Article of Footwear Having An Upper Incorporating A Knitted Component

• US 20140230277A1
• Filed: 04/25/2014
• Published: 08/21/2014
• Est. Priority Date: 12/18/2008
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh, Shaffer, Benjamin A., Huffa, Bruce
• Granted Patent: US 9,027,260 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 23/0205 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 formed of unitary knit construction, the knitted component comprising a first knitted layer and a second knitted layer that are at least partially coextensive with each other, the knitted component including a plurality of tubular structures, the plurality of tubular structures comprising the first knitted layer and the second knitted layer that are overlapping and joined to each other along opposite edges to define sides of a first tube and a second tube, the first tube and the second tube being formed by the first knitted layer and the second knitted layer to have unitary knit construction so as to be a one-piece element with the remaining portion of the knitted component; and

a strand extending through the first tube and the second tube, a portion of the strand extending between a first end of the first tube and a first end of the second tube to form a loop;

wherein the first end of the first tube and the first end of the second tube are separated at a first distance; and

wherein a second end of the first tube and a second end of the second tube area are separated at a second distance, wherein the second distance is greater than the first distance.

2. The article of footwear of claim 1, wherein the strand exits the second end of the first tube and the second end of the second tube and is secured to the sole structure.

3. The article of footwear of claim 1, wherein the knitted component defines an aperture adjacent to the first end of the first tube and the first end of the second tube, and further comprising a lace that extends through the aperture and the loop.

4. The article of footwear of claim 1, wherein a space between the first tube and the second tube gradually increases from the first ends to the second ends.

5. The article of footwear of claim 1, wherein the first tube and the second tube cooperate to define a V-shaped structure.

6. The article of footwear of claim 1, wherein the knitted component defines a medial side of the upper and a lateral side of the upper;

wherein the first tube and the second tube are both disposed on one of the medial side and the lateral side;

wherein the second end of the first tube and the second end of the second tube are disposed proximate the sole structure; and

wherein the first end of the first tube and the first end of the second tube are spaced away from the sole structure.

7. An article of footwear having an upper and a sole structure secured to the upper, the upper having a heel region and a forefoot region, the upper comprising:

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

at least one tubular structure disposed on the knitted component, the at least one tubular structure comprising the first knitted layer and the second knitted layer that are overlapping and joined to each other along opposite edges to define sides of a tube; 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;

wherein the tube formed by the first knitted layer and the second knitted layer has a unitary knit construction so as to be a one-piece element with the remaining portion of the knitted component; and

wherein the tube is oriented along a longitudinal direction of the article of footwear; and

wherein the tube extends generally between the heel region and the forefoot region.

8. The article of footwear of claim 7, wherein the tube extends continuously from the heel region to the forefoot region.

9. The article of footwear of claim 7, wherein the upper defines a vertical direction that extends away from sole structure;

wherein the tube is a first tube;

wherein the first knitted layer and the second knitted layer overlap and are joined to each other along opposite edges to define sides of a second tube;

wherein the second tube has a unitary knit construction so as to be part of the one-piece element with the remaining portion of the knitted component; and

wherein the second tube is separated at a distance from the first tube in the vertical direction.

10. The article of footwear of claim 7, wherein the upper defines a midfoot region, and wherein the tube extends continuously across the heel region, the midfoot region, and the forefoot region.

11. An article of footwear having an upper and a sole structure secured to the upper, the upper having a medial side and a lateral side, the upper comprising:

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

a plurality of tubular structures disposed on the knitted component, at least one of the tubular structures comprising the first knitted layer and the second knitted layer that are overlapping and joined to each other along opposite edges to define sides of a first pair of adjacent tubes on the medial side, another of the tubular structures comprising the first knitted layer and the second knitted layer that are overlapping and joined to each other along opposite edges to define sides of a second pair of adjacent tubes on the lateral side; and

at least one yarn having a configuration of a one-dimensional material, the at least one yarn extending through the first pair of adjacent tubes, the at least one yarn extending through the second pair of adjacent tubes;

wherein the first pair of adjacent tubes and the second pair of adjacent tubes have a unitary knit construction so as to be a one-piece element with the remaining portion of the knitted component; and

wherein the first pair of adjacent tubes include first ends, wherein the first pair of adjacent tubes include second ends that are separated at a greater distance than the first ends; and

wherein the second pair of adjacent tubes include third ends, wherein the second pair of adjacent tubes include fourth ends that are separated at a greater distance than the third ends.

12. The article of footwear of claim 11, wherein the at least one yarn extends between the first ends of the first pair of adjacent tubes to define a first loop, and wherein the at least one yarn extends between the third ends of the second pair of adjacent tubes to define a second loop, and further comprising a lace that is received by the first loop and the second loop.

14. The article of footwear of claim 11, wherein a first space between the first pair of adjacent tubes gradually increases from the first ends to the second ends, and wherein a second space between the second pair of adjacent tubes gradually increases from the third ends to the fourth ends.

15. The article of footwear of claim 11, wherein the first pair of adjacent tubes define a first V-shaped structure, and wherein the second pair of adjacent tubes defines a second V-shaped structure.

16. The article of footwear of claim 11, wherein the at least one yarn includes a first yarn and a second yarn;

and

wherein the first yarn extends through the first pair of adjacent tubes, and wherein the second yarn extends through the second pair of adjacent tubes.

17. The article of footwear of claim 16, wherein the first yarn extends out of the second ends of the first pair of adjacent tubes and is attached to the sole structure;

and

wherein the second yarn extends out of the fourth ends of the second pair of adjacent tubes and is attached to the sole structure.

18. The article of footwear of claim 11, wherein the second ends of the first pair of adjacent tubes are disposed proximate the sole structure;

wherein the first ends of the first pair of adjacent tubes are spaced away from the sole structure;

wherein the fourth ends of the second pair of adjacent tubes are disposed proximate the sole structure; and

wherein the third ends of the second pair of adjacent tubes are spaced away from the sole structure.

13. The article of footwear 12, wherein the knitted component defines a first aperture adjacent to the first ends of the first pair of adjacent tubes, wherein the knitted component defines a second aperture adjacent the third ends of the second pair of adjacent tubes, and wherein the lace is received by the first loop, the first aperture, the second loop, and the second aperture.