of footwear recited in claim 23, wherein a first area of the knitted component has a first knit type and a second area of the knitted component has a second knit type, the first knit type being different than the second knit type.

28. The article of footwear recited in claim 23, wherein a first area of the knitted component has a first yarn type and a second area of the knitted component has a second yarn type, the first yarn type being different than the second yarn type.

29. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising a knitted component that includes:

a first knitted layer and a second knitted layer formed of unitary knit construction, the first knitted layer being at least partially coextensive with the second knitted layer to define an interior volume between the first knitted layer and the second knitted layer; and

a plurality of floating yarns located within the interior volume and extending between the first knitted layer and the second knitted layer.

30. The article of footwear recited in claim 29, wherein the upper defines an interior void for receiving a foot and an ankle opening providing access to the void, the first knitted layer, the second knitted layer, and the floating yarns being positioned adjacent to the ankle opening.

31. The article of footwear recited in claim 30, wherein the first knitted layer, the second knitted layer, and the floating yarns are located on a medial side of the upper, located on a lateral side of the upper, and extend around a heel region of the upper.

32. An article of footwear having an upper and a sole structure secured to the upper, the upper defining an interior void for receiving a foot of a wearer, and the upper having an ankle opening that provides access to the void, the upper comprising a knitted component that includes:

a first knitted layer forming at least a portion of an exterior surface of the upper adjacent to the ankle opening;

a second knitted layer forming at least a portion of an interior surface of the upper adjacent to the ankle opening; and

a plurality of floating yarns located between the first knitted layer and the second knitted layer,

wherein the first knitted layer and the second knitted layer are joined to each other at the ankle opening and at a location spaced from the ankle opening to define a separated area therebetween, and the floating yarns are located in the separated area.

33. The article of footwear recited in claim 32, wherein the knitted component extends along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper.

34. The article of footwear recited in claim 32, wherein the floating yarns are substantially parallel to the first knitted layer and the second knitted layer.

35. The article of footwear recited in claim 32, wherein a portion of the knitted component located in a midfoot region of the footwear defining a tube formed of unitary knit construction, and a strand extends through a length of the tube.

36. A method of manufacturing an article of footwear, the method comprising:

utilizing a flat knitting process to form a knitted component that includes at least one yarn incorporating a thermoplastic polymer material;

heating at least an area of the knitted component to fuse the yarn incorporating the thermoplastic polymer material; and

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

37. The method recited in claim 36, wherein the step of utilizing the flat knitting process includes locating the yarn incorporating the thermoplastic polymer material throughout the knitted component.

38. The method recited in claim 36, wherein the step of utilizing the flat knitting process includes locating the yarn incorporating the thermoplastic polymer in only the area of the knitted component.

39. The method recited in claim 36, wherein the step of incorporating includes locating the area of the knitted component in a heel region of the footwear.

40. The method recited in claim 36, wherein the step of incorporating includes locating the area of the knitted component in a forefoot region of the footwear.

41. A method of manufacturing an article of footwear, the method comprising:

utilizing a flat knitting process to form a knitted component that includes a first knitted layer, a second knitted layer, and a plurality of yarns secured to the first knitted layer and the second knitted layer and extending from the first knitted layer to the second knitted layer; and

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

42. The method recited in claim 41, further including a step of selecting the yarns to be mono-filament yarns.