Footwear Uppers With Knitted Tongue Elements

• US 20120233884A1
• Filed: 02/20/2012
• Published: 09/20/2012
• Est. Priority Date: 10/07/2009
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Greene, Pamela S.
• Granted Patent: US 9,295,298 B2
• Time in Patent Office: Days
• US Class Current: 36/84
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/02 Uppers; Boot legs
• CPC Class Codes: A43B 23/0205 characterised by the material material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/025 assembled by stitching
• CPC Class Codes: A43B 23/0265 having different properties in different directions
• CPC Class Codes: A43B 23/028 Resilient uppers, e.g. shock absorbing
• CPC Class Codes: A43B 23/26 Tongues for shoes
• CPC Class Codes: A43B 3/0031 provided with a pocket, e.g. for keys or a card
• 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 1/104 Openwork fabric, e.g. pelerine fabrics
• CPC Class Codes: D04B 1/123 with laid-in unlooped yarn, e.g. fleece fabrics with elastic weft yarn D04B1/18
• CPC Class Codes: D10B 2403/0241 enhancing mechanical properties
• 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 may incorporate various elements that are at least partially formed through a knitting process, such as a circular knitting process or a flat knitting process. Examples of the elements include tongue elements, collar elements, and collar-throat elements. In some configurations, the elements include compressible areas and flange areas. The compressible areas may include free yarn sections that impart compressibility, and the flange areas may be utilized to join the components to the article of footwear.

Claims

1. A tongue element of an article of footwear comprising a knitted component having a compressible area and a flange area extending outward from the compressible area, the compressible area including a first knit layer and a second knit layer formed of unitary knit construction, wherein (a) areas of the first knit layer and the second knit layer are spaced from each other to define a cavity within the knitted component, (b) edges of the first knit layer and the second knit layer are joined to each other around at least a portion of the cavity, and (c) a plurality of free yarn sections is located within the cavity.

2. The tongue element of claim 1, wherein the plurality of free yarn sections is a plurality of material loops.

3. The tongue element of claim 1, wherein the plurality of free yarn sections is formed of unitary knit construction with the first knit layer.

4. The tongue element of claim 2, wherein another plurality of free yarn sections is located within the cavity and is formed of unitary knit construction with the second knit layer.

5. The tongue element of claim 1, wherein the knitted component defines a flange in the flange area extending outward from one of the first knit layer and the second knit layer.

6. The tongue element of claim 1, wherein the knitted component defines a flange in the flange area extending outward from each of the first knit layer and the second knit layer.

7. The tongue element of claim 1, wherein the knitted component forms a majority of an exterior of the tongue element.

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

a material layer forming at least a portion of an exterior surface of the upper; and

a tongue element including a knitted component formed of unitary knit construction, the knitted component having a compressible area and a flange area extending outward from the compressible area, the compressible area forming portions of both the exterior surface and an opposite interior surface of the upper and defining a cavity within the knitted component that includes a plurality of free yarn sections, and the flange area being located inward from the material layer and secured adjacent to the material layer,

9. The article of footwear of claim 8, wherein the plurality of free yarn sections is a plurality of material loops.

10. The article of footwear of claim 8, wherein the knitted component forms a majority of an exterior of the tongue element.

11. The article of footwear of claim 8, wherein the plurality of free yarn sections is formed of unitary knit construction with the knitted component.

12. The article of footwear of claim 8, wherein the article of footwear further comprises an additional material layer located parallel to the first material layer and inward from the exterior surface, and a portion of the flange area is located between the material layer and the additional material layer.

13. The article of footwear recited in claim 8, wherein the material layer is a knitted component having a knit structure, and the compressible area of the tongue element includes the knit structure.

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

a first knitted component defining at least a portion of a void within the upper for receiving a foot, and the first knitted component defining an ankle opening to provide the foot with access to the void; and

a tongue element joined to the first knitted component, the tongue element including a second knitted component being formed of unitary knit construction and defining an interior cavity, a plurality of free yarn sections being located within the cavity.

15. The article of footwear of claim 14, wherein the plurality of free yarn sections is a plurality of material loops.

16. The article of footwear of claim 14, wherein the plurality of free yarn sections is formed of unitary knit construction with the second knitted component.

17. The article of footwear of claim 14, wherein the second knitted component has a compressible area and a flange area extending outward from the compressible area, the compressible area defining the interior cavity, and the flange area being joined to the first knitted component.

18. The article of footwear of claim 14, wherein the knitted component forms a majority of an exterior of the tongue element.

19. The article of footwear of claim 14, wherein a first knit structure is incorporated in an area of the first knitted component, a second knit structure is incorporated in an area of the second knitted component, and the first knit structure is substantially the same as the second knit structure.

20. The article of footwear of claim 14, wherein a first type of yarn is incorporated in an area of the first knitted component, a second type of yarn is incorporated in an area of the second knitted component, and the first type of yarn is substantially the same as the second type of yarn.

21. The article of footwear of claim 14, wherein an area of the first knitted component has a first color, an area of the second knitted component has a second color, and the first color is substantially the same as the second color.