ARTICLE OF FOOTWEAR WITH KNITTED COMPONENT HAVING BIASED INTER-TOE MEMBER

• US 20160302526A1
• Filed: 03/02/2016
• Published: 10/20/2016
• Est. Priority Date: 04/14/2015
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Meir, Adrian
• Granted Patent: US 10,130,142 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 23/0265 having different properties in different directions
• CPC Class Codes: A43B 23/04 Uppers made of one piece; Uppers with inserted gussets
• CPC Class Codes: A43B 3/0036 characterised by a special shape or design
• CPC Class Codes: D04B 1/12 characterised by thread material
• CPC Class Codes: D10B 2401/041 thermoplastic; thermosetting
• CPC Class Codes: D10B 2401/061 elastic
• 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 includes a sole structure and an upper that is attached to the sole structure. The upper includes a forefoot region that is configured to receive a plurality of toes of a foot. The upper includes a first zone having a first elasticity, a second zone having a second elasticity, and a third zone having a third elasticity. The third zone is disposed between the first zone and the second zone. The third elasticity is greater than the first elasticity and the second elasticity. The third zone is configured to bias the first zone and the second zone toward each other. The third zone is biased generally toward the sole structure and configured to be received in a space located between two of the plurality of toes of the foot.

Claims

1. An article of footwear configured to support a foot, the article of footwear comprising:

a sole structure; and

an upper that is attached to the sole structure, the upper including a forefoot region that is configured to receive a plurality of toes of the foot, the upper including;

a first zone having a first elasticity;

a second zone having a second elasticity; and

a third zone having a third elasticity, the third zone disposed between the first zone and the second zone;

the third elasticity being greater than the first elasticity and the second elasticity;

the third zone configured to bias the first zone and the second zone toward each other;

the third zone biased generally toward the sole structure and configured to be received in a space formed between two of the plurality of toes of the foot.

2. The article of footwear of claim 1, wherein the upper includes a heel region;

wherein the third zone is biased generally toward the heel region.

3. The article of footwear of claim 1, wherein the third zone and the first zone cooperate to define a toe cavity that is configured to receive at least one of the plurality of toes;

the toe cavity defined by an inner surface of the upper;

wherein at least a portion of the inner surface is configured to nest against the at least one toe.

4. The article of footwear of claim 3, wherein the at least one toe is a hallux of the foot;

wherein the third zone and the second zone cooperate to define an additional toe cavity that is configured to receive a second toe of the foot; and

wherein the third zone is configured to be received in the space located between the hallux and the second toe.

5. The article of footwear of claim 1, wherein the upper includes a knitted component formed of unitary knit construction;

and

wherein the knitted component defines the third zone.

6. The article of footwear of claim 5, wherein the knitted component defines at least one of an inner surface of the upper and an outer surface of the upper.

7. The article of footwear of claim 1, wherein the upper includes a knitted component and wherein the knitted component defines the first zone, the second zone, and the third zone;

and

wherein the first zone, the second zone, and the third zone are formed of unitary knit construction with each other.

8. The article of footwear of claim 1, wherein the third zone is knitted from an elastic yarn;

wherein at least one of the first zone and the second zone is knitted from an additional yarn; and

wherein the elastic yarn has greater elasticity than the additional yarn.

9. The article of footwear of claim 1, wherein the upper includes a heel region;

wherein the sole structure includes an attachment area that attaches to the upper;

wherein the third zone includes a front portion and a lofted portion, wherein the front portion extends from the attachment area away from the sole structure,

wherein the lofted portion extends from the front portion generally toward the heel region; and

wherein the front portion and the lofted portion are configured to be received within the space formed between two of the plurality of toes.

10. The article of footwear of claim 1, wherein the sole structure includes an attachment area that attaches to the upper;

wherein the upper includes a collar with a collar opening configured to allow passage of the foot into and out of the upper;

wherein the upper includes a throat that is disposed between a medial side and a lateral side of the upper;

wherein the first zone is disposed proximate the medial side;

wherein the second zone is disposed proximate the lateral side; and

wherein the third zone extends from the attachment area of the sole structure, along the throat, toward the collar.

11. The article of footwear of claim 10, wherein the third zone extends along the throat to the collar, and wherein the third zone extends continuously around the collar opening.

12. The article of footwear of claim 1, wherein the first elasticity is substantially equal to the second elasticity.

13. A method of manufacturing an article of footwear configured to be worn on a foot with a plurality of toes, the method comprising:

forming an upper of the article of footwear to include a first zone, a second zone, and a third zone that is disposed between the first zone and the second zone; and

attaching a sole structure to the upper;

wherein forming the upper includes providing the first zone with a first elasticity, providing the second zone with a second elasticity, and providing the third zone with a third elasticity, the third elasticity being greater than the first elasticity and the second elasticity;

wherein forming the upper includes forming the third zone such that the third zone biases the first zone and the second zone toward each other;

wherein forming the upper includes forming the third zone such that the third zone is biased toward the sole structure and is configured to be received in a space located between two of the plurality of toes of the foot.

14. The method of claim 13, further comprising applying at least one of heat and pressure to the upper to shape a forefoot region of the upper such that:

the first zone and the third zone cooperate to define a first toe cavity that is configured to receive a first toe of a wearer'"'"'s foot; and

the second zone and the third zone cooperate to define a second toe cavity that is configured to receive a second toe of the wearer'"'"'s foot.

15. The method of claim 13, wherein attaching the sole structure includes attaching an attachment area of the sole structure to the upper such that the third zone extends to the attachment area.

16. The method of claim 13, wherein forming the upper includes knitting a knitted component formed of unitary knit construction that defines the third zone.

17. The method of claim 13, wherein knitting the knitted component includes knitting the first zone, the second zone, and the third zone formed of unitary knit construction with each other.

18. An article of footwear configured to support a foot, the article of footwear comprising:

a sole structure with an attachment area; and

an upper that is attached to the attachment area of the sole structure, the upper including a knitted component formed of unitary knit construction, the knitted component defining a forefoot region and a heel region of the upper, the forefoot region including;

a first zone extending from the attachment area and defining a first cavity configured to receive a hallux of the foot, the first zone having a first elasticity;

a second zone extending from the attachment area and defining a second cavity configured to receive a second toe of the foot, the second zone having a second elasticity; and

a third zone extending from the attachment area and disposed between the first zone and the second zone, the third zone having a third elasticity that is greater than the first elasticity and the second elasticity;

wherein the third zone biased toward the sole structure and biased generally toward the heel region; and

wherein the third zone configured to be received within a space located between the hallux and the second toe.

19. The article of footwear of claim 18, wherein the third zone includes a front portion and a lofted portion, wherein the front portion extends from the attachment area away from the sole structure, wherein the lofted portion extends from the front portion generally toward the heel region;

and

wherein the front portion and the lofted portion are configured to be received within the space located between the hallux and the second toe.

20. The article of footwear of claim 18, wherein the upper includes a collar with a collar opening configured to allow passage of the foot into and out of the upper;

wherein the upper includes a throat that is disposed between a medial side and a lateral side of the upper;

wherein the first zone is disposed proximate the medial side;

wherein the second zone is disposed proximate the lateral side; and

wherein the third zone extends from the attachment area of the sole structure, along the throat, toward the collar.

21. The article of footwear of claim 18, wherein the first elasticity is substantially equal to the second elasticity.

22. An upper for an article of footwear that is configured to support a foot, the upper configured to attach to a sole structure, the upper comprising:

a knitted component formed of unitary knit construction, the knitted component defining a sole attachment area that is configured to attach to the sole structure, the knitted component defining a forefoot region of the upper, the forefoot region including;

a first zone having a first elasticity;

a second zone having a second elasticity; and

a third zone having a third elasticity, the third zone disposed between the first zone and the second zone;

the third elasticity being greater than the first elasticity and the second elasticity;

the third zone configured to bias the first zone and the second zone toward each other to define an inter-toe member;

the inter-toe member configured to be biased generally toward the sole structure and configured to be received in a space located between two of the plurality of toes of the foot.

23. The upper of claim 22, wherein the third zone includes a fold that defines the inter-toe member.

24. The upper of claim 22, wherein the knitted component includes a peripheral edge;

wherein at least a portion of the peripheral edge defines the sole attachment area; and

wherein the inter-toe member defines a recess at the peripheral edge.

25. The upper of claim 22, wherein the third zone is knitted from an elastic yarn;

wherein at least one of the first zone and the second zone is knitted from an additional yarn; and

wherein the elastic yarn has a greater elasticity than the additional yarn.

26. The upper of claim 22, wherein the knitted component defines a heel region of the upper;

and

wherein the inter-toe member is biased generally toward the heel region.