Article of footwear incorporating a knitted component
First Claim
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1. A method for manufacturing an upper for an article of footwear, the method comprising:
- forming a knitted component to include a throat area, an attachment area, a first tubular structure, and a second tubular structure, the attachment area configured to be attached to a sole structure, the first tubular structure and the second tubular structure extending from the throat area to the attachment area, the first tubular structure and the second tubular structure being separated by an adjacent region, the first tubular structure and the second tubular structure projecting from the adjacent region, at least one of the first tubular structure and the second tubular structure defining a protrusion that has a different thickness from the adjacent region, the protrusion including a first area and a second area, the first area and the second area projecting in opposite directions from the adjacent region;
positioning a skin layer adjacent to the knitted component and in an overlapping configuration such that the skin layer overlaps the first tubular structure, the second tubular structure, and the adjacent region, the skin layer overlapping the first area;
locating the skin layer and the knitted component between a first surface and a second surface of a press, the first surface including a first material, and the second surface including a second material, the first material having greater compressibility than the second material; and
compressing the skin layer and the knitted component between the first surface and the second surface to join the skin layer to the knitted component;
protruding the first area of the protrusion and the skin layer together into the first material to a first depth; and
protruding the second area of the protrusion into the second material to a second depth;
wherein an inlaid strand extends through the first tubular structure;
wherein a plurality of yarn sections are within the second tubular structure and extend across the second tubular structure; and
wherein the first depth is greater than the second depth.
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Abstract
An article of footwear has an upper and a sole structure secured to the upper. The upper includes a knitted component and, in some configurations, a skin layer secured to the knitted component. The knitted component may have a plurality of protruding areas that extend outward and away from a void within the upper for receiving a foot of a wearer. The protruding areas may include one or both of (a) a first tubular structure and an inlaid strand extending through the first tubular structure and (b) a second tubular structure and yarn sections extending across the second tubular structure.
119 Citations
20 Claims
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1. A method for manufacturing an upper for an article of footwear, the method comprising:
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forming a knitted component to include a throat area, an attachment area, a first tubular structure, and a second tubular structure, the attachment area configured to be attached to a sole structure, the first tubular structure and the second tubular structure extending from the throat area to the attachment area, the first tubular structure and the second tubular structure being separated by an adjacent region, the first tubular structure and the second tubular structure projecting from the adjacent region, at least one of the first tubular structure and the second tubular structure defining a protrusion that has a different thickness from the adjacent region, the protrusion including a first area and a second area, the first area and the second area projecting in opposite directions from the adjacent region; positioning a skin layer adjacent to the knitted component and in an overlapping configuration such that the skin layer overlaps the first tubular structure, the second tubular structure, and the adjacent region, the skin layer overlapping the first area; locating the skin layer and the knitted component between a first surface and a second surface of a press, the first surface including a first material, and the second surface including a second material, the first material having greater compressibility than the second material; and compressing the skin layer and the knitted component between the first surface and the second surface to join the skin layer to the knitted component; protruding the first area of the protrusion and the skin layer together into the first material to a first depth; and protruding the second area of the protrusion into the second material to a second depth; wherein an inlaid strand extends through the first tubular structure; wherein a plurality of yarn sections are within the second tubular structure and extend across the second tubular structure; and wherein the first depth is greater than the second depth. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of manufacturing an element, the method comprising:
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forming a knitted component to include a throat area, an attachment area, a first tubular structure, and a second tubular structure, the attachment area configured to be attached to a sole structure, the first tubular structure and the second tubular structure extending from the throat area to the attachment area, the first tubular structure and the second tubular structure being separated by an adjacent region, the first tubular structure and the second tubular structure projecting from the adjacent region, at least one of the first tubular structure and the second tubular structure defining a protrusion that has a greater thickness than the adjacent region, the protrusion including a first area and a second area, the first area and the second area projecting in opposite directions from the adjacent region; positioning a skin layer adjacent to the knitted component and in an overlapping configuration such that the skin layer overlaps the first tubular structure, the second tubular structure, and the adjacent region, the skin layer overlapping the first area; locating the skin layer and the knitted component between a first surface and a second surface of a press, the skin layer being located adjacent to the first surface, and the knitted component being located adjacent to the second surface, the first surface including a first material, and the second surface including a second material, the first material having greater compressibility than the second material, and each of the first surface and the second surface having a substantially planar configuration; heating the skin layer and the knitted component; and compressing the skin layer and the knitted component between the first surface and the second surface such that (a) the skin layer together with the first area of the protrusion protrude into the first surface to a first depth, (b) portions of the skin layer that are in contact with the adjacent region of the knitted component protrude into the first surface to a second depth, and (c) the second area of the protrusion protrudes into the second surface to a third depth, the first depth being greater than the second depth, and the first depth being greater than the third depth; wherein an inlaid strand extends through the first tubular structure; and wherein a plurality of yarn sections are within the second tubular structure and extend across the second tubular structure. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20)
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Specification