Article of footwear having a flat knit upper construction or other upper construction

• US 8,225,530 B2
• Filed: 11/10/2006
• Issued: 07/24/2012
• Est. Priority Date: 11/10/2006
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Sokolowski, Susan L., Dua, Bhupesh, Thomas, Edward Nathaniel
• Primary Examiner(s): Kavanaugh, Ted
• Application Number:
  US11/558,501
• Publication Number:
  US 20080110049A1
• Time in Patent Office: 2,083 Days
• Field of Search: 36/501, 36/89, 36/9.R, 36/71.R, 121/42.G, 121/46.C, 223/9
• US Class Current: 36/9.R
• CPC Class Codes: A41B 11/00 Hosiery; Panti-hose elastic stockings for curative purposes A61F13/08
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/02 Uppers; Boot legs
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 23/04 Uppers made of one piece; Uppers with inserted gussets
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 3/0031 provided with a pocket, e.g. for keys or a card
• CPC Class Codes: A43C 1/04 with rings or loops
• CPC Class Codes: A43C 11/14 Clamp fastenings , e.g. strap fastenings; Clamp-buckle fastenings; Fastenings with toggle levers
• CPC Class Codes: A43C 11/1493 Strap fastenings having hook and loop-type fastening elements
• CPC Class Codes: D04B 1/22 specially adapted for knitting goods of particular configuration
• CPC Class Codes: D04B 1/24 wearing apparel
• CPC Class Codes: D10B 2403/0113 One surface including hollow piping or integrated straps, e.g. for inserts or mountings
• CPC Class Codes: D10B 2403/032 Flat fabric of variable width, e.g. including one or more fashioned panels
• CPC Class Codes: D10B 2403/0331 with one or more convex or concave portions of limited extension, e.g. domes or pouches
• CPC Class Codes: D10B 2501/043 Footwear
• CPC Class Codes: D10B 2501/061 Piped openings (pockets)

Abstract

An article of footwear may include an upper with a knitted element formed through a flat knitting process. In one configuration, the knitted element has an area with a first layer and a second layer at least partially coextensive with the first layer. The first layer is formed of unitary construction with the second layer, and the second layer is joined to the first layer at opposite sides of the second layer. In another configuration, a knitted element for footwear includes a foot-receiving portion and one or more straps formed of unitary construction with the foot-receiving portion. The foot-receiving portion defines a void for receiving the foot, and the strap(s) extend outward from sides of the foot-receiving portion.

Claims

1. A method of manufacturing an article of footwear, comprising:

forming during a knitting process a knitted element that includes a seamless knitted foot-receiving portion and a pair of knitted straps of unitary construction with the foot-receiving portion, the knitted straps extending outward from a face of the knitted element; and

forming an opening for receiving a foot in the foot-receiving portion during the knitting process.

2. The method recited in claim 1, wherein the forming includes utilizing a flat knitting process to form the knitted element.

3. The method recited in claim 1, wherein the forming includes locating the straps to be adjacent an opening in the foot-receiving portion.

4. The method recited in claim 1, wherein the forming includes tapering the straps.

5. The method recited in claim 1, wherein the forming includes structuring each strap to have a first width adjacent the foot-receiving portion and a second width at an end portion, the first width being greater than the second width.

6. The method recited in claim 1, wherein the pair of straps extend outward from at least one of a lateral facing side and a medial facing side of the foot-receiving portion.

7. The method recited in claim 1, wherein the pair of straps are configured to extend around an ankle.

8. The method recited in claim 1, wherein the pair of straps are configured to extend over an upper surface of a foot.

9. The method recited in claim 1, further comprising securing at least a portion of a fastener to an end of the first strap.

10. The method recited in claim 1, wherein the forming includes knitting the seamless knitted foot-receiving portion with a finished foot-receiving opening.

11. The method recited in claim 1, further comprising securing the knitted element to a sole element.

12. A method of manufacturing an article of footwear, comprising:

forming during a knitting process a knitted element that includes a seamless knitted foot-receiving portion and a first knitted strap of unitary construction with the foot-receiving portion, wherein the foot-receiving portion extends under a heel of a foot, the first knitted strap extending outward from a face of the knitted element;

forming an opening for receiving the foot in the foot-receiving portion during the knitting process; and

securing at least a portion of a fastener to an end of the first strap.

13. The method recited in claim 12, wherein the forming includes utilizing a flat knitting process to form the knitted element.

14. The method recited in claim 12, wherein the forming includes locating the first strap to be adjacent an opening in the foot-receiving portion.

15. The method recited in claim 12, wherein the forming includes forming a second strap of unitary construction with the foot-receiving portion.

16. The method recited in claim 15, wherein the first strap and the second strap are on opposite sides of the foot-receiving portion.

17. The method recited in claim 15, wherein the first strap and the second strap are on the same side of the foot-receiving portion.

18. The method recited in claim 12, wherein the forming includes forming a second strap of unitary construction with the foot-receiving portion on the same side of the foot-receiving portion as the first strap, forming a third strap of unitary construction with the foot-receiving portion on an opposite side of the foot-receiving portion from the first and second straps, and forming a fourth strap of unitary construction with the foot-receiving portion on the opposite side of the foot-receiving portion from the first and second straps.

19. The method recited in claim 12, wherein the first strap extends outward from at least one of a lateral facing side and a medial facing side of the foot-receiving portion.

20. The method recited in claim 12, wherein the first strap is configured to extend around an ankle.

21. The method recited in claim 12, wherein the first strap is configured to extend over an upper surface of a foot.

22. The method recited in claim 12, wherein the strap is at least 6 inches long.

23. The method recited in claim 12, wherein the forming includes knitting the seamless knitted foot-receiving portion with a finished foot-receiving opening.

24. The method recited in claim 12, further comprising securing the knitted element to a sole element.

25. A method of manufacturing an article of footwear, comprising:

forming during a knitting process a knitted element that includes a seamless knitted foot-receiving portion and a first knitted strap of unitary construction with the foot-receiving portion,

wherein the foot-receiving portion has at least one of a lateral facing side and a medial facing side and defines a void for receiving a foot, and

wherein the first strap extends outward from an exterior face of the at least one lateral facing side and medial facing side of the foot-receiving portion.

26. The method recited in claim 25, wherein the forming includes utilizing a flat knitting process to form the knitted element.

27. The method recited in claim 25, wherein the forming includes forming a second strap of unitary construction with the foot-receiving portion.

28. The method recited in claim 27, wherein the first strap and the second strap are on opposite sides of the foot-receiving portion.

29. The method recited in claim 27, wherein the first strap and the second strap are on the same side of the foot-receiving portion.

30. The method recited in claim 25, wherein the forming includes forming a second strap of unitary construction with the foot-receiving portion on the same side of the foot-receiving portion as the first strap, forming a third strap of unitary construction with the foot-receiving portion on an opposite side of the foot-receiving portion from the first and second straps, and forming a fourth strap of unitary construction with the foot-receiving portion on the opposite side of the foot-receiving portion from the first and second straps.

31. The method recited in claim 25, wherein the first strap is configured to extend around an ankle.

32. The method recited in claim 25, wherein the first strap is configured to extend over an upper surface of a foot.

33. The method recited in claim 25, further comprising securing at least a portion of a fastener to an end of the first strap.

34. The method recited in claim 25, wherein the forming includes knitting the seamless knitted foot-receiving portion with a finished foot-receiving opening.

35. The method recited in claim 25, further comprising securing the knitted element to a sole element.

36. The method recited in claim 25, wherein the strap is joined to the foot-receiving portion proximate an opening for receiving a user'"'"'s foot.