Article of footwear incorporating a trimmed knitted upper

• US 9,339,076 B2
• Filed: 02/27/2014
• Issued: 05/17/2016
• Est. Priority Date: 09/05/2013
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Droege, John, Podhajny, Daniel A.
• Primary Examiner(s): BAYS, MARIE D
• Application Number:
  US14/191,619
• Publication Number:
  US 20150059211A1
• Time in Patent Office: 810 Days
• Field of Search: 36/45, 121/46.C, 121/46.CK
• US Class Current: 1/1
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/02 Uppers; Boot legs
• CPC Class Codes: A43B 23/0205 characterised by the material material of the lining A43B23/07, material of toe stiffeners or heel stiffeners A43B23/08
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/0255 assembled by gluing or thermo bonding
• CPC Class Codes: A43B 23/0275 with a part of the upper particularly rigid, e.g. resisting articulation or torsion
• CPC Class Codes: A43B 23/086 made of impregnated fabrics, plastics or the like
• CPC Class Codes: A43B 3/0089 with means to identify the size of the shoe
• CPC Class Codes: A43B 5/00 Footwear for sporting purposes non-skid devices, e.g. ice-spurs or studs for football shoes, A43C15/00
• CPC Class Codes: A43C 1/00 Shoe lacing fastenings garment fastening devices A41F
• CPC Class Codes: D04B 1/123 with laid-in unlooped yarn, e.g. fleece fabrics with elastic weft yarn D04B1/18
• CPC Class Codes: D10B 2403/0113 One surface including hollow piping or integrated straps, e.g. for inserts or mountings
• CPC Class Codes: D10B 2403/0243 enhancing functional properties
• 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 connected to the sole structure. The upper includes a flat knitted component formed of unitary knit construction. The flat knitted component includes a trim region that defines a trimmed outer edge of the flat knitted component. The trimmed outer edge is disposed proximate to the sole structure. The trimmed outer edge defines a first dimension of the flat knitted component that corresponds to a first foot size. The trim region further defines a trim line that is spaced from the trimmed outer edge in an inboard direction on the flat knitted component. The trim line defines a second dimension of the flat knitted component that corresponds to a second foot size.

Claims

1. An article of footwear associated with one of a first foot size and a second foot size, the article of footwear comprising:

a sole structure; and

an upper that is connected to the sole structure, the upper including a flat knitted component formed of unitary knit construction;

the flat knitted component including a trim region that defines a trimmed outer edge of the flat knitted component, the trimmed outer edge being disposed proximate to the sole structure;

wherein the trimmed outer edge of the flat knitted component is associated with a first dimension of the upper that corresponds to the first foot size;

wherein the trim region further comprises a trim line that is spaced from the trimmed outer edge in an inboard direction on the flat knitted component; and

wherein the trim line defines a second dimension of the upper that corresponds to the second foot size, the second foot size being smaller than the first foot size.

2. The article of footwear of claim 1, the upper further comprising a skin layer, the skin layer being attached to the flat knitted component along a portion of the trimmed outer edge to prevent unraveling of the flat knitted component at the trimmed outer edge.

3. The article of footwear of claim 1, wherein the flat knitted component includes at least one fusible strand that is disposed proximate the trimmed outer edge, the at least one fusible strand being configured to prevent unraveling of the flat knitted component at the trimmed outer edge.

4. The article of footwear of claim 1, wherein the flat knitted component comprises a knit element and at least one tensile strand, the knit element and the tensile strand being formed of unitary knit construction;

wherein the knit element includes the trim region;

wherein the at least one tensile strand further includes an inlaid portion that is inlaid within the knit element and an exposed portion that is exposed from the knit element;

wherein the exposed portion of the at least one tensile strand is disposed adjacent the trimmed outer edge and is configured to be manipulated for moving and adjusting the inlaid portion relative to the knit element; and

wherein the exposed portion is spaced from the trimmed outer edge in the inboard direction on the flat knitted component.

5. The article of footwear of claim 4, wherein the inlaid portion is a first inlaid portion, the at least one tensile strand further including a second inlaid portion that is inlaid within the knit element;

and

wherein the exposed portion of the at least one tensile strand extends continuously between the first inlaid portion and the second inlaid portion.

6. The article of footwear of claim 4, wherein the knit element includes a first layer and a second layer formed of unitary knit construction;

wherein the first layer and the second layer overlay each other and are disconnected in the trim region;

wherein the first layer and the second layer cooperate to define the trimmed outer edge; and

wherein the exposed portion of the at least one tensile strand is disposed between the first layer and the second layer in the trim region.

7. The article of footwear of claim 4, wherein the knit element includes a body that is at least partially bordered by the trim region;

wherein the knit element includes a first layer and a second layer formed of unitary knit construction, wherein the first layer and the second layer overlay each other and are connected in the body;

wherein the first layer extends away in an outboard direction from the body and the second layer to define the trim region and the trimmed outer edge; and

wherein the exposed portion of the at least one tensile strand is disposed on the first layer within the trim region.

8. The article of footwear of claim 1, wherein the trimmed outer edge extends continuously between a medial side of the upper, a forefoot region of the upper, and a lateral side of the upper.

9. An article of footwear configured to fit a foot size, the article of footwear comprising:

a sole structure; and

an upper that is connected to the sole structure, the upper including a knitted component formed of unitary knit construction, the knitted component comprising;

a knit element that includes a trim region that defines a trimmed outer edge of the knitted component, wherein the trimmed outer edge is trimmed to a predetermined dimension, the predetermined dimension corresponding to the foot size; and

a tensile strand formed of unitary knit construction with the knit element, the tensile strand including an inlaid portion that is inlaid within the knit element, the tensile strand further including an exposed portion that is exposed from the knit element;

wherein the exposed portion is disposed adjacent the trimmed outer edge;

wherein the exposed portion is configured to be manipulated for moving and adjusting the inlaid portion relative to the knit element; and

wherein the exposed portion is spaced from the trimmed outer edge in an inboard direction on the knit element.

10. The article of footwear of claim 9, wherein the inlaid portion is a first inlaid portion, the tensile strand further including a second inlaid portion that is inlaid within the knit element;

and

wherein the exposed portion extends continuously between the first inlaid portion and the second inlaid portion.

11. The article of footwear of claim 9, wherein the knit element includes a first layer and a second layer formed of unitary knit construction;

wherein the first layer and the second layer overlay each other and are disconnected in the trim region;

wherein the first layer and the second layer cooperate to define the trimmed outer edge; and

wherein the exposed portion is disposed between the first layer and the second layer in the trim region.

12. The article of footwear of claim 9, wherein the knit element further includes a body that is at least partially bordered by the trim region;

wherein the knit element includes a first layer and a second layer formed of unitary knit construction;

wherein the first layer and the second layer overlay each other and are connected in the body;

wherein the first layer extends away in an outboard direction from the body and the second layer to define the trim region and the outer edge; and

wherein the exposed portion of the tensile strand is disposed on the first layer within the trim region.

13. A knitted component configured to be integrated into an upper of an article of footwear, the knitted component formed of unitary knit construction, the knitted component comprising:

a knit element, the knit element including a body and a trim region, the body configured to define at least a portion of the upper, the trim region defining an outer edge of the knit element, a first dimension of the knit element defined at least partly by the outer edge, the trim region configured to be trimmed along a predetermined trim line to reduce the first dimension to a second dimension; and

a tensile strand, the tensile strand being formed of unitary knit construction with the knit element, the tensile strand comprising;

an inlaid portion that is inlaid within the knit element; and

an exposed portion that is exposed from the knit element, the exposed portion being disposed adjacent the outer edge of the knit element;

wherein the exposed portion is configured to be manipulated for moving and adjusting the inlaid portion relative to the knit element; and

wherein the exposed portion is spaced from the outer edge of the knit element in an inboard direction on the knit element.

14. The knitted component of claim 13, further comprising a skin layer that is attached to a surface of the knit element.

15. The knitted component of claim 13, wherein the outer edge includes at least one indentation, and wherein the predetermined trim line is located within the trim region so as to remove the at least one indentation when the trim region is trimmed.

16. The knitted component of claim 13, wherein the knit element includes at least one fusible strand.

17. The knitted component of claim 13, wherein the inlaid portion is a first inlaid portion, the tensile strand further including a second inlaid portion that is inlaid within the knit element;

and

wherein the exposed portion extends continuously between the first inlaid portion and the second inlaid portion.

18. The knitted component of claim 13, the knit element further comprising a first layer and a second layer formed of unitary knit construction;

wherein the first layer and the second layer overlay each other and are disconnected in the trim region; and

wherein the exposed portion is disposed between the first layer and the second layer in the trim region.

19. The knitted component of claim 13, the knit element further comprising a first layer and a second layer formed of unitary knit construction;

wherein the first layer and the second layer overlay each other and are connected in the body, the first layer extending away in an outboard direction from the body and the second layer to define the trim region and the outer edge; and

wherein the exposed portion of the tensile strand is disposed on the first layer within the trim region.

20. The knitted component of claim 13, wherein the upper is configured to fit one of a first foot size and a second foot size, the first foot size being larger than the second foot size;

wherein the trim region is configured to be trimmed along a predetermined first trim line to reduce the first dimension to the second dimension, wherein the second dimension corresponds to the first foot size; and

wherein the trim region is configured to be trimmed along a predetermined second trim line to reduce the first dimension to a third dimension, wherein the third dimension corresponds to the second foot size.