Article of footwear having an upper incorporating a knitted component

• US 9,668,533 B2
• Filed: 03/06/2014
• Issued: 06/06/2017
• Est. Priority Date: 12/18/2008
• Status: Active Grant

• Current Assignee: Fabdesigns, Inc., Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh, Shaffer, Benjamin A., Huffa, Bruce
• Primary Examiner(s): Worrell, Danny
• Application Number:
  US14/198,620
• Publication Number:
  US 20140245639A1
• Time in Patent Office: 1,188 Days
• 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 7/20 Ankle-joint supports or holders
• CPC Class Codes: A43C 1/04 with rings or loops
• CPC Class Codes: D04B 1/106 at a selvedge, e.g. hems or turned welts
• 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: D04B 1/24 wearing apparel
• CPC Class Codes: D10B 2401/041 thermoplastic; thermosetting
• CPC Class Codes: D10B 2403/0113 One surface including hollow piping or integrated straps, e.g. for inserts or mountings
• CPC Class Codes: D10B 2403/022 Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics
• 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 has an upper that includes a knitted component and a sole structure secured to the upper. The knitted component may define a tube formed of unitary knit construction, and a strand may extend through a length of the tube. As another example, the knitted component may have a pair of at least partially coextensive knitted layers formed of unitary knit construction, and a plurality of floating yarns may extend between the knitted layers. In some configurations, the knit type or yarn type may vary in different regions of the knitted component to impart different properties. Additionally, the knitted component may incorporate a thermoplastic yarn that is fused in different regions of the knitted component to impart different properties. A flat knitting process or a variety of other knitting processes may be utilized to form the knitted component.

Claims

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

a knitted component formed of unitary knit construction, the knitted component including at least one tubular structure disposed on the upper;

the at least one tubular structure comprising a first knitted layer and a second knitted layer that are at least partially coextensive with each and are joined along edges of the first knitted layer and the second knitted layer to form a tube defining an unsecured central area of the tubular structure;

a strand having a configuration of a one-dimensional material, the strand extending through the unsecured central area of the tube between the first knitted layer and the second knitted layer;

wherein the tube formed by the first knitted layer and the second knitted layer has a unitary knit construction so as to be a one-piece element with the upper; and

the knitted component including at least one yarn formed from a thermoplastic polymer material and incorporated into one of the first knitted layer and the second knitted layer, wherein the thermoplastic polymer material is fused to at least a portion of the strand extending through the tube.

2. The article of footwear according to claim 1, wherein the at least one yarn formed from the thermoplastic polymer material is incorporated into the first knitted layer and the second knitted layer.

3. The article of footwear according to claim 1, wherein the thermoplastic polymer material is fused to lock loops of the knitted component incorporating the at least one yarn formed from the thermoplastic polymer material together.

4. The article of footwear according to claim 1, wherein the strand is made of the thermoplastic polymer material.

5. The article of footwear according to claim 4, wherein the thermoplastic polymer material of the strand is fused to yarns forming at least one of the first knitted layer and the second knitted layer of the tubular structure.

6. The article of footwear according to claim 5, wherein the strand is fused to at least one of the first knitted layer and the second knitted layer to lock the position of the strand within the tube.

17. The article of footwear of claim 1, wherein the cross-sectional width of the strand is substantially equal to its cross-sectional thickness.

7. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a first yarn forming a first knitted layer that comprises at least a portion of an exterior surface of the upper;

a second yarn forming a second knitted layer that comprises at least a portion of an interior surface of the upper, the second knitted layer formed of unitary knit construction with the first knitted layer, the second knitted layer being positioned adjacent to the first knitted layer and at least partially coextensive with the first knitted layer;

at least one tubular structure comprising the first knitted layer and the second knitted layer, the first knitted layer and the second knitted layer overlapping and joined to each other along opposite edges to define sides of a tube between the first knitted layer and the second knitted layer; and

a strand having a configuration of a one-dimensional material, the strand extending through the tube and between the first knitted layer and the second knitted layer;

wherein the tube formed by the first knitted layer and the second knitted layer has a unitary knit construction so as to be a one-piece element with the upper; and

wherein at least one of the first yarn and the second yarn includes a thermoplastic polymer material fused to at least a portion of the strand extending through the tube.

8. The article of footwear according to claim 7, wherein the first knitted layer extends along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper;

and

wherein the at least one tubular structure extends along at least one of the medial side and the lateral side of the upper.

9. The article of footwear according to claim 8, wherein the at least one tubular structure is oriented to extend upward from an area proximal the sole structure;

and

a portion of the strand extends outward from an end of the tubular structure and forms a loop that receives a lace.

10. The article of footwear according to claim 7, wherein the strand is fused to at least one of the first knitted layer and the second knitted layer to lock the position of the strand within the tube.

11. The article of footwear according to claim 7, wherein the upper includes at least one fused area, the at least one fused area including the at least one of the first yarn and the second yarn that includes the thermoplastic polymer material fused to lock loops of the first knitted layer and the second knitted layer together.

12. The article of footwear according to claim 11, wherein the at least one fused area is disposed in a heel region of the upper.

13. The article of footwear according to claim 11, wherein the at least one fused area is disposed in a forefoot region of the upper.

14. The article of footwear according to claim 7, wherein the strand is made of the thermoplastic polymer material.

18. The article of footwear of claim 7, wherein the cross-sectional width of the strand is substantially equal to its cross-sectional thickness.

15. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component formed of unitary knit construction, the knitted component comprising a first knitted layer and a second knitted layer that are at least partially coextensive with each other;

the knitted component including a plurality of tubular structures, the plurality of tubular structures comprising the first knitted layer and the second knitted layer that are overlapping and joined to each other along opposite edges to define sides of a first tube and a second tube, the first tube and the second tube being formed by the first knitted layer and the second knitted layer to have unitary knit construction so as to be a one-piece element with the remaining portion of the knitted component, the first tube disposed at a first location on the knitted component, the second tube disposed at a second location on the knitted component, the first tube and the second tube extending in an upward direction from an area proximal the sole structure, and first ends of the first tube and the second tube being located in an upper area of the upper and second ends of the first tube and the second tube being located in the area proximal the sole structure;

a strand extending through the first tube and the second tube, a portion of the strand extending between the first ends of the first tube and the second tube to form a loop,

wherein at least one of the first knitted layer and the second knitted layer are formed by a yarn made of a thermoplastic polymer material that is fused to at least a portion of the strand extending through the first tube and the second tube.

16. The article of footwear according to claim 15, wherein the strand is fused to at least one of the first knitted layer and the second knitted layer to lock the position of the strand within the tube.

19. The article of footwear of claim 15, wherein the strand has a configuration of a one-dimensional material.

20. The article of footwear of claim 19, wherein the cross-sectional width of the strand is substantially equal to its cross-sectional thickness.