Packaged Dyed Knitted Component

• US 20150320136A1
• Filed: 05/06/2014
• Published: 11/12/2015
• Est. Priority Date: 05/06/2014
• Status: Active Grant

• Current Assignee: Nike Innovate C.V. (Nike, Inc.)
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh, Hawkinson, Karen
• Granted Patent: US 10,194,711 B2
• Time in Patent Office: Days
• 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 23/0245 characterised by the constructive form
• CPC Class Codes: D02G 3/328 containing elastane
• CPC Class Codes: D02G 3/36 Cored or coated yarns or threads D02G3/34, D02G3/40 take precedence; elastic yarns or threads D02G3/32
• CPC Class Codes: D04B 1/12 characterised by thread material
• CPC Class Codes: D04B 1/16 synthetic threads
• CPC Class Codes: D04B 1/24 wearing apparel
• CPC Class Codes: D10B 2401/14 Dyeability
• CPC Class Codes: D10B 2501/043 Footwear

Abstract

A method of manufacturing an article of footwear includes providing a yarn that is at least partially package dyed. The method also includes flat knitting a knitted component at least partially from the yarn. The knitted component has an area with a density of at least twenty-eight courses per inch (28 CPI). Moreover, the method includes forming at least a portion of an upper of the article of footwear with the knitted component.

Claims

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

providing a yarn that is at least partially package dyed;

flat knitting a knitted component at least partially from the yarn, the knitted component having an area, the area having a density of at least twenty-eight courses per inch (28 CPI); and

forming at least a portion of an upper of the article of footwear with the knitted component.

2. The method of claim 1, wherein providing the yarn includes package dyeing at least a portion of the yarn.

3. The method of claim 2, wherein providing the yarn includes texturizing the at least a portion of the yarn before package dyeing the at least a portion of the yarn.

4. The method of claim 3, wherein providing the yarn includes increasing the thickness of the yarn from a first thickness to at least approximately 0.30 millimeters after package dyeing the at least a portion of the yarn.

5. The method of claim 4, wherein the yarn is a composite yarn that includes a covering strand and a core strand, and wherein providing the yarn includes:

texturizing the covering strand,

package dyeing the covering strand after texturizing the covering strand,

and at least one of;

re-texturizing the covering strand after package dyeing the covering strand, and

air covering the covering strand over the core strand to form the composite yarn.

6. The method of claim 5, wherein the core strand is resiliently elastic, and wherein the composite strand is resiliently stretchable between a first length and a second length.

7. The method of claim 1, wherein knitting the knitted component includes forming the area with a stitch density of at least four hundred stitches per square inch (400 stitches/in²).

8. The method of claim 1, wherein knitting the knitted component includes feeding the yarn toward the area at a tension of up to sixty grams (60 g).

9. The method of claim 1, wherein flat knitting the knitted component includes flat knitting the knitted component using a flat knitting machine, wherein the flat knitting machine has a predetermined gauge, and

wherein flat knitting the knitted component includes knitting with a needle that is larger than the predetermined gauge.

10. The method of claim 1, wherein providing the yarn includes providing a composite yarn having a core strand that is at least partially covered by a covering strand, and wherein the covering strand is package dyed.

11. The method of claim 1, wherein knitting the knitted area includes forming a tuck stitch with the yarn.

12. An article of footwear comprising:

a sole assembly; and

an upper that is attached to the sole assembly, the upper including a flat knitted component, the flat knitted component formed of unitary knit construction, the flat knitted component including an area that is formed from a yarn,

the yarn being at least partially packed dyed, and

the area having a density of at least twenty-eight courses per inch (28 CPI).

13. The article of footwear of claim 12, wherein the area has a stitch density of at least four hundred stitches per square inch (400 stitches/in²).

14. The article of footwear of claim 13, wherein the area has a stitch density of at least four hundred fifty stitches per square inch (450 stitches/in²).

15. The article of footwear of claim 14, wherein the area has a stitch density of at least four hundred eighty stitches per square inch (480 stitches/in²).

16. The article of footwear of claim 12, wherein the yarn is a composite yarn including a covering strand,

wherein the composite strand further includes a core strand, and

wherein the covering strand at least partially covers the core strand.

17. The article of footwear of claim 16, wherein the core strand is resiliently elastic, and wherein the composite yarn is resiliently stretchable between a first length and a second length.

18. The article of footwear of claim 12, wherein the package dyed yarn is incorporated within the area in a tuck stitch.

19. A method of manufacturing an article of footwear comprising:

providing a covering strand;

texturizing the covering strand;

package dyeing the covering strand after texturizing the covering strand;

re-texturizing the covering strand after package dyeing the covering strand;

air covering the covering strand over a core strand to form a composite yarn;

flat knitting a flat knitted component at least partially from the composite yarn; and

forming the article of footwear from the knitted component.

20. The method of claim 19, wherein re-texturizing the covering strand includes increasing a thickness of the covering strand from a first thickness to at least approximately 0.30 millimeters, and

wherein flat knitting the flat knitted component includes forming an area of the knitted component to have at least twenty-eight courses per inch (28 CPI).

21. The method of claim 20, wherein flat knitting the flat knitted component includes forming the area with a stitch density of at least four hundred stitches per square inch (400 stitches/in²).