Article of footwear incorporating a knitted component with integrally knit contoured portion

• US 9,848,672 B2
• Filed: 03/04/2013
• Issued: 12/26/2017
• Est. Priority Date: 03/04/2013
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Podhajny, Daniel A.
• Primary Examiner(s): BAYS, MARIE D
• Application Number:
  US13/783,900
• Publication Number:
  US 20140245634A1
• Time in Patent Office: 1,758 Days
• Field of Search: 36 84, 36 45, 36 48, 36 47, 36 54
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/0245 characterised by the constructive form
• CPC Class Codes: A43B 23/025 assembled by stitching
• CPC Class Codes: A43B 23/0265 having different properties in different directions
• CPC Class Codes: A43B 23/0275 with a part of the upper particularly rigid, e.g. resisting articulation or torsion
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 23/26 Tongues for shoes
• CPC Class Codes: D04B 1/108 Gussets, e.g. pouches or heel or toe portions
• 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 1/22 specially adapted for knitting goods of particular configuration
• 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 upper for an article of footwear includes a knitted component having unitary knit construction. The knitted component has a base portion configured to be disposed adjacent the sole structure. The knitted component also includes one or more side portions that extend from the base portion. Furthermore, the knitted component can have at least a first edge and a second edge that are joined at a seam to define a void that receives a foot. Additionally, the upper can include a tensile strand that extends through a passage defined between an exterior surface and an interior surface of the base portion.

Claims

1. An upper for an article of footwear that is configured to be connected to a sole structure and configured to receive a foot, the upper comprising:

a knitted component comprising a one-piece unit of unitary knit construction and comprising;

a base portion configured to be disposed adjacent the sole structure, a heel portion and a forefoot portion that extend from opposite ends of the base portion when in an unassembled configuration, a medial portion and a lateral portion that extend from opposite sides of the base portion when in an unassembled configuration, the medial and lateral portion cooperating to define a throat area between the medial and lateral portions, and a tongue portion that is configured to be disposed in the throat area, the tongue portion decoupled from at least one of the medial portion and the lateral portion and extending from the base portion;

a first edge of the knitted component; and

a second edge of the knitted component configured to be abbutingly coupled to the first edge at a seam causing the base portion, the heel portion, the forefoot portion, the medial portion, the lateral portion and the tongue portion to cooperatively define a void that is configured to receive the foot, wherein the seam is the only seam of the upper.

2. The upper of claim 1, wherein the heel portion and base portion cooperate to define a surface of a heel cavity having three dimensional curvature.

3. The upper of claim 1, wherein the forefoot portion and base portion cooperate to define a surface of a forefoot cavity having three dimensional curvature.

4. The upper of claim 1, wherein a gap is defined between the forefoot portion and one of the medial and lateral portions, the tongue portion extending from the base portion and disposed within the gap.

5. The upper of claim 1, wherein the knitted component includes a first tapered area with a first tapered boundary and a second tapered area with a second tapered boundary, the first tapered boundary joined to the second tapered boundary to provide the knitted component with a three dimensionally contoured surface.

6. The upper of claim 1, wherein the tongue portion includes a curved region having a plurality of knit courses that radiate from a common area to provide the curved region with curvature.

7. The upper of claim 1, further comprising a tensile strand that is incorporated in the unitary knit construction, the tensile strand extending across at least one of the base portion, the medial portion, and the lateral portion.

8. The upper of claim 7, wherein the tensile strand extends continuously between the base portion and one of the medial portion and the lateral portion.

9. The upper of claim 8, wherein the tensile strand extends continuously from the medial portion, through the base portion, to the lateral portion.

10. The upper of claim 9, wherein the tensile strand alternatingly extends between the medial portion and the lateral portion, the tensile strand extending through the base portion as the tensile strand alternates between the medial portion and the lateral portion.

11. The upper of claim 7, wherein the tensile strand includes a turn configured to receive and support a closure element that selectively secures the upper to the foot.

12. The upper of claim 11, wherein one of the medial portion and the lateral portion includes an opening and the turn extends at least partially around the opening, the, opening and the turn configured to cooperatively receive and support the closure element.

13. The upper of claim 12, wherein the turn is exposed from the one of the medial portion and the lateral portion.

14. The upper of claim 12, wherein the turn is enclosed between an exterior surface and an interior surface of the one of the medial portion and the lateral portion.

15. The upper of claim 7, wherein the base portion defines an interior surface of the knitted component and an exterior surface of the knitted component, a passage being defined between the interior surface and the exterior surface, and wherein the tensile strand extends through the passage.

16. The upper of claim 15, wherein a first longitudinal portion of the tensile strand is disposed inside the passage and a second longitudinal portion of the tensile strand is exposed from the passage.

17. The upper of claim 1, wherein the first edge and the second edge are coupled at the seam by at least one of stitching, bonding, welding, fasteners, tape and adhesives.

18. The upper of claim 1, wherein the seam includes stitching that is independent of stitching of the unitary knit construction.

19. The upper of claim 18, wherein the seam extends continuously from the base portion to at least one of the medial portion, the lateral portion, and the forefoot portion.

20. The upper of claim 19, wherein the seam is spaced from the heel portion such that the heel portion is seamless.