Method of lasting an article of footwear

• US 9,578,928 B2
• Filed: 10/30/2013
• Issued: 02/28/2017
• Est. Priority Date: 08/02/2010
• Status: Active Grant

• Current Assignee: Fabdesigns, Inc., Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Farris, Bryan N.
• Primary Examiner(s): Kavanaugh, Ted
• Application Number:
  US14/066,754
• Publication Number:
  US 20140123409A1
• Time in Patent Office: 1,217 Days
• Field of Search: 121/45, 121/42.C, 121/42.F
• US Class Current: 1/1
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 13/14 characterised by the constructive form
• CPC Class Codes: A43B 13/38 Built-in insoles joined to uppers during the manufacturing process, e.g. structural insoles; Insoles glued to shoes during the manufacturing process
• 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 23/025 assembled by stitching
• 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 9/00 Footwear characterised by the assembling of the individual parts
• CPC Class Codes: A43B 9/02 Footwear stitched or nailed through
• CPC Class Codes: A43B 9/12 Stuck or cemented footwear
• CPC Class Codes: A43D 3/00 Lasts
• CPC Class Codes: A43D 3/02 Lasts for making or repairing shoes making of wooden lasts B27M3/20
• CPC Class Codes: D04B 1/22 specially adapted for knitting goods of particular configuration
• CPC Class Codes: D10B 2403/021 Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
• CPC Class Codes: D10B 2403/022 Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics
• CPC Class Codes: D10B 2501/043 Footwear
• CPC Class Codes: Y10T 442/40 Knit fabric [i.e., knit strand or strip material]

Abstract

A method of manufacturing an article of footwear may include assembling at least a portion of an upper of the article of footwear, the upper having a lower perimeter edge. A knitted component forming a portion of the upper includes at least one strand formed with the knitted component. The strand passes through opposite sides of the upper along the lower perimeter edge. The strand is tensioned, and a sole structure of the article of footwear is joined to the upper.

Claims

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

forming a knitted component that defines an interior void for receiving a foot, includes a pair of opposite sides, and has at least one strand that passes through the opposite sides and forms a w-shaped configuration between the opposite sides, wherein the knitted component is formed on a knitting machine;

placing the knitted component over a last;

tensioning the strand to tighten the knitted component around the last; and

joining a sole structure of the article of footwear to the knitted component.

2. The method recited in claim 1, wherein the step of tensioning the strand includes drawing the opposite sides closer together along substantially all of a length of the knitted component.

3. The method recited in claim 1, further including a step of removing the strand from the knitted component after the step of joining the sole structure to the knitted component.

4. The method recited in claim 1, wherein the step of forming the knitted component includes utilizing a flat knitting process.

5. The method recited in claim 1, wherein the step of forming the knitted component includes providing the knitted component with a lower perimeter edge that extends around the knitted component between a lateral side and a medial side;

and

wherein the strand passes through the lower perimeter edge on the lateral side and the medial side of the knitted component.

6. The method recited in claim 1, further comprising forming the strand passing through the opposite sides of the knitted component in a single operation with the step of forming the knitted component.

7. The method recited in claim 1, wherein the knitted component including the strand passing through the opposite sides of the knitted component is formed as a one-piece element.

8. A method of manufacturing an article of footwear, the method comprising:

forming a knitted component that;

(a) forms at least a portion of an upper of the article of footwear and defines an interior void for receiving a foot, (b) includes a lower perimeter edge extending around the knitted component between a lateral side and a medial side of the upper, and (c) has at least one strand that extends through the lower perimeter edge on opposite sides of the knitted component so as to extend between the lateral side and the medial side of the upper, wherein the knitted component is formed on a knitting machine;

placing the knitted component having the at least one strand over a last;

tensioning the at least one strand to tighten the knitted component around the last; and

joining a sole structure of the article of footwear to the knitted component.

9. The method recited in claim 8, wherein the step of tensioning the at least one strand includes drawing the lower perimeter edge on the lateral side and the medial side closer together along substantially all of a length of the upper.

10. The method recited in claim 8, wherein the step of joining the sole structure to the knitted component includes bonding the sole structure to the knitted component along the lower perimeter edge.

11. The method recited in claim 8, further including a step of removing the at least one strand from the knitted component after the step of joining the sole structure to the knitted component.

12. The method recited in claim 8, wherein the step of forming the knitted component includes utilizing a flat knitting process to knit the knitted component having the at least one strand.

13. The method recited in claim 8, wherein the at least one strand passes through the lower perimeter edge of the knitted component on the lateral side and the medial side of the upper in an alternating manner so as form a w-shaped configuration.

14. The method recited in claim 8, further comprising forming the at least one strand passing through the lower perimeter edge on opposite sides of the knitted component in a single operation with the step of forming the knitted component.

15. The method recited in claim 8, wherein the knitted component including the strand passing through the lower perimeter edge on opposite sides of the knitted component is formed as a one-piece element.

16. The method recited in claim 8, wherein the step of forming the knitted component further comprises forming the knitted component with at least two knit types.

17. The method recited in claim 8, wherein the step of forming the knitted component further includes forming the knitted component with the at least one strand passing through the lower perimeter edge in an alternating manner between the opposite sides of the knitted component along an entirety of a length of the upper.

18. The method recited in claim 8, wherein the step of forming the knitted component further includes forming at least one tube in the knitted component comprising overlapping knitted layers.

19. The method recited in claim 18, further comprising the step of laying in at least one lace strand within the at least one tube during the step of forming the knitted component.

20. A method of manufacturing an upper for an article of footwear, the method comprising:

forming a knitted component that defines an interior void for receiving a foot, includes a pair of opposite sides, includes at least one tube with overlapping knitted layers, and has at least one strand that passes through the opposite sides and forms a w-shaped configuration between the opposite sides, wherein the knitted component is formed on a knitting machine;

placing the knitted component over a last; and

tensioning the strand to tighten the knitted component around the last,

wherein forming the knitted component includes laying in at least one lace strand within the at least one tube.