Knitted component for an article of footwear including a full monofilament upper

• US 9,072,335 B1
• Filed: 02/03/2014
• Issued: 07/07/2015
• 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:
  US14/170,947
• Time in Patent Office: 519 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, 36/501
• US Class Current: 1/1
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/00 Uppers; Boot legs; Stiffeners; Other single parts of footwear
• CPC Class Codes: A43B 23/0235 Different layers of different material
• 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 1/04 with rings or loops
• CPC Class Codes: D04B 1/126 with colour pattern, e.g. intarsia fabrics
• CPC Class Codes: D04B 1/16 synthetic threads
• 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 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 full monofilament upper is described. The full monofilament upper incorporates a knitted component including a monofilament knit element. The monofilament knit element is 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. A knitted component for incorporating into a full monofilament upper of an article of footwear, the knitted component comprising:

a monofilament knit element formed by at least one monofilament strand, the monofilament knit element defining substantially all of an exterior surface of the full monofilament upper and an opposite interior surface of the full monofilament upper, the interior surface defining a void for receiving a foot;

wherein the monofilament knit element extends (a) through each of a forefoot region, a midfoot region, and a heel region of the article of footwear, and (b) across a top of the full monofilament upper between a medial side and a lateral side of the article of footwear; and

wherein the monofilament knit element includes a first side and an opposite second side formed by a plurality of intermeshed loops that define courses of the at least one monofilament strand, the first side forming a portion of the exterior surface of the full monofilament upper and the second side forming a portion of the interior surface of the full monofilament upper.

2. The knitted component according to claim 1, wherein the at least one monofilament strand comprises a first monofilament strand and a second monofilament strand.

3. The knitted component according to claim 2, wherein the first monofilament strand and the second monofilament strand each have a diameter of approximately 0.08 mm.

4. The knitted component according to claim 1, wherein the monofilament knit element comprises two knitted layers formed of unitary knit construction, the two knitted layers being overlapping and at least partially coextensive with each other;

and

wherein a first knitted layer includes the first side of the monofilament knit element forming the portion of the exterior surface and a second knitted layer includes the second side of the monofilament knit element forming the portion of the interior surface.

5. The knitted component according to claim 4, wherein the monofilament knit element includes a first monofilament strand and a second monofilament strand;

and

wherein the first knitted layer is formed by the first monofilament strand and the second knitted layer is formed by the second monofilament strand.

6. The knitted component according to claim 5, wherein the monofilament knit element includes at least one knit structure including a cross tuck stitch.

7. The knitted component according to claim 6, wherein the at least one knit structure includes a monofilament tuck strand having a first diameter extending between the first knitted layer and the second knitted layer.

8. The knitted component according to claim 7, wherein the first monofilament strand and the second monofilament strand each comprise two ends of a monofilament strand having a second diameter.

9. The knitted component according to claim 8, wherein the first diameter and the second diameter are equal.

10. The knitted component according to claim 9, wherein the first diameter and the second diameter are approximately 0.08 mm.

11. The knitted component according to claim 8, wherein the first diameter and the second diameter are different.

12. The knitted component according to claim 11, wherein the first diameter is larger than the second diameter.

13. The knitted component according to claim 7, wherein the first monofilament strand and the second monofilament strand each comprise two ends of monofilament having different diameters.

14. The knitted component according to claim 13, wherein the two ends of monofilament include a first end having a first diameter and a second end having a second diameter;

and

wherein the first diameter is larger than the second diameter.

15. The knitted component according to claim 14, wherein the first diameter is approximately 0.125 mm and the second diameter is approximately 0.08 mm.

16. The knitted component according to claim 14, wherein the monofilament tuck strand includes the first end and the second end.

17. The knitted component according to claim 1, wherein at least one course of the monofilament knit element includes a fusible strand.

18. The knitted component according to claim 1, further comprising an inlaid tensile element extending through at least a portion of the monofilament knit element.

19. A method of manufacturing a knitted component for incorporating into a full monofilament upper of an article of footwear, the method comprising:

knitting a monofilament knit element using at least one monofilament strand, the monofilament knit element forming substantially all of an exterior surface of the full monofilament upper and an opposite interior surface of the full monofilament upper, the interior surface defining a void for receiving a foot;

wherein the monofilament knit element extends (a) through each of a forefoot region, a midfoot region, and a heel region of the article of footwear, and (b) across a top of the full monofilament upper between a medial side and a lateral side of the article of footwear; and

wherein the step of knitting the monofilament knit element includes knitting a first side and an opposite second side by forming a plurality of intermeshed loops that define courses using the at least one monofilament strand, the first side forming a portion of the exterior surface of the full monofilament upper and the second side forming a portion of the interior surface of the full monofilament upper.

20. The method according to claim 19, wherein the step of knitting using the at least one monofilament strand further comprises:

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

21. The method according to claim 20, wherein the first monofilament strand and the second monofilament strand each have a diameter of approximately 0.08 mm.

22. The method according to claim 19, wherein the step of knitting using the first monofilament strand and the second monofilament strand includes knitting with the first monofilament strand and the second monofilament strand run together through a single dispensing tip of a feeder of a knitting machine.

23. The method according to claim 19, wherein the step of knitting the monofilament knit element further comprises:

knitting two knitted layers of unitary knit construction, the two knitted layers being overlapping and at least partially coextensive with each other;

the two knitted layers comprising a first knitted layer and a second knitted layer, wherein the first knitted layer includes the first side of the monofilament knit element forming the portion of the exterior surface and wherein the second knitted layer includes the second side of the monofilament knit element forming the portion of the interior surface.

24. The method according to claim 23, wherein the step of knitting the monofilament knit element further comprises:

knitting the first knitted layer using a first monofilament strand; and

knitting the second knitted layer using a second monofilament strand.

25. The method according to claim 24, wherein the step of knitting the monofilament knit element includes knitting at least one knit structure including a cross tuck stitch.

26. The method according to claim 25, wherein the step of knitting the at least one knit structure includes knitting using a monofilament tuck strand having a first diameter;

and

extending the monofilament tuck strand between the first knitted layer and the second knitted layer using the cross tuck stitch.

27. The method according to claim 24, wherein the first monofilament strand and the second monofilament strand each comprise two ends of monofilament having different diameters.

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

29. The method according to claim 19, 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.