METHOD OF KNITTING A KNITTED COMPONENT FOR AN ARTICLE OF FOOTWEAR

• US 20140352173A1
• Filed: 05/31/2013
• Published: 12/04/2014
• Est. Priority Date: 05/31/2013
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Bell, Thomas G., Dua, Bhupesh, Lyttle, Amy, Huffman, Julie
• Granted Patent: US 9,538,803 B2
• Time in Patent Office: Days
• US Class Current: 36/50.1
• CPC Class Codes: A43B 1/00 Footwear characterised by the material
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/024 Different layers of the same material
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 23/028 Resilient uppers, e.g. shock absorbing
• CPC Class Codes: A43B 23/07 Linings therefor lining laminated with upper A43B23/026
• CPC Class Codes: A43B 3/0031 provided with a pocket, e.g. for keys or a card
• CPC Class Codes: A43D 11/00 Machines for preliminary treatment or assembling of upper-parts, counters, or insoles on their lasts preparatory to the pulling-over or lasting operations; Applying or removing protective coverings
• CPC Class Codes: A43D 111/00 Shoe machines with conveyors for jacked shoes or for shoes or shoe parts
• CPC Class Codes: D04B 1/102 with stitch pattern D04B1/06, D04B1/08 take precedence
• CPC Class Codes: D04B 1/24 wearing apparel
• CPC Class Codes: D04B 21/06 Patterned fabrics or articles open-work fabrics D04B21/10
• CPC Class Codes: D04B 21/207 Wearing apparel or garment blanks
• CPC Class Codes: D04B 9/42 specially adapted for producing goods of particular configuration
• CPC Class Codes: D10B 2501/043 Footwear
• CPC Class Codes: D10B 2501/061 Piped openings (pockets)

Abstract

An article of footwear incorporates a textile upper. The upper comprises a knitted component. The knitted component may be warp knitted. The knitted component has an outer side and an inner side that can have different knit configurations. The knitted component can also incorporate portions of a single layer construction and portions of a double layer construction. The double layer construction forms pockets on portions of the knitted component. Inserts can be placed into the pockets to provide support, stability, or other desired properties to the portions of the knitted component.

Claims

1. A method of making an upper for an article of footwear, comprising:

knitting a knitted textile element of unitary knit construction with a first indicating portion corresponding to the outline of a knitted component and a second indicating portion corresponding to a pocket in the knitted component;

cutting the knitted textile element along the first indicating portion to separate the knitted component from excess material of the knitted textile element;

cutting the knitted component along the second indicating portion to create an opening to the pocket;

inserting an insert member into the pocket and closing the pocket; and

joining edges of the knitted component to form the upper.

2. The method according to claim 1, wherein knitting the knitted textile element includes knitting a first portion comprised of a single layer of material and knitting a second portion comprised of two distinct layers of material.

3. The method according to claim 1, wherein the insert member comprises a cushioning member.

5. The method according to claim 1, wherein the method includes associating a sole structure with the upper.

6. The method according to claim 1, wherein the insert member comprises a rigid material.

7. The method according to claim 1, further comprising:

heating at least a portion of the knitted component including the pocket having the insert member disposed within.

8. The method according to claim 7, wherein the heating step fixes the insert member within the pocket.

4. The method according to claim 4, wherein the cushioning member is made of a foam material.

9. A method of knitting a knitted component for use as an upper in an article of footwear, comprising:

knitting a first portion of the knitted component so that the first portion comprises a single layer construction;

knitting a second portion of the knitted component so that the second portion comprises a double layer construction with a pocket;

knitting a knitted indicating portion configured to indicate a location for cutting a layer of the second portion to provide access to the pocket; and

wherein the first portion, the second portion and the knitted indicating portion are of unitary knit construction.

10. The method according to claim 9, wherein knitting the first portion comprises knitting a first side of the first portion to have a first knit configuration and knitting a second side of the first portion to have a second knit configuration that is different from the first knit configuration.

11. The method according to claim 9, wherein knitting the second portion comprises knitting the double layer construction such that a first layer of the double layer construction has a first knit configuration and a second layer of the double layer construction has a second knit configuration that is different from the first knit configuration.

12. The method according to claim 9, wherein knitting comprises warp knitting the knitted textile element.

13. The method according to claim 9, wherein the knitted indicating portion comprises perforations.

14. The method according to claim 9, wherein the knitted indicating portion is associated with a portion of the second portion that is adjacent to the first portion.

15. The method according to claim 9, wherein the knitted indicating portion is visible only on one side of the textile element.

16. An article of footwear, comprising:

an upper incorporating a knitted component;

the knitted component having a first portion that comprises a single layer of material and the knitted component having a second portion that comprises two layers of material that are separated to form a pocket in the knitted component; and

wherein an outer side of the first portion is formed of unitary knit construction with a first layer of the second portion and wherein an inner side of the first portion is formed of unitary knit construction with a second layer of the second portion.

17. The article of footwear according to claim 16, wherein the knitted component is a warp-knitted textile material.

18. The article of footwear according to claim 16, wherein the knitted component includes a knitted indicating portion corresponding to a portion for cutting open the second portion.

19. The article of footwear according to claim 16, wherein an insert material is disposed within the pocket of the second portion.

20. The article of footwear according to claim 19, wherein the insert material is fixed in place within the pocket.

21. The article of footwear according to claim 20, wherein the insert material is attached to a portion of the pocket.

22. The article of footwear according to claim 20, wherein the insert material is disposed between opposite sides of the pocket that are attached to each other.

23. The article of footwear according to claim 16, wherein the outer side comprises a first set of yarns and wherein the inner side comprises a second set of yarns that is substantially different from the first set of yarns.

24. The article of footwear according to claim 23, wherein the first set of yarns and the second set of yarns comprise substantially different materials.

25. The article of footwear according to claim 23, wherein the first set of yarns are knitted into a first knit configuration and wherein the second set of yarns are knitted into a second knit configuration that is substantially different from the first knit configuration.

26. The article of footwear according to claim 23, wherein the first layer of the second portion comprises the first set of yarns and wherein the second layer of the second portion comprises the second set of yarns.