Article of footwear including a monofilament knit element with peripheral knit portions

• US 8,997,529 B1
• Filed: 02/03/2014
• Issued: 04/07/2015
• Est. Priority Date: 02/03/2014
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Podhajny, Daniel A.
• Primary Examiner(s): Worrell, Danny
• Application Number:
  US14/170,978
• Time in Patent Office: 428 Days
• Field of Search: 661/69.R, 661/70, 661/71, 661/77, 661/78.R, 661/96, 662/02, 36/45, 36/47, 36/48, 36/49, 121/42.R, 121/46.R, 121/46, 121/42.P
• US Class Current: 66/177
• 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 23/024 Different layers of the same material
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43C 1/00 Shoe lacing fastenings garment fastening devices A41F
• CPC Class Codes: A43C 1/04 with rings or loops
• 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: D10B 2401/041 thermoplastic; thermosetting
• 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 including a knitted component having a monofilament knit element with peripheral knit portions is described. The knitted component includes a monofilament knit element formed by knitting with a monofilament strand. The monofilament knit element is formed of unitary knit construction with the remaining portions of the knitted component, including peripheral portions that are knit using a natural or synthetic twisted fiber yarn. An inlaid tensile element can extend through the knitted component, including portions of the monofilament knit element. The monofilament knit element may be knitted with a monofilament strand according to a variety of knit structures.

Claims

1. An article of footwear having an upper and a sole structure secured to the upper, the upper including a knitted component comprising:

a monofilament knit element formed by at least one monofilament strand, the monofilament knit element forming a substantial majority of the upper and extending through at least a portion of each of a forefoot region, a midfoot region, and a heel region of the article of footwear; and

a peripheral portion formed by a first yarn, the first yarn being a natural or synthetic twisted fiber yarn;

wherein the monofilament knit element is formed of unitary knit construction with the peripheral portion of the knitted component such that the knitted component is a one-piece element; and

wherein the monofilament knit element comprises two knitted layers formed of unitary knit construction using the at least one monofilament strand, the two knitted layers being overlapping and at least partially coextensive with each other.

2. The article of footwear according to claim 1, wherein at least one course of the first yarn is substantially continuous with at least one course of the monofilament strand.

3. The article of footwear according to claim 1, wherein the peripheral portion includes a collar portion of the knitted component, the collar portion extending around and defining a throat opening of the upper of the article of footwear.

4. The article of footwear according to claim 3, wherein the peripheral portion further comprises a throat portion, the throat portion extending outward from the collar portion through an instep area of the upper;

and

wherein the collar portion and the throat portion are formed of unitary knit construction with each other and the monofilament knit element.

5. The article of footwear according to claim 1, wherein the at least one monofilament strand comprises a first monofilament strand and a second monofilament strand.

6. The article of footwear according to claim 5, wherein the first monofilament strand and the second monofilament strand each have a diameter of approximately 0.08 mm.

7. The article of footwear according to claim 1, wherein the at least one monofilament strand comprises a single monofilament strand.

8. The article of footwear according to claim 7, wherein the single monofilament strand has a diameter of approximately 0.125 mm.

9. The article of footwear according to claim 1, wherein at least one course of the monofilament knit element includes a fusible strand.

10. The article of footwear according to claim 1, further comprising an inlaid tensile element extending through at least a portion of the monofilament knit element.

11. A method of manufacturing an article of footwear having an upper and a sole structure secured to the upper, the upper including a knitted component, the method comprising:

knitting a monofilament knit element using at least one monofilament strand, the monofilament knit element forming a substantial majority of the upper and extending through at least a portion of each of a forefoot region, a midfoot region, and a heel region of the article of footwear;

knitting a peripheral portion using a first yarn, the first yarn being a natural or synthetic twisted fiber yarn; and

knitting the monofilament knit element of unitary knit construction with the peripheral portion of the knitted component so as to form the knitted component as a one-piece element; and

wherein the step of knitting the monofilament knit element further comprises knitting two knitted layers of unitary knit construction using the at least one monofilament strand, the two knitted layers being overlapping and at least partially coextensive with each other.

12. The method according to claim 11, the method further comprising:

knitting at least one course of the first yarn to be substantially continuous with at least one course of the monofilament strand.

13. The method according to claim 11, wherein the step of knitting the peripheral portion further comprises:

knitting a collar portion of the knitted component using the first yarn, the collar portion extending around and defining a throat opening of the upper of the article of footwear.

14. The method according to claim 13, wherein the step of knitting the peripheral portion further comprises:

knitting a throat portion of the knitted component, the throat portion extending outward from the collar portion through an instep area of the upper; and

knitting the collar portion and the throat portion of unitary knit construction with each other and the monofilament knit element so as to form the knitted component as a one-piece element.

15. The method according to claim 11, wherein the step of knitting the monofilament knit element using the at least one monofilament strand further comprises:

knitting the monofilament knit element using a first monofilament strand and a second monofilament strand.

16. The method according to claim 15, wherein the first monofilament strand and the second monofilament strand each have a diameter of approximately 0.08 mm.

17. The method according to claim 11, wherein the step of knitting the monofilament knit element using the at least one monofilament strand comprises knitting using a single monofilament strand.

18. The method according to claim 17, wherein the single monofilament strand has a diameter of approximately 0.125 mm.

19. The method according to claim 11, wherein the step of knitting the monofilament knit element includes knitting at least one course of the monofilament knit element using a fusible strand.

20. The method according to claim 11, wherein the method further comprises:

inlaying an inlaid tensile element within at least a portion of the monofilament knit element during the step of knitting the monofilament knit element.