Method of manufacturing an article of footwear having a knit upper with a polymer layer
First Claim
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1. A method of manufacturing an article of footwear, the method comprising:
- utilizing a flat knitting process to form a knitted component having a first surface and an opposite second surface and including a tubular structure, wherein the tubular structure comprises a first knitted layer and a second knitted layer that are overlapping and joined along opposite edges to form an unsecured central area of the tubular structure;
bonding a polymer layer to the first surface of the knitted component such that the polymer layer infiltrates and bonds to the first knitted layer of the tubular structure and remains unsecured to the second knitted layer of the tubular structure; and
incorporating the knitted component and the polymer layer into an upper of the article of footwear, the polymer layer forming a majority of an exterior surface of the upper.
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Abstract
A method of manufacturing an article of footwear with an upper and a sole structure secured to the upper is described. The upper includes a knitted component and a polymer layer. The knitted component is formed of unitary knit construction and 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. The polymer layer is bonded to the knitted component and may form a majority of an exterior surface of the upper. The polymer layer may be formed from a thermoplastic polymer material.
82 Citations
19 Claims
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1. A method of manufacturing an article of footwear, the method comprising:
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utilizing a flat knitting process to form a knitted component having a first surface and an opposite second surface and including a tubular structure, wherein the tubular structure comprises a first knitted layer and a second knitted layer that are overlapping and joined along opposite edges to form an unsecured central area of the tubular structure; bonding a polymer layer to the first surface of the knitted component such that the polymer layer infiltrates and bonds to the first knitted layer of the tubular structure and remains unsecured to the second knitted layer of the tubular structure; and incorporating the knitted component and the polymer layer into an upper of the article of footwear, the polymer layer forming a majority of an exterior surface of the upper. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of manufacturing an article of footwear including an upper incorporating a knitted component, the method comprising:
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forming the knitted component of unitary knit construction during a knitting process, the knitted component including a tubular structure comprising a first knitted layer and a second knitted layer that are overlapping and joined along opposite edges to form an unsecured central area of the tubular structure; inlaying a strand having a configuration of a one-dimensional material within at least a portion of a length of the unsecured central area of the tubular structure during the knitting process; securing a polymer layer to the knitted component, the polymer layer forming a majority of an exterior surface of the upper; and wherein the polymer layer infiltrates and bonds to the first knitted layer of the tubular structure and remains unsecured to the second knitted layer of the tubular structure. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification