Method of Forming An Article Of Footwear Incorporating A Knitted Upper With Tensile Strand

• US 20150059210A1
• Filed: 09/05/2013
• Published: 03/05/2015
• Est. Priority Date: 09/05/2013
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Droege, John, Podhajny, Daniel A.
• Granted Patent: US 10,092,058 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 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 23/0255 assembled by gluing or thermo bonding
• CPC Class Codes: A43B 23/0275 with a part of the upper particularly rigid, e.g. resisting articulation or torsion
• CPC Class Codes: A43B 3/26 adjustable as to length or size
• 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: D10B 2403/0112 One smooth surface, e.g. laminated or coated
• 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

A method of forming an article of footwear includes knitting a knitted component having a knit element and a tensile strand that are formed of unitary knit construction as a one-piece element. The knitted component is configured to at least partially form an upper for the article of footwear. The knit element defines a body and a trim region, and the trim region defines an outer edge of the knit element. The tensile strand includes at least one inlaid portion that is inlaid within the knit element. The tensile strand also includes an exposed portion that is exposed from the knit element and that is disposed adjacent the outer edge. The exposed portion is spaced from the outer edge in an inboard direction on the knit element. The method further includes manipulating the exposed portion to move and adjust the at least one inlaid portion relative to the knit element.

Claims

1. A method of forming an article of footwear, the method comprising:

knitting a knitted component having a knit element and a tensile strand that are formed of unitary knit construction as a one-piece element, the knitted component configured to at least partially form an upper for the article of footwear, the knit element defining a body and a trim region, the trim region defining an outer edge of the knit element, the tensile strand including at least one inlaid portion that is inlaid within the knit element, the tensile strand also including an exposed portion that is exposed from the knit element and that is disposed adjacent the outer edge, wherein the exposed portion is spaced from the outer edge in an inboard direction on the knit element; and

pulling on the exposed portion to move and adjust the at least one inlaid portion relative to the knit element.

2. The method of claim 1, wherein knitting the knitted component includes defining a first inlaid portion and a second inlaid portion of the tensile strand, and wherein the exposed portion extends continuously between the first inlaid portion and the second inlaid portion.

3. The method of claim 1, wherein knitting the knitted component includes forming the outer edge with a first layer and a second layer formed of unitary knit construction, the first layer and the second layer overlaying each other and connected in the body, the first layer and the second layer overlaying each other and disconnected in the trim region, and wherein knitting the knitted component includes disposing the exposed portion of the tensile strand between the first layer and the second layer in the trim region.

4. The method of claim 1, wherein knitting the knitted component includes knitting the knitted component with a first layer and a second layer formed of unitary knit construction, the first layer and the second layer overlaying each other and connected in the body, the first layer extending further in an outboard direction on the knitted component than the second layer to define the trim region and the outer edge, and wherein knitting the knitted workpiece includes disposing the exposed portion of the tensile strand on the first layer within the trim region.

5. The method of claim 1, further comprising attaching a skin layer to the knitted component.

6. The method of claim 5, further comprising trimming the knitted component within the trim region after attaching the skin layer to the knitted component.

7. The method of claim 6, further comprising:

fixing a first area of the knitted component to a support surface and fixing a second area of the knitted component to the support surface the first area and the second area being spaced from each other along the outer edge, an indentation in the outer edge of the knitted component defined between the first area and the second area, and

wherein trimming the knitted component includes removing the indentation from the outer edge of the knitted component.

8. The method of claim 7, further comprising selecting whether to form the article of footwear to fit a first foot size or a second foot size, wherein trimming the knitted component includes trimming the knitted component along a first trim line when it is selected to form the article of footwear to fit the first foot size, and wherein trimming the knitted component includes trimming the knitted component along a second trim line when it is selected to form the article of footwear to fit the second foot size, the second trim line being spaced from the first trim line in the inboard direction on the knitted component.

9. The method of claim 8, further comprising attaching a sole to the knitted component after trimming the knitted component, wherein attaching the sole includes attaching the exposed portion of the tensile strand to the sole.

10. A workpiece configured for forming one of a first upper for a first article of footwear and a second upper for a second article of footwear, the first upper and the first article of footwear configured to fit to a first foot size, and the second upper and the second article of footwear configured to fit to a second foot size, the workpiece comprising:

a knitted component having a knit element and a tensile strand that are formed of unitary knit construction, the knitted component configured to at least partially form one of the first upper and the second upper, the knit element defining a body and a trim region, the trim region defining an outer edge of the knit element, the tensile strand including at least one inlaid portion that is inlaid within the knit element, the tensile strand also including an exposed portion that is exposed from the knit element and that is disposed adjacent the outer edge, the exposed portion being configured for pulling to thereby move and adjust the at least one inlaid portion relative to the knit element, wherein the exposed portion is spaced from the outer edge in an inboard direction on the knit element, and wherein the trim region is trimmable along one of a first trim line to form the first upper and a second trim line to form the second upper.

11. The workpiece of claim 10, wherein the knitted component includes a first inlaid portion and a second inlaid portion of the tensile strand, and wherein the exposed portion extends continuously between the first inlaid portion and the second inlaid portion.

12. The workpiece of claim 10, wherein the knit element includes a first layer and a second layer formed of unitary knit construction, the first layer and the second layer overlaying each other and connected in the body, the first layer and the second layer overlaying each other and disconnected in the trim region, and wherein the exposed portion of the tensile strand is disposed between the first layer and the second layer in the trim region.

13. The workpiece of claim 10, wherein the knit element includes a first layer and a second layer formed of unitary knit construction, the first layer and the second layer overlaying each other and connected in the body, the first layer extending further in an outboard direction on the knitted component than the second layer to define the trim region and the outer edge, and wherein the exposed portion of the tensile strand is disposed on the first layer within the trim region.

14. The workpiece of claim 10, further comprising a skin layer that is attached to the knitted component, the skin layer lying over at least one of the first trim line and the second trim line.

15. The workpiece of claim 10, further comprising a sole structure that is attached to one of the first upper and the second upper, the sole structure further attached to the exposed portion of the tensile strand.