U.S. patent application number 13/442239 was filed with the patent office on 2012-10-11 for seamless upper for footwear and method for making the same.
This patent application is currently assigned to DASHAMERICA, INC. D/B/A PEARL IZUMI USA, INC., DASHAMERICA, INC. D/B/A PEARL IZUMI USA, INC.. Invention is credited to Carol Little.
Application Number | 20120255201 13/442239 |
Document ID | / |
Family ID | 46964981 |
Filed Date | 2012-10-11 |
United States Patent
Application |
20120255201 |
Kind Code |
A1 |
Little; Carol |
October 11, 2012 |
SEAMLESS UPPER FOR FOOTWEAR AND METHOD FOR MAKING THE SAME
Abstract
This invention relates generally to footwear and methods for
making the same, more particularly to a seamless upper for footwear
and methods for making a seamless upper. In one aspect of the
invention, the upper is seamless and/or is of unitary construction
that defines an interior void for comfortably receiving a foot.
Inventors: |
Little; Carol; (Boulder,
CO) |
Assignee: |
DASHAMERICA, INC. D/B/A PEARL IZUMI
USA, INC.
Louisville
CO
|
Family ID: |
46964981 |
Appl. No.: |
13/442239 |
Filed: |
April 9, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61473473 |
Apr 8, 2011 |
|
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|
Current U.S.
Class: |
36/84 ;
12/142R |
Current CPC
Class: |
A43D 999/00 20130101;
A43B 23/042 20130101; D10B 2501/043 20130101; D04B 21/20 20130101;
A43D 111/00 20130101; A43B 23/0235 20130101; A43B 23/0215 20130101;
A43B 1/04 20130101; A43B 7/08 20130101; D04B 21/207 20130101; A43B
23/0245 20130101 |
Class at
Publication: |
36/84 ;
12/142.R |
International
Class: |
A43B 1/04 20060101
A43B001/04; A43D 8/00 20060101 A43D008/00 |
Claims
1. An article of footwear comprising an upper portion, the upper
portion comprising a seamless knitted material and configured with
a foot-receiving portion, the foot-receiving portion defining a
void for receiving a foot of a user.
2. The article of footwear of claim 1, wherein the seamless knitted
material is selected from the group consisting of interloop knit,
interweave knit, warp knit, weft knit, circular knit and flat
knit.
3. The article of footwear of claim 1, wherein the seamless knitted
material comprises at least one of rayon, polyester, polyacrylic,
silk, cotton, wool and elastane.
4. The article of footwear of claim 1, wherein the upper portion
comprises at least one of an end cap portion, a vamp portion and a
heel portion.
5. The article of footwear of claim 4, wherein at least one of an
end cap portion, a vamp portion and a heel portion comprises an
elastomeric material.
6. The article of footwear of claim 1, wherein the upper portion is
configured to engage a footwear sole.
7. The article of footwear of claim 1, wherein the upper portion is
configured to engage with one or more structural inserts in
communication with a vamp portion of the upper.
8. The article of footwear of claim 1, wherein the upper portion
forms an article of footwear.
9. The article of footwear of claim 1, wherein the upper further
comprises a plurality of knitted eyelets.
10. The article of footwear of claim 1, wherein the knitted
material has a plurality of different knitted textures formed by
varying at least one of a stitch type and a yarn type.
11. A method of manufacturing an upper for an article of footwear,
comprising: forming a seamless knitted material that includes a
foot-receiving portion; forming an opening for receiving a foot of
a user in the foot-receiving portion during the knitting process;
and forming the upper.
12. The method recited in claim 11, wherein the forming includes
utilizing a double needle knitting process to form the knitted
element.
13. The method recited in claim 11, wherein the upper further
comprises a plurality of knitted eyelets.
14. The method recited in claim 11, wherein the upper portion is
configured to engage a footwear sole.
15. A method of manufacturing an article of footwear, the method
comprising: knitting a textile element with a surrounding textile
structure, the knitted textile element configured to form a
seamless footwear upper; removing the knitted textile element from
the surrounding knitted textile structure; forming the knitted
textile element into an article of footwear upper.
16. The method of claim 15, wherein the knitted textile element has
a substantially planar configuration upon removal from the
surrounding knitted textile structure.
17. The method of claim 15, wherein the knitted textile element has
a plurality of different knitted textures formed by varying at
least one of a stitch type and a yarn type.
18. The method of claim 15, wherein simultaneously knitting a
textile element with a surrounding textile structure includes
utilizing a jacquard double needle-bar raschel knitting
machine.
19. The method recited in claim 15, wherein the upper further
comprises a plurality of knitted eyelets.
20. The method recited in claim 15, wherein the upper portion is
configured to engage a footwear sole.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/473,473, entitled "SEAMLESS UPPER FOR
FOOTWEAR AND METHOD FOR MAKING THE SAME" filed on Apr. 8, 2011, the
entire disclosure of which is incorporated by reference herein.
FIELD OF INVENTION
[0002] This invention relates generally to an upper for footwear,
more particularly to a seamless upper for footwear and method for
making the same.
BACKGROUND OF THE INVENTION
[0003] The upper portion of footwear vary in composition and design
based on several design parameters, to include
function/performance, weight, cost, aesthetics, comfort and ease of
manufacture. Athletic shoes, for example, typically emphasize
performance as dictated by the sport. A running shoe is commonly of
lighter-weight than a tennis shoe, for example, given a running
shoe generally does not require the lateral support of a tennis
shoe. Given the particular cost-competitive nature of footwear and
the volumes involved, ease of manufacture is another important
consideration. Furthermore, any footwear must be comfortable.
[0004] Typically, athletic footwear comprises an upper portion and
a sole portion. The upper provides a covering for the foot that
securely receives and positions the foot with respect to the sole
structure. In addition, the upper may have a configuration that
protects the foot and provides ventilation, thereby cooling the
foot and removing perspiration. The sole structure is typically
secured to a lower surface of the upper and is generally positioned
between the foot and the ground. The upper and the sole structure
operate cooperatively to provide a comfortable structure that is
suited for a wide variety of ambulatory activities, such as walking
and running
[0005] The materials forming the upper may be selected based upon
the properties of wear-resistance, flexibility, stretchability, and
air-permeability, for example. With regard to the exterior layer,
the toe area and the heel area may be formed of leather, synthetic
leather, or a rubber material to impart a relatively high degree of
wear-resistance. Leather, synthetic leather, and rubber materials,
however, may not exhibit the desired degree of flexibility and
air-permeability. Accordingly, various other areas of the exterior
layer of the upper may be formed from a synthetic or natural
textile material. The exterior layer of the upper may be formed,
therefore, from numerous material elements that each impart
different properties to specific portions of the upper. Similarly,
the interior layer of the upper may be formed of a moisture-wicking
textile that removes perspiration from the area immediately
surrounding the foot. In traditional articles of athletic footwear,
the various layers may be joined with an adhesive, and stitching
may be utilized to join elements within a single layer or to
reinforce specific areas of the upper.
[0006] Frequently, a fabric or a textile is used as a shoe upper of
an athletic shoe. It is said that proper elasticity inherent in the
shoe upper made of a fabric is advantageous in that it does not
give a sense of oppression and a sense of fatigue. With respect to
the shoe upper made of a fabric having such elasticity, U.S. Pat.
Nos. 3,793,750 and 4,043,058 (both incorporated by reference for
all purposes) each propose a shoe upper having a multi-layer
sandwich construction prepared by interposing a plastic foam layer,
such as a polyurethane layer, between an outer fabric layer and an
inner fabric layer and bonding them. However, the above-mentioned
shoe upper having a plastic foam layer interposed therein is not
necessarily satisfactory in air permeability. Therefore, this
causes problems such that the inside of the shoe becomes stuffy and
hot because of abnormal temperature increase attributable to the
sweating and generation of heat from feet during exercise, which
brings about a discomfort. Further, although the above-mentioned
resin foam layer has elasticity, it is large in resistance to the
movement between the outer and inner fabric layers, because it is
bonded to each of the outer and inner fabric layers with an
adhesive, which leads to a large resistance of the shoe upper per
se to bending. This inhibited the effect of alleviating a sense of
oppression and a sense of fatigue for the feet. Textiles used in
footwear uppers generally provide a lightweight, air-permeable
structure that is flexible and comfortably receives the foot.
Commonly, knitting materials have heightened movement and
flexibility. A textile may be defined as any manufacture from
fibers, filaments, or yarns characterized by flexibility, fineness,
and a high ratio of length to thickness. However, the prior art use
of fabrics and/or textiles in footwear uppers typically require
seams. Seams introduce difficulties and limitations, to include
difficulties in manufacture and freedom of design, and unintended
abrasion to the user causing, for example, blisters and thereby
compromising athletic performance.
[0007] In order to impart other properties to the footwear,
including durability and stretch-resistance, additional materials
are commonly combined with the textile, including leather,
synthetic leather, or rubber, for example. With regard to
durability, U.S. Pat. No. 4,447,967 to Zaino discloses an upper
formed of a textile material that has a polymer material injected
into specific zones to reinforce the zones against abrasion or
other forms of wear. Regarding stretch resistance, U.S. Pat. No.
4,813,158 to Brown and U.S. Pat. No. 4,756,098 to Boggia both
disclose a substantially inextensible material that is secured to
the upper, thereby limiting the degree of stretch in specific
portions of the upper. U.S. Pat. Nos. 4,447,967; 4,813,158; and
4,756,098 are incorporated by reference for all purposes.
[0008] It is desirable to minimize the number and types of
materials in footwear, particularly athletic footwear. Fewer
materials reduce costs and increase efficiency, given that shoe
manufacture is a labor intensive process. The typical shoe
manufacturing process encompasses the steps of cutting the upper
material, reducing the thickness of the joining edges ("skiving"),
reducing the thickness of the upper pieces ("splitting"), cementing
the interlining to the upper pieces ("interlining"), forming the
eyelets, stitching the upper pieces together, shaping the upper
over a last ("lasting") and cementing, molding or sewing the bottom
of the shoes to the upper ("bottoming"). Modern footwear designs,
particularly athletic shoe designs, require numerous upper pieces
and complicated manufacturing steps, leading to high labor costs.
In addition, incorporating separate materials into an upper may
involve multiple distinct manufacturing steps requiring multiple
individuals. Employing multiple materials, in addition to textiles,
may also detract from the breathability of footwear. Additionally,
a new pattern is required and the manufacturing process must be
retooled for every new design and style and for each desired shoe
size.
[0009] In an effort to reduce labor costs, published PCT
application WO 90/03744, incorporated herein by reference for all
purposes, describes the use of heat embossing to minimize the
number of manufacturing steps. The published application describes
a process of manufacturing shoe components, including an entire
one-piece upper, in which a multi-layered upper material is heat
embossed in a compression mold to reduce the thickness of the
material, to close or seal the edges, to incorporate a functional
design or pattern lines, and for strain management. After the
embossing step, the backsides of the embossed upper material are
stitched together by means of a back strip and the upper material
is lasted and bottomed to form the completed shoe. This process
greatly reduces the cutting and stitching steps and can eliminate
the skiving, splitting and interlining steps of the typical shoe
manufacturing process. However, this shoe manufacturing process
does not greatly reduce the assembly time and costs associated with
creating new patterns and retooling the manufacturing process for
new designs, new styles and different shoe sizes. Rather, a new
pattern and a new embossing mold must be created for each change in
design and a separate embossing mold must be used for each desired
shoe size. Similarly, numerous upper materials, in varying colors
and textures must be kept in inventory to accommodate desired
changes in style.
[0010] From the perspective of manufacturing, utilizing multiple
materials to impart different properties to an article of footwear
may be an inefficient practice. For example, the various materials
utilized in a conventional upper are not generally obtained from a
single supplier. Accordingly, a manufacturing facility must
coordinate the receipt of specific quantities of materials with
multiple suppliers that may have distinct business practices or may
be located in different regions or countries. The various materials
may also require additional machinery or different assembly line
techniques to cut or otherwise prepare the material for
incorporation into the footwear. In addition, incorporating
separate materials into an upper may involve a plurality of
distinct manufacturing steps requiring multiple individuals.
Employing multiple materials, in addition to textiles, may also
detract from the breathability of footwear. Leather, synthetic
leather, or rubber, for example, are not generally permeable to
air. Accordingly, positioning leather, synthetic leather, or rubber
on the exterior of the upper may inhibit air flow through the
upper, thereby increasing the amount of perspiration, water vapor,
and heat trapped within the upper and around the foot.
[0011] The prior art uppers for footwear typically utilize multiple
components or materials and require multiple manufacturing steps.
Furthermore, the prior art uppers traditionally require one or more
seams. Thus, existing uppers result in reduced footwear
performance, increased manufacturing complexity, time and cost, and
limited freedom of design. Therefore, there is a need for a
seamless upper for footwear and process for making the same.
SUMMARY OF THE INVENTION
[0012] Certain embodiments of the present disclosure relate to an
upper for footwear and methods for making the footwear upper. The
invention involves application of a knitting process to the
production of footwear uppers and entire footwear. In one preferred
embodiment, a knitting process is disclosed to create a completely
seamless upper portion of a shoe. The process can form the seamless
footwear upper in a single step. In another embodiment, an entire
seamless article of footwear, including the upper portion, is
formed. Some benefits of this process include ease and efficiency
of production, reduction of assembly time, maximum comfort through
reduction of seams, and freedom of design. The methods can include
weaving and/or knitting the upper. The knitting process typically
includes forming upper by interconnecting a series of stitches or
loops.
[0013] Although many of the embodiments are focused on athletic
footwear, other applications are available. Such applications
include activities in which one or more of increased footwear
performance, decreased manufacturing complexity, time and cost, and
greater freedom of design is desired. Further, the use of the
disclosed seamless uppers for footwear have applications beyond
footwear, to include clothing, protective wrappings or covers,
medical care such as for use as wrappings for burn-victims,
geriatric care, and any application where seamless covering is
desired.
[0014] Furthermore, the concepts disclosed with respect to footwear
and footwear uppers may be applied to footwear styles that are
specifically designed for a variety of other athletic activities,
including basketball, baseball, football, soccer, walking, and
hiking, for example, and may also be applied to various
non-athletic footwear styles. Accordingly, one skilled in the
relevant art will recognize that the concepts disclosed herein may
be applied to a wide range of footwear styles and are not limited
to the specific embodiments discussed below and depicted in the
figures.
[0015] The concepts also may be applied to footwear styles that are
generally considered to be non-athletic, including dress shoes,
loafers, sandals, and work boots. The concepts disclosed herein
apply, therefore, to a wide variety of footwear styles. Also,
aspects of this invention may be used in conjunction with other
portions of a footwear structure, such as a layer within an upper
member structure, an interior lining for a footwear product (such
as a sock liner), and a bootie member (optionally for inclusion in
a footwear structure).
[0016] As used herein, the term "a" or "an" entity refers to one or
more of that entity. As such, the terms "a" (or "an"), "one or
more" and "at least one" can be used interchangeably herein. It is
also to be noted that the terms "comprising", "including", and
"having" can be used interchangeably.
[0017] As used herein, "at least one", "one or more", and "and/or"
are open-ended expressions that are both conjunctive and
disjunctive in operation. For example, each of the expressions "at
least one of A, B and C", "at least one of A, B, or C", "one or
more of A, B, and C", "one or more of A, B, or C" and "A, B, and/or
C" means A alone, B alone, C alone, A and B together, A and C
together, B and C together, or A, B and C together.
[0018] As used herein, the term, "innersole" refers to a removable
portion of the sole of an article of footwear, which is inserted
into the article of footwear from the opening in the upper and
which is designed to provide support to the wearer's foot,
depending upon the wearer's anatomy and the intended use of the
article of footwear.
[0019] As used herein, the term, "midsole" refers to that portion
of the sole of an article of footwear sandwiched between the
innersole and the outsole, to which is attached the outsole.
[0020] As used herein, the term, "outsole" refers to that portion
of the sole of an article of footwear that is furthest from the
upper.
[0021] As used herein "knit construction" refers to one or both of
the knit stitch and the yarns and/or threads comprising the knit
stitch. As used herein, the terms "knit element", "knit structure",
"textile" and "textile element" refer to the material used in
constructing the upper.
[0022] As used herein, the term, "vamp" refers to a part of a shoe
upper that covers any portion on the top part of the foot between
where the toes and the legs connect to the foot.
[0023] As used herein, the term, "upper" refers to any portion of
the shoe above the sole. As used herein, the terms "shoe" and
"footwear" refer to an article to be worn by a user's foot.
[0024] By way of providing additional background, context, and to
further satisfy the written description and enablement requirements
of 35 U.S.C. .sctn.112, the following references are incorporated
by reference in their entireties for the express purpose of
explaining the nature of uppers for footwear and knitting and to
further describe the various tools and other apparatus commonly
associated therewith: U.S. Patent Publication No. 2011/0059288
entitled "Flannel Sheeting Fabric for Use in Home Textiles"; U.S.
Patent Publication No. 2011/0067455 entitled "Knitting Machine";
U.S. Patent Publication No. 2011/0067455 entitled "Warp Knitted
Fabric, Method of Manufacturing the Same, and Knit Structure of
Warp Knitted Fabric; U.S. Patent Publication No. 2011/0056248 to
Sato entitled "Shoe and Method of Manufacturing the Same"; U.S.
Patent Publication No. 2009/0241374 to Oya entitled "Garment"; U.S.
Patent Publication No. 2009/0064721 entitled "Warp Knitting Fabric
And Its Manufacturing Method; U.S. Pat. No. 7,770,271 Entitled
"Method And Device For Operating A Creel Designed For A Winding
System And Corresponding Creel; U.S. Pat. No. 7,536,761 entitled
"Device And Method For Spreading A Carbon Fiber Hank; U.S. Pat. No.
7,458,236 entitled "Device For Feeding Fiber Bands To A Knitting
Machine"; U.S. Pat. No. 7,332,836 entitled "Guide Bar Drive In A
Knitting Machine", U.S. Pat. No. 7,331,200 entitled "Knitting
Machine"; U.S. Pat. No. 7,299,660 entitled "Knitting Machine"; U.S.
Pat. No. 7,120,976 entitled "Process And Apparatus For Laying Fiber
Bands Of Filaments"; U.S. Pat. No. 6,993,939 entitled "Method And
System For Producing A Multi-Layer, Pre-Fixed Thread Or Fiber
Arrangement"; U.S. Pat. No. 6,691,535 entitled "Fabric For The
Formation Of Garment Pieces, The Garment Pieces Obtained Therefrom
And The Garments Produced Therewith"; U.S. Pat. No. 6,651,420
entitled "Method And Device For Treating Filament Yarn With Air";
U.S. Pat. No. 6,354,069 entitled "Method And Device For Treating
Filament Yarn With Air"; U.S. Pat. No. 6,322,255 entitled "Joint
Bearing Between Two Structural Elements Of Warp Knitting Machines";
U.S. Pat. No. 6,253,583 entitled "Warp Knitting Machine With
Pattern"; U.S. Pat. No. 6,247,337 entitled "Gripping Breadth
Holders In A Warp Knitting Machine"; U.S. Pat. No. 6,233,798
entitled "Warping Machine And Process For Producing Pattern Warps";
U.S. Pat. No. 6,212,915 entitled "Warp Knitting Machine With Thread
Sheet Turning Arrangement"; U.S. Pat. No. 6,151,929 entitled
"Device For Fastening Active Components To The Bar Of A Wrap
Knitting Machine And Accompanying Tool For Removing And Installing
The Active Components"; U.S. Pat. No. 6,151,923 entitled "Apparatus
for Supplying A Multi-Layer, Multi-Axial Layer Of Yarn To The
Knitting Site Of A Warp Knitting Machine"; U.S. Pat. No. 6,009,729
entitled "Process For A Knitting Machine Employing Thread
Processing Elements Embedded In Carrier"; U.S. Patent Publication
No. 2010/0146823 to Yoshihiro entitled "Sold and Method of
Manufacturing Sole"; U.S. Patent Publication No. 2010/0011479 to
Onoda, entitled "Sportswear"; U.S. Patent Publication No.
2009/0241377 to Kita entitled "Sole Structure for a Shoe"; U.S.
Patent Publication No. 2008/0120871 to Sato entitled "Upper
Structure for a Shoe"; U.S. Pat. No. 7,886,461 to Sato Entitled
"Midfoot Structure of a Sole Assembly for a Shoe"; U.S. Pat. No.
7,051,460 to Orei et al. entitled "Light Weight Shoes"; U.S. Patent
Publication No. 2008/0179030 to O'Connor entitled "Subassembly for
Industrial Fabrics"; U.S. Patent Publication No. 2004/0237599 to
Kondou et al. entitled " Elastic Knitting Fabric Having Multilayer
Structure"; U.S. Pat. No. 7,552,604 to Waldrop et al. entitled
"Double Needle Bar
[0025] Elastomeric Spacer Knit"; U.S. Patent Publication No.
2009/0056857 to Heinrich et al. entitled "Method for Producing a
Multidirectional Fabric Web"; U.S. Patent Publication No.
2007/0224897 to Shimazaki entitled "Fabric and Textile Product";
U.S. Pat. No. 7,070,845 to Thomas et al. entitled "Fluid-Filled
Bladder For An Article Of Footwear."
[0026] In addition, by way of providing additional background,
context, and to further satisfy the written description and
enablement requirements of 35 U.S.C. .sctn.112, the following
references are incorporated by reference in their entireties for
the express purpose of explaining the nature of uppers for footwear
and knitting and to further describe the various tools and other
apparatus commonly associated therewith: U.S. Patent Publication
No. 2012/0055044, U.S. Patent Publication No. US2005/0193592; U.S.
Patent Publication No. U.S. 2010/0325916; U.S. Patent Publication
No. US2012/0005922; U.S. Patent Publication No. U.S. 2008/0196181;
U.S. Patent Publication No. 2012/0079743; U.S. Patent Publication
No. 2012/0079741; U.S. Patent Publication No. 2009/0084142; U.S.
Patent Publication No. 2010/0107590; U.S. Patent Publication No.
2010/0107383; U.S. Patent Publication No. 2010/0107382; U.S. Patent
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[0027] In one embodiment of the invention, an upper for an article
of footwear comprises a textile element formed with a knitting
machine. In one aspect of the invention, the upper is seamless
and/or is of unitary construction. The knitting machine may have a
configuration that forms the textile element through either warp
knitting or weft knitting.
[0028] Another aspect of the invention involves a method of
manufacturing an article of footwear. The method includes a step of
mechanically-manipulating a yarn with a circular knitting machine,
for example, to form a cylindrical textile structure. In addition,
the method involves removing at least one textile element from the
textile structure, and incorporating the textile element into an
upper of the article of footwear so as to form a seamless upper
and/or entire footwear that is seamless.
[0029] In another aspect of the invention, an article of footwear
has a seamless upper and a sole structure secured to the upper. The
upper incorporates a textile element formed with a knitting
machine. The textile element is removed from a textile structure
that includes an outline of the textile element, and the textile
element has edges that are joined together to define at least a
portion of a void for receiving a foot.
[0030] In one embodiment, an upper is at least partially formed
from a textile element that defines an interior void for
comfortably receiving a foot and securing a position of the foot
relative to sole structure. Various edges of textile element are
then secured together to form the shape of upper. In some
embodiments, textile element may form all of upper, substantially
all of upper, or textile element may only be a portion of an
upper.
[0031] Various materials may be utilized in manufacturing the upper
of footwear. The upper of an article of athletic footwear, for
example, may be formed from multiple material layers that include
an exterior layer, an intermediate layer, and an interior layer.
The materials forming the exterior layer of the upper may be
selected based upon the properties of wear-resistance, flexibility,
and air-permeability, for example. With regard to the exterior
layer, the toe area and the heel area may be formed of leather,
synthetic leather, or a rubber material to impart a relatively high
degree of wear-resistance. Leather, synthetic leather, and rubber
materials may not exhibit the desired degree of flexibility and
air-permeability. Accordingly, various other areas of the exterior
layer of the upper may be formed from a synthetic or natural
textile. The exterior layer of the upper may be formed, therefore,
from numerous material elements that each impart different
properties to specific portions of the upper.
[0032] This disclosure provides methods for seamlessly knitting a
tubular upper for a shoe. Circular knitting and warp knitting are
examples of processes for forming the upper portion. Warp knitting
is a family of knitting methods in which the yarn zigzags along the
length of the fabric, i.e., following adjacent columns ("wales") of
knitting, rather than a single row ("course"). The circular or weft
knitting process includes knitting one yarn around the perimeter of
a circular tube. Woven fabrics usually offer dimensional stability,
whereas weft knitted fabrics are typically more elastic. Warp
knitted fabrics combine these two properties: they can be produced
as dimensionally stable, elastic as well as highly elastic. Warp
knit fabrics are typically used for athletic apparel, swimwear, and
intimate apparel where a more durable knit fabric is needed
[0033] An intermediate layer of the upper may be formed from a
lightweight polymer foam material that provides cushioning and
protects the foot from objects that may contact the upper.
Similarly, an interior layer of the upper may be formed of a
moisture-wicking textile that removes perspiration from the area
immediately surrounding the foot. In some articles of athletic
footwear, the various layers may be joined with an adhesive, and
stitching may be utilized to join elements within a single layer or
to reinforce specific areas of the upper.
[0034] Although the materials selected for the upper vary
significantly, textile materials often form at least a portion of
the exterior layer and interior layer. A textile may be defined as
any manufacture from fibers, filaments, or yarns characterized by
flexibility, fineness, and a high ratio of length to thickness.
[0035] Textiles generally fall into two categories. The first
category includes textiles produced directly from webs of filaments
or fibers by randomly interlocking to construct non-woven fabrics
and felts. The second category includes textiles formed through a
mechanical manipulation of yarn, thereby producing a woven fabric,
for example.
[0036] Yarn is the raw material utilized to form textiles in the
second category. In general, yarn is defined as an assembly having
a substantial length and relatively small cross-section that is
formed of at least one filament or a plurality of fibers. Fibers
have a relatively short length and require spinning or twisting
processes to produce a yarn of suitable length for use in textiles.
Common examples of fibers are cotton and wool. Filaments, however,
have an indefinite length and may merely be combined with other
filaments to produce a yarn suitable for use in textiles. Modern
filaments include a plurality of synthetic materials such as rayon,
nylon, polyester, and polyacrylic, with silk being the primary,
naturally-occurring exception. Yarn may be formed of a single
filament, which is conventionally referred to as a monofilament
yarn, or a plurality of individual filaments grouped together. Yarn
may also include separate filaments formed of different materials,
or the yarn may include filaments that are each formed of two or
more different materials. Similar concepts also apply to yarns
formed from fibers. Accordingly, yarns may have a variety of
configurations that generally conform to the definition provided
above.
[0037] The various techniques for mechanically manipulating yarn
into a textile include interweaving, intertwining and twisting, and
interlooping. Interweaving is the intersection of two yarns that
cross and interweave at right angles to each other. The yarns
utilized in interweaving are conventionally referred to as warp and
weft. Intertwining and twisting encompasses procedures such as
braiding and knotting where yarns intertwine with each other to
form a textile. Interlooping involves the formation of a plurality
of columns of intermeshed loops, with knitting being the most
common method of interlooping.
[0038] At least some of advantages of warp knit over circular knit
are: durabilty; greater range of design construction; ability to
create mesh type and size; location and type of compress, stretch
and thickness; ability to change yarns along at least the warp of
the material; ability to change the yarns between the front and
back of the knitted tube; creation of a substantially seamless
structure; and the ability to create a substantially seamless
structure in a footwear construction/format. For example, the upper
can be knitted to have areas of cushioning, compression,
breathability, color, and yarn content.
[0039] Flat knitting, when used in example structures according to
this invention, can provide various advantages. For example, flat
knitting can be used to provide textile structures for use in
footwear uppers of a final desired shape such that textile cutting
steps can be avoided (which eliminates waste, avoids the need to
finish cut edges, saves time, saves money, etc.). Flat knitted
elements also can be formed directly in desired three dimensional
shapes, which can help avoid the need to use additional support
structures in the overall footwear construction (which also saves
time, money, etc.; produces a lighter and/or more flexible product;
may eliminate seams and at least some sewing, etc.; etc.). By
selectively placing multiple different yarns and/or stitch patterns
at multiple different locations in the overall structure during the
knitting process, flat knitted products may have multiple different
physical properties (e.g., different stretchability, different
moisture management capabilities, etc.) at multiple different
locations or zones within a single, unitary construction (e.g.,
different properties at different zones or locations within a
single footwear structure). Additionally, flat knitting can be used
to produce pockets, tunnels, or other layered structures in the
final product.
[0040] Textile elements may be formed through a flat knitting
process. In general, flat knitting is a method for producing
knitted material in which the material is turned periodically
(i.e., the material is knitted from alternating sides). The two
sides (otherwise referred to as "faces") of the material are
conventionally designated as the "right side" (i.e., the side that
faces outwards, towards the viewer) and the "wrong side" (i.e., the
side that faces inwards, away from the viewer). Flat knitting may
be contrasted with circular knitting, in which the fabric is always
knitted from the same side. Various circular knitting techniques
are known, for example, narrow tube circular knitting and wide tube
circular knitting. More specific examples of circular knitting
techniques are described in U.S. Published Patent Publication No.
2005/0193592, which publication is entirely incorporated herein by
reference. In contrast with circular knitting, flat knitting may be
more complicated because the same stitch (as seen from the right
side) is produced by two different movements when knitted from the
right and wrong sides. Accordingly, a knit stitch (as seen from the
right side) may be produced by a knit stitch on the right side or
by a purl stitch on the wrong side. In flat knitting, the fabric is
usually turned after every row. Although flat knitting provides a
suitable manner for forming textile elements, other types of
knitting may also be utilized, including wide tube circular
knitting, narrow tube circular knit jacquard, single knit circular
knit jacquard, double knit circular knit jacquard, and warp knit
jacquard, for example. An advantage of flat knitting over various
other types of knitting is that the flat knitting process may be
utilized to form generally three-dimensional structures or
structures wherein layers of material overlap each other (i.e., are
at least partially coextensive) to form loops or other overlapping
configurations. More particularly, the flat knitting process may
make structures wherein layers are joined to each other such that
opposite sides of one layer are formed of unitary construction with
the other layer. In addition, flat knitting may be utilized to form
areas with different types of stitches and areas with different
types of yarns. For example, a forward portion of an upper may be
configured so as to stretch to a different degree than non-ribbed
configurations of center portions and/or rearward portions.
Moreover, textile elements may be formed from a less stretchable
type of stitch than forward portion and the yarn selected for
selected textile elements may be more wear-resistant than the yarn
selected for a forward portion. As another example, the knit/yarn
combination utilized for rearward portion may be selected to impart
stretch and recovery to ankle opening. Accordingly, the flat
knitting process may be utilized to form a generally
three-dimensional or overlapping structure having areas with
different properties that are produced from combinations of
different types of stitches and different types of yarns. Also this
feature reduces waste and saves time and money in the manufacturing
process.
[0041] In one embodiment, the upper is formed from a textile
element and may also include laces or other elements associated
with a conventional upper for footwear. The textile element is a
single material element that is formed to exhibit a unitary (i.e.,
one-piece) construction, and textile element is formed or otherwise
shaped to extend around the foot. The textile element may be formed
as a part of a larger textile element. The textile element is then
removed from the larger textile element to form the shape of
upper.
[0042] The textile element is a single material element with a
unitary construction, as discussed above. As defined for purposes
of the present invention, unitary construction and/or "seamless" is
intended to express a configuration wherein portions of a textile
element are not joined together by seams or other connections. The
textile element is primarily formed from one or more yarns that are
mechanically-manipulated through either an interweaving,
intertwining and twisting, or interlooping process, for example. As
discussed, interweaving is the intersection of two yarns that cross
and interweave at right angles to each other. The yarns utilized in
interweaving are conventionally referred to as warp and weft.
Intertwining and twisting encompasses procedures such as braiding
and knotting where yarns intertwine with each other to form a
textile. Interlooping involves the formation of a plurality of
columns of intermeshed loops, with knitting being the most common
method of interlooping. Textile element may, therefore, be formed
from one of these processes for manufacturing a textile.
[0043] A variety of mechanical processes have been developed to
manufacture a textile. In general, the mechanical processes may be
classified as either warp knitting or weft knitting. With regard to
warp knitting, various specific sub-types that may be utilized to
manufacture a textile include tricot, raschel, and double
needle-bar raschel (which further includes jacquard double
needle-bar raschel). With regard to weft knitting, various specific
sub-types that may be utilized to manufacture a textile include
circular knitting and flat knitting. Various types of circular
knitting include sock knitting (narrow tube), body garment
(seamless or wide tube), and jacquard.
[0044] The textile element may be formed through any of the
mechanical processes discussed above. Accordingly, textile element
may be formed on either a warp knitting machine or a weft knitting
machine. As an example, not intending to limit the disclosure, one
suitable knitting machine for forming textile element is a circular
knit jacquard machine. In one embodiment, a textile element as
formed via a circular knit jacquard machine has various areas of
cushioning, compression, breathability, color, and yarn
content.
[0045] Another suitable knitting machine for forming textile
element is a wide-tube circular knitting machine that is produced
in the Lonati Group by Santoni S.p.A. of Italy under the SM8 TOP1
model number. A wide-tube circular knitting machine, as produced by
Santoni S.p.A., forms a generally cylindrical textile structure and
is capable of forming various types of stitches within a single
textile structure. In general, the wide-tube circular knitting
machine may be programmed to alter the design on the textile
structure through needle selection. That is, the type of stitch
that is formed at each location on the textile structure may be
selected by programming the wide-tube circular knitting machine
such that specific needles either accept or do not accept yarn at
each stitch location. In this manner, various patterns, textures,
or designs may be selectively and purposefully imparted to the
textile structure.
[0046] Textile structure may be formed with a wide-tube circular
knitting machine, as discussed above. The types of stitches that
form textile structure may be varied to form an outline of one or
more textile elements on textile structure. That is, the wide-tube
circular knitting machine may be programmed to form different types
of stitches in textile structure so as to outline one or more
textile elements. The yarn forming textile element may be generally
defined as an assembly having a substantial length and relatively
small cross-section that is formed of at least one filament or a
plurality of fibers.
[0047] As another example, not intending to limit the disclosure,
of a suitable knitting machine for forming textile element is that
of U.S. Pat. No. 8,132,431. The disclosure provides a knitting
machine that includes a shogging drive, a swing-through drive, and
at least one guide bar, which is moveable by the shogging drive in
a shogging direction and by the swing-through drive perpendicular
to the shogging direction. The sequence of movements of the guide
bar is controlled such that in a loop formation the guide bar is
moved once back and once forth in a shogging direction. (The
shogging direction is the direction that corresponds to the
longitudinal extension of the guide bar, i.e., the direction in
which all of the guides of the guide bar are arranged one behind
the other.) Further, a slide surface pairing has two slide surfaces
oriented perpendicularly to the shogging direction, and the
shogging drive acts on the guide bar via the slide surface pairing.
In accordance with embodiments, the shogging drive can include a
transfer element guided in the shogging direction, which supports
one of the slide surfaces of the slide surface pairing. The
transfer element may be formed as an actuator rod. U.S. Pat. No.
8,132,431 is incorporated by reference for all purposes.
[0048] Without intending to limit the invention, in order to
provide the stretch and recovery properties to upper and/or textile
element a yarn that incorporates an elastane fiber may be utilized.
Such elastane fibers are available from E.I. duPont de Nemours
Company under the Lycra trademark. Such fibers may have the
configuration of covered Lycra, wherein the fiber includes a Lycra
core that is surrounded by a nylon sheath. One suitable yarn, for
example, includes a 70 denier elastane core that is covered with
nylon having a 2 ply, 80 denier, 92 filament structure. Other
fibers or filaments exhibiting elastic properties may also be
utilized, to include but not limited to spandex, elaspan, creora,
roica, dorlastan, linel and espa.
[0049] As discussed above, a yarn that incorporates elastane fibers
is suitable for textile element. A plurality of other yarns,
whether elastic or inelastic, are also suitable for the textile
element. The characteristics of the yarn selected for textile
element depend primarily upon the materials that form the various
filaments and fibers. Cotton, for example, provides a soft hand,
natural aesthetics, and biodegradability. Elastane fibers, as
discussed above, provide substantial stretch and recoverability.
Rayon provides high luster and moisture absorption. Wool also
provides high moisture absorption, in addition to insulating
properties. Polytetrafluoroethylene coatings may provide a low
friction contact between the textile and the skin. Nylon is a
durable and abrasion-resistant material with high strength.
Finally, polyester is a hydrophobic material that also provides
relatively high durability. Accordingly, the materials comprising
the yarn may be selected to impart a variety of physical properties
to textile element, and the physical properties may include, for
example, strength, stretch, support, stiffness, recovery, fit, and
form.
[0050] In addition to varying the stitch types to form textures,
the type of yarn utilized in various areas of textile elements may
be changed to impart different properties. Yarn may be formed from
cotton, wool, elastane, rayon, nylon, and polyester, for example.
Each of these yarn types may impart differing properties. For
example, elastane may be utilized to impart stretch, wool may be
utilized for insulation, and nylon may be utilized for durability.
Accordingly, different yarn types may be utilized to impart
different properties. The types of knitting that may be utilized to
form different zones with different properties (e.g., yarn
characteristics, textures, etc.) may vary significantly to include
the various warp knitting and weft knitting processes discussed
earlier, such as tricot, raschel, double needle-bar raschel,
circular knitting, and flat knitting, for example.
[0051] Textile element is depicted as having a generally smooth,
non-varied stitch configuration. That is, similar stitches are
utilized throughout textile element to impart a common texture to
the various portions of textile element. As discussed above,
however, a wide-tube circular knitting machine is generally capable
of forming various types of stitches within a single textile
structure. The wide-tube circular knitting machine may, therefore,
vary the stitches within textile element to produce various
patterns, designs, or textures, for example. Various types of
stitches may also be formed with other types of knitting
machines.
[0052] Many conventional articles of footwear incorporate uppers
with various material elements that each exhibit different
properties. For example, a first material element may be smooth,
and a second material element may be textured. The first and second
material elements are then stitched together to form a portion of
the conventional upper. Textile element also exhibits smooth and
textured areas. In contrast with the conventional upper, however,
first texture and second texture are incorporated into a single,
unitary element of textile, rather than two separate elements that
are stitched or otherwise joined together.
[0053] Various warp knitting or weft knitting processes may be
utilized to form textile element, or the various other textile
elements discussed above. An advantage of this process is that
various stitches may be incorporated into specific locations of
textile element to modify the physical properties or aesthetics of
textile element. Whereas a conventional upper includes various
elements that stitched or adhesively joined, textile element is a
single, unitary element of material. From the perspective of
manufacturing, utilizing multiple materials to impart different
properties to an article of footwear may be an inefficient
practice. By forming textile element to be a single, unitary
element of material, however, efficiency is increased in that upper
may include a single textile element, rather than numerous joined
elements.
[0054] A variety of knitting processes may be utilized to form
textile element, as discussed above. As a specific example, a
jacquard double needle-bar raschel knitting machine may be utilized
to form a flat textile structure, and may also be utilized to form
the textile structure to have the configuration of a spacer mesh
textile. Unlike textile structure, which exhibits a generally
cylindrical configuration, the textile structure formed with the
jacquard double needle-bar raschel knitting machine will have a
flat configuration. Like textile structure, however, an outline of
a textile element may be imparted to the textile structure formed
with the jacquard double needle-bar raschel knitting machine. That
is, differences in the stitches within the textile structure may
form an outline with the shape and proportions of the intended
textile element. Accordingly, the textile element may be removed
from the textile structure and incorporated into footwear. In
addition, the jacquard double needle-bar raschel knitting machine
may be utilized to impart various textures, different properties,
or different yarn types to the textile element. Similarly, other
types of knitting, such as a flat knitting, may be utilized within
the scope of the present invention to impart various textures,
different properties, or different yarn types to the textile
element.
[0055] A double needle-bar raschel is one example of a warp knit
machine which can knit two sides of fabric at one time. It is
possible to use this type of machine to knit a warp knit tube by
stitching the two sides of the fabric together during the knitting
process. A warp knitting machine can engineered to knit a shaped
tube by utilizing a jacquard double needle bar machine. A
electronic jacquard double needle bar can make a shaped tube with
an engineered construction. There are a number of possibilities for
upper design and performance. The following can be adjusted in
order to create uppers for a specific applications: yarn types
(such as, elastic, non-eleastic, yarn size, fiber type (such as
denier, composition, polyester, nylon, etc.)), stitch construction
(such as mexh, more closed or open for breathability and/or
durability), for stretch and/or elastic propertis, rigidty (for
support and fit), size (for shoe fit).
[0056] In one embodiment, a shoe upper is knitted using a knitting
machine such as a tricot knitting machine or a raschel knitting
machine. The knitting may be stepwise conducted through a step of
knitting one or more knit layers or types (such as, for example, an
outer and inner knit fabric layer) and a step of connecting the one
or more knit layers or types with crossing threads. Alternatively,
the knitting may be constructed using a double raschel knitting
machine which can knit a shoe upper simply in one step because it
can simultaneously conduct the two above-mentioned steps.
[0057] Any desired type of cutting operation may be utilized
without departing from the invention, including, for example, die
cutting, laser cutting, hand cutting, and the like. Also, any
desired type of material may be used without departing from this
invention. The material may be a material having a higher modulus
of elasticity (e.g., more resistant to tensile stretching forces
and/or providing a higher compression force) as compared to that of
the fabric elements making up other portions of the upper and/or
footwear structure (e.g., compared to the stretch resistance or
compressive force applying capability for the spandex, cotton,
polyester, or other fabric elements making up the structure). As
some more specific examples, material may be materials commonly
used in tackle twill production, a canvas type material, a
polyester type material, a thermoplastic polyurethane adhesive
material, for example.
[0058] In some embodiments, a seamless upper component formed via
warp knitting and/or circular knitting is configured to fit a shoe
last and heat set into shape. The seamless upper is then attached
to a shoe sole, for example, to create a finished shoe. In some
embodiments the upper can be knitted and/or jointed to a structural
element to form the shoe where one or both of the upper and
structural element include support structure(s), form an
exoskeleton, a cinching or closer system. Some embodiments include
an insole insert.
[0059] In one embodiment, the knitted fabrics of the upper are not
of substantially uniform thickness, but instead form contours,
ridges, or patterns.
[0060] In one embodiment, only the upper of the footwear is of
seamless knit. In another embodiment, the entire footwear, to
include the upper, is of seamless knit.
[0061] In one embodiment, the textile element is a
"dimensionalized" structure, as disclosed in U.S. Pat. No.
8,133,824, which is incorporated by reference for all purposes.
[0062] In one embodiment, the upper comprises one or more knitted
eyelets that are seamless and/or integrally and/or simultaneously
constructed with the construction of the upper.
[0063] In one embodiment, the upper is constructed of a single type
of knit construction. In one embodiment, the upper is constructed
of a single layer and/or is constructed of a single stitch
configuration. In one embodiment, the upper is constructed such
that it does not have longitudinal edges.
[0064] In one embodiment, the upper is constructed to incorporate a
single type of textile having a plurality of knit constructions. In
one embodiment, the upper is constructed to incorporate a single
type of textile having a single type of knit construction. In one
embodiment, the upper is constructed with a circular knitting
machine to form a cylindrical textile structure that incorporates a
single type of textile having a plurality of knit
constructions.
[0065] In one embodiment, the upper is constructed with a
weft-knitted textile element that incorporates a single type of
textile having a single knit construction. In one embodiment, the
upper is constructed with a weft-knitted textile element that
incorporates a single layer and/or is constructed of a single
stitch configuration.
[0066] In one embodiment, the knitting element is constructed
during a knitting process.
[0067] In one embodiment, the upper does not feature an overlapped
configuration of knitted material and/or layers.
[0068] In one embodiment, the upper is constructed of a knitted
element that is not a woven element. In one embodiment, the upper
is not constructed of a woven element and/or not constructed of an
element substantially formed on a loom.
[0069] In one embodiment, an article of footwear comprises an upper
and a sole structure attached to the upper.
[0070] In one embodiment, an article of footwear comprises an upper
and a sole structure attached to the upper, the upper comprises
lace-receiving elements and/or eyelets and the upper does not
comprise strands that extend proximal to the lace-receiving
elements to an area proximal to the sole structure.
[0071] In one embodiment, the upper comprises a knitted element
having a lateral side and an opposite medial side, the knitted
element defining at least one lateral channel formed between two
spaced-apart knitted layers and located on the lateral side and at
least one medial channel formed between two spaced-apart knitted
layers and located on the medial side, each of the lateral channel
and the medial channel being formed of unitary construction.
[0072] The preceding is a simplified summary of the invention to
provide an understanding of some aspects of the invention. This
summary is neither an extensive nor exhaustive overview of the
invention and its various embodiments. It is intended neither to
identify key or critical elements of the invention nor to delineate
the scope of the invention but to present selected concepts of the
invention in a simplified form as an introduction to the more
detailed description presented below. As will be appreciated, other
embodiments of the invention are possible utilizing, alone or in
combination, one or more of the features set forth above or
described in detail below.
[0073] The present disclosure, in various embodiments,
configurations, or aspects, includes components, methods,
processes, systems and/or apparatus substantially as depicted and
described herein, including various aspects embodiments,
configurations, sub-combinations, and subsets thereof. Those of
skill in the art will understand how to make and use the various
aspects, embodiments, configurations, sub-combinations, and subsets
of the present disclosure after understanding the disclosure. The
present disclosure, in various aspects, embodiments, and
configurations, includes providing devices and processes in the
absence of items not depicted and/or described herein or in various
aspects, embodiments, or configurations hereof, including in the
absence of such items as may have been used in previous devices or
processes, e.g., for improving performance, achieving ease and\or
reducing cost of implementation.
[0074] The foregoing discussion of the disclosure has been
presented for purposes of illustration and description. The
foregoing is not intended to limit the disclosure to the form or
forms disclosed herein. In the foregoing Detailed Description for
example, various features of the disclosure are grouped together in
one or more aspects, embodiments, or configurations for the purpose
of streamlining the disclosure. The features of the aspects,
embodiments, or configurations of the disclosure may be combined in
alternate aspects, embodiments, or configurations other than those
discussed above. This method of disclosure is not to be interpreted
as reflecting an intention that the claims require more features
than are expressly recited in each claim. Rather, as the following
claims reflect, inventive aspects lie in less than all features of
a single foregoing disclosed aspect, embodiment, or configuration.
Thus, the following claims are hereby incorporated into this
Detailed Description, with each claim standing on its own as a
separate preferred embodiment.
[0075] Moreover, though the description of the disclosure has
included description of one or more aspects, embodiments, or
configurations and certain variations and modifications, other
variations, combinations, and modifications are within the scope of
the invention, e.g., as may be within the skill and knowledge of
those in the art, after understanding the present disclosure. It is
intended to obtain rights which include alternative aspects,
embodiments, or configurations to the extent permitted, including
alternate, interchangeable and/or equivalent structures, functions,
ranges or steps to those claimed, whether or not such alternate,
interchangeable and/or equivalent structures, functions, ranges or
steps are disclosed herein, and without intending to publicly
dedicate any patentable subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0076] The accompanying drawings are incorporated into and form a
part of the specification to illustrate several examples. These
drawings, together with the description, explain the principles of
the invention(s). The drawings simply illustrate preferred and
alternative examples of how the invention(s) can be made and used
and are not to be construed as limiting the invention(s) to only
the illustrated and described examples.
[0077] Further features and advantages will become apparent from
the following, more detailed, description of the various
embodiments of the invention(s), as illustrated by the drawings
referenced below.
[0078] FIG. 1A is a perspective view of one embodiment of a
seamless upper for footwear;
[0079] FIG. 1B is a bottom-view of the embodiment of a seamless
upper for footwear of FIG. 1A;
[0080] FIG. 1C is a top-view of the embodiment of a seamless upper
for footwear of FIG. 1A;
[0081] FIG. 1D is a lateral three-fourths view of the embodiment of
a seamless upper for footwear of FIG. 1A;
[0082] FIG. 1E is a medial three-fourths view of the embodiment of
a seamless upper for footwear of FIG. 1A;
[0083] FIG. 2 is a schematic of weaving, weft knitting and warp
knitting;
[0084] FIG. 3 depicts one method of the formation of a plurality of
footwear uppers;
[0085] FIG. 4 depicts another method of the formation of a
plurality of footwear uppers;
[0086] FIG. 5 is a perspective view of another embodiment of a
seamless upper for footwear;
[0087] FIG. 6 is a perspective view of another embodiment of a
seamless upper for footwear in which the footwear undergoes a
plastic dip step;
[0088] FIG. 7A is a perspective view of one embodiment of knitted
eyelets;
[0089] FIG. 7B is a perspective view of another embodiment of
knitted eyelets;
[0090] FIG. 8A is a perspective view of another embodiment of a
seamless upper for footwear;
[0091] FIG. 8B is a top view of the embodiment of a seamless upper
for footwear of FIG. 8A;
[0092] FIG. 9 is a top-view of one method of the formation of the
embodiment of a seamless upper for footwear of FIG. 8A;
[0093] FIG. 10A is a perspective view of another embodiment of a
seamless upper for footwear;
[0094] FIG. 10B is a top-view of the embodiment of a seamless upper
for footwear of FIG. 10A in which the toe cap reinforcement portion
is unassembled to the seamless upper;
[0095] FIG. 10C is a top-view of the embodiment of a seamless upper
for footwear of FIG. 10A in which the vamp reinforcement portion is
unassembled to the seamless upper;
[0096] FIG. 10D is a top-view of the embodiment of a seamless upper
for footwear of FIG. 10A in which the heel cap reinforcement
portion is unassembled to the seamless upper;
[0097] FIG. 11 is a side view of another embodiment of a seamless
upper for footwear with a mid-sole portion;
[0098] FIG. 12 is a cut-away side-view of further describing the
embodiment of a seamless upper for footwear with a mid-sole portion
of FIG. 11;
[0099] FIG. 13 is a perspective view of another embodiment of a
seamless upper for footwear;
[0100] FIG. 14 is a perspective view of another embodiment of a
seamless upper for footwear;
[0101] FIG. 15A is a cut-away side view of another embodiment of a
seamless upper for footwear;
[0102] FIG. 15B is a cut-away side view of another embodiment of a
seamless upper for footwear; and
[0103] FIG. 16 is a perspective view of another embodiment of a
seamless upper for footwear.
DETAILED DESCRIPTION
[0104] The present disclosure relates to an upper for footwear and
methods for making the footwear upper. The invention involves
application of a knitting process to the production of footwear
uppers. In one preferred embodiment, a knitting process is
disclosed to create a completely seamless upper portion of a shoe.
The process can form the footwear upper in a single step. Some
benefits of this process include ease and efficiency of production,
reduction of assembly time, maximum comfort through reduction of
seams, and freedom of design. The methods can include weaving
and/or knitting the upper. The knitting process typically includes
forming upper by interconnecting a series of stitches or loops.
[0105] In the following description, and for the purposes of
explanation, numerous specific details are set forth in order to
provide a thorough understanding of the various aspects of the
invention. It will be understood, however, by those skilled in the
relevant arts, that the present invention may be practiced without
these specific details. In other instances, known structures and
devices are shown or discussed more generally in order to avoid
obscuring the invention. In many cases, a description of the
operation is sufficient to enable one to implement the various
forms of the invention, particularly when the operation is to be
implemented in software. It should be noted that there are many
different and alternative configurations, devices and technologies
to which the disclosed inventions may be applied. The full scope of
the inventions is not limited to the examples that are described
below.
[0106] The following description will typically be with reference
to specific structural embodiments and methods. It is to be
understood that there is no intention to limit the invention to the
specifically disclosed embodiments and methods but that the
invention may be practiced using other features, elements, methods
and embodiments. Preferred embodiments are described to illustrate
the present invention, not to limit its scope, which is defined by
the claims. Furthermore the embodiments of discussed may be
combined with any one or more other embodiments described
explicitly or impliedly herein. Those of ordinary skill in the art
will recognize a variety of equivalent variations on the
description that follows. Like elements in various embodiments are
commonly referred to with like reference numerals.
[0107] In one embodiment of the invention, an upper for an article
of footwear comprises a textile element formed with a knitting
machine. In one aspect of the invention, the upper is seamless
and/or is of unitary construction. The knitting machine may have a
configuration that forms the textile element through either warp
knitting or weft knitting.
[0108] Another aspect of the invention involves a method of
manufacturing an article of footwear. The method includes a step of
mechanically-manipulating a yarn with a circular knitting machine,
for example, to form a cylindrical textile structure. In addition,
the method involves removing at least one textile element from the
textile structure, and incorporating the textile element into an
upper of the article of footwear so as to form a seamless upper
and/or entire footwear that is seamless.
[0109] In another aspect of the invention, an article of footwear
has a seamless upper and a sole structure secured to the upper. The
upper incorporates a textile element formed with a knitting
machine. The textile element is removed from a textile structure
that includes an outline of the textile element, and the textile
element has edges that are joined together to define at least a
portion of a void for receiving a foot.
[0110] In one embodiment, an upper is at least partially formed
from a textile element that defines an interior void for
comfortably receiving a foot and securing a position of the foot
relative to sole structure. Various edges of textile element are
then secured together to form the shape of upper. In some
embodiments, textile element may form all of upper, substantially
all of upper, or textile element may only be a portion of an
upper.
[0111] Referring now to FIGS. 1-16, several representations and
configurations of the present invention are shown. In regard to
FIGS. 1A-E, one embodiment of a seamless upper for footwear is
depicted. Footwear 100 is shown with bottom portion 130 and top
portion (herein also referred to as the "upper" or "upper portion")
120. Footwear 100 comprises heel portion 103, toe portion 102, vamp
portion 104, and upper covering 108. In the embodiment of the
footwear 100 shown in FIGS. 1A-E, the footwear 100 is depicted with
three types of knit. More specifically, heel portion 103 and toe
portion 102 are shown with an abrasive resistant knit, vamp portion
104 with a supportive knit, and remaining portions such as upper
covering 108 and bottom 130 of a breathable/open knit. The
supportive knit of vamp portion 104 is generally of tighter knit
than the breathable/open knit of upper covering 108 and bottom 130.
However, the various knits are constructed so as to be
substantially or completely seamless. FIG. 1A depicts the footwear
100 as worn by a user (not shown). In the configuration of FIG. 1A,
the upper forms 130 a void on the interior of the footwear 100 for
receiving a user's foot. In contrast, FIG. 1C depicts a top-view of
the footwear 100 when not worn by a user, such that the
aforementioned void is nearly or completely closed. In one
embodiment, another knit with elastic properties is fitted to an
upper portion of the upper covering 108 so as to expand
sufficiently to allow the aforementioned void to form and enable
the interior of the footwear 100 to receive a user's foot. In other
embodiments of the footwear 100 and/or upper portion 120 is
comprised of substantially the same knit material, while in other
embodiments of the footwear 100 and/or upper portion 120 is
comprised of a plurality of knits.
[0112] The knitted upper can have one or more support and/or
tightening zones. The knit construction of the one or more support
and/or tightening zones may include elastomeric yarns and/or a knit
that more constrictive within the tightening zone(s) than in
non-tightening zones. Furthermore, the support and/or tightening
zone(s) may comprise a knit construction that is stronger, tougher
and/or more capable of carrying a load than the knit construction
of the non-tightening zone(s). One or more zones of the upper can
comprise an open knit. Preferably, the open knit is a knit
construction that is substantially "breathable". As used herein a
"breathable" refers to permeability to one or more of air, oxygen,
and water vapor.
[0113] One or more zones of the upper can comprise a cushioning
knit. Preferably, the cushioning knit is a knit construction has at
least some shock absorbing properties. As used herein "shock
absorbing" refers to smoothing out, damping and/or dissipating
impact and/or impulse energy, as for example the impact energy when
a person's foot strikes a surface when running or walking The
cushioning knit is typically positioned about one or more of
tightening zone(s) and the insole.
[0114] Preferably, one or more zones of the upper are substantially
abrasion resistant. More preferably, the abrasion resistant zone(s)
comprise a knit construction that is substantially durable to
abrasion. As used herein "abrasion resistance" refers to rubbing
and/or scrapping away by mechanical and/or frictional action. Even
more preferably, the one or more abrasion resistant zones comprise
an abrasion resistant knit construction. Non-limiting examples of
abrasion resistant knit construction comprise one or both of a high
density knit and abrasion resistant yarns and/or threads.
[0115] It can be appreciated that the knitted upper can optionally
have one or more breathable zones, one or more tightening and/or
support zones; one or more cushioning zones; and optionally one or
more abrasion resistant zones. Furthermore, any one of the optional
one or more breathable, tightening and/or support, cushioning and
abrasion resistant zones can include in addition to its
corresponding knit construction, knit constructions corresponding
to the breathable, tightening and/or support, cushioning and
abrasion resistant knit constructions. That is for example, the
breathable zone, in addition to including a breathable knit
construction, may also include, in some embodiments, a cushioning
knit construction.
[0116] In regard to FIG. 2, a schematic of weaving, weft knitting
and warp knitting is provided. More specifically, a basket weave is
depicted as well as a weft knit and warp knit. In one embodiment,
the footwear 100 and/or upper portion 120 are comprised of one or
more of weft knitting and warp knitted material.
[0117] Various warp knitting or weft knitting processes may be
utilized to form textile element, or the various other textile
elements discussed above. An advantage of this process is that
various stitches may be incorporated into specific locations of
textile element to modify the physical properties or aesthetics of
textile element. Whereas a conventional upper includes various
elements that stitched or adhesively joined, textile element is a
single, unitary element of material. From the perspective of
manufacturing, utilizing multiple materials to impart different
properties to an article of footwear may be an inefficient
practice. By forming textile element to be a single, unitary
element of material, however, efficiency is increased in that upper
may include a single textile element, rather than numerous joined
elements.
[0118] A variety of knitting processes may be utilized to form
textile element, as discussed above. As a specific example, a
jacquard double needle-bar raschel knitting machine may be utilized
to form a flat textile structure, and may also be utilized to form
the textile structure to have the configuration of a spacer mesh
textile. Unlike textile structure, which exhibits a generally
cylindrical configuration, the textile structure formed with the
jacquard double needle-bar raschel knitting machine will have a
flat configuration. Like textile structure, however, an outline of
a textile element may be imparted to the textile structure formed
with the jacquard double needle-bar raschel knitting machine. That
is, differences in the stitches within the textile structure may
form an outline with the shape and proportions of the intended
textile element. Accordingly, the textile element may be removed
from the textile structure and incorporated into footwear. In
addition, the jacquard double needle-bar raschel knitting machine
may be utilized to impart various textures, different properties,
or different yarn types to the textile element. Similarly, other
types of knitting, such as a flat knitting, may be utilized within
the scope of the present invention to impart various textures,
different properties, or different yarn types to the textile
element.
[0119] In regard to FIGS. 3 and 4, depictions of methods of
formation and/or cutting of footwear and/or upper portions 302 are
shown. In each of FIGS. 3 and 4, the top-most area represents a
single knitted sheet 301 as output from a knitting machine (not
shown). FIG. 3 depicts that in some embodiments a plurality of
knitted uppers 302 be formed in a single knitted sheet 301. It can
be can be appreciated that a process which forms a plurality of
knitted uppers in knitting process is preferable to a process which
forms individual knitted uppers and/or to a process which forms a
woven upper. FIG. 4 depicts that in some embodiments the uppers 302
can be knitted on a single knitted sheet 301 in a configuration to
substantially reduce waste of knitted sheet that is not part of the
knitted upper.
[0120] In regard to FIG. 5, a perspective view of another
embodiment of a seamless upper for footwear 500 is depicted. FIG. 5
depicts that in some embodiments the knit direction 501 can wrap
around a wearer's foot in a medial/lateral direction. In other
embodiments, the knit direction 501 can wrap around a wearer's foot
in the anterior (toe)/posterior (heel) direction. It can be
appreciated that embodiments having the knit direction 501 in a
medial/lateral direction can further include one or more support
and/or tightening zones that wrap around a wearer's foot in the
medial/lateral direction. In some embodiments, the knit elements
501 can can carry stress around the wearer's foot, as for example
without limitation stresses from a lacing system for securing the
shoe on a wearer's foot.
[0121] In some embodiments, the knitted upper 504 can include a
knitted toe 502. The toe knit construction 502 can be one or more
of breathable, tightening and/or support, cushioning and abrasion
resistant knit constructions. The one or more of breathable,
tightening and/or support, cushioning and abrasion resistant knit
constructions can be formed by the knit stitching or by one or more
yarns forming the knit stitching.
[0122] In other embodiments, the knitted upper 504 can include a
knitted heel 503. The heel knit construction 504 can be one or more
of breathable, tightening and/or support, cushioning and abrasion
resistant knit constructions. The one or more of breathable,
tightening and/or support, cushioning and abrasion resistant knit
constructions can be formed by the knit stitching or by one or more
yarns forming the knit stitching.
[0123] In regard to FIG. 6, a perspective view of another
embodiment of a seamless upper for footwear 600 is depicted. In one
embodiment, FIG. 6 depicts that a shoe 600 comprising a knitted
upper can be coated with a material such as, but not limited to, a
plastic dip 610. The plastic dip may provide an aspect to the shoe
such as but limited to abrasion resistance, water resistance, one
or more team colors, a decorative element or such. FIG. 6 depicts
the toe 602 and heel 603 being coated with the plastic dip. In some
embodiments the plastic dip is applied by the owner of the shoe, in
other embodiments the plastic dip may be applied by one of shoe.
The "plastic" dip may be any material known to one skilled in the
art to have abrasion resistance characteristics, to include, for
example, natural rubber, latex, synthetic rubber, and other
fiber-encased resinous materials, synthetic materials, polymers,
and natural materials.
[0124] In regard to FIG. 7, perspective views of two embodiments of
knitted eyelets of the knitted upper 700 are shown. In the
embodiment FIG. 7A, an eyelet void 701 is formed in an upper
surface. In the embodiment of FIG. 7B, an eyelet loop 702 is formed
in the upper 700. The eyelets may comprise any knitted construction
formed any knit stitching known within the art.
[0125] In regard to FIGS. 8A-B and 9, another embodiment of a
seamless upper for footwear is shown. FIG. 8A is a perspective view
and FIG. 8B is a top view the embodiment of a seamless upper 801.
FIG. 9 is a top-view of one method of the formation of the
embodiment of a seamless upper 801, depicting the seamless upper
801 and knitted vamps (or sides) 802 as manufactured by a knitting
machine (whose knitted output rolls are depicted as the upper and
lower parallel dashed lines. The knitted upper 801 can be knitted
with one or more knitted side 802, toe 803 and heel 804 wings. The
knitted side 802, toe 803 and heel 804 wings can comprise any knit
construction. Furthermore, the knit constructions of the side 802,
toe 803 and heel 804 can be the same or can differ. In some
embodiments the one or more knitted side 802, toe 803 and heel 804
wings can comprise one or both of a different knit stitching and a
differing yarns than the knitted upper 801. While not wanting to be
limited by example, the one or more knitted side 802, toe 803 and
heel 804 wings can comprise a reinforcing and/or abrasion
resistance knit stitching and/or yarn different from the knit
stitching and/or yarn(s) of the knitted upper 801. In some
embodiments the knitted side 802, toe 803 and heel 804 wings can
comprise a tubular knit construction 805. By way of a non-limiting
example, the tubular knit construction 805 can form a spacer knit
to wrap around the wearer's foot.
[0126] In regard to FIGS. 10A-D, another embodiment of a seamless
upper 801 for footwear is shown. FIG. 10A is a perspective view of
this embodiment. FIGS. 10B-D depict top-views in which the
respective toe cap reinforcement portion 803, vamp (side)
reinforcement 802 and heel cap 804 portions are unassembled to the
seamless upper 801. In this embodiment, the knitted side wings
(vamps) 802 form a shoe quarter. The knitted side wings/vamps 802
can be in the form of a space mesh that can wrap around the shoe
quarter to give a more traditional shoe upper aesthetic.
[0127] In one embodiment, the knitted upper has one or more medial
and/or lateral side wings 802. The side wings may be wrapped around
the knitted upper 801 about one or both of medial and lateral side
of the knitted upper 801. Preferably, the side wings 802 further
support the medial and lateral sides of the upper and/or a foot
positioned within the knitted upper 801. Preferably one or both of
the knitted toe 802 and heel 804 wings comprises an abrasion
resistance knit construction.
[0128] In regard to FIG. 11, a side view of another embodiment of a
seamless upper for footwear 1100 is depicted. FIG. 11 depicts
footwear 1100 comprising a knitted upper 1102 having a knitted
mid-sole 1101. The knitted mid-sole 1101 is positioned between the
upper 1102 and the sole 1103. Preferably, the knitted mid-sole 1101
joins the upper 1102 to the sole 1103. The knitted mid-sole 1101
can comprise a knit construction differing form the knitted upper
1102 knit construction. In one embodiment, the knitted mid-sole
1101 is formed by molding and/or adhesively joining the sole 1103
to the knitted upper 1102. More specifically, during the molding of
the sole 1103 to the upper 1102, when a resin is injected into a
mold to form the sole 1103, the injected resin impregnates at least
some of the knitted upper 1102 to form the knitted mid-sole 1101.
In the case of adhesively joining the sole 1103 to the knitted
upper 1102, it can be appreciated that the adhesive will impregnate
the knitted upper to form the knitted mid-sole 1101.
[0129] In regard to FIG. 12, a cut-away side view of another
embodiment of a seamless upper for footwear is depicted. FIG. 12
depicts footwear comprising a knitted upper joined to a sole 1201
by passing a quarter or vamp wing 1205 of the knitted upper through
a void 1204 of the sole 1201. The sole 1201 comprises a mid-sole
1202 and an outer sole 103, the void 1204 is preferably position
about the mid-sole 1201.
[0130] In regard to FIG. 13, a perspective view of another
embodiment of a seamless upper for footwear 1300 is depicted. FIG.
13 depicts knitted footwear 1300 comprising a knitted upper 1301
joined to a footwear sole 1303. The knitted footwear upper 1300 can
comprise a plurality of voids 1302. The knitted footwear 1300 can
be one of a sandal, slipper, water, or such footwear item. The sole
1303 can be one of adhesively joined, molded and formed by knitted
composition to knitted upper 1301.
[0131] In regard to FIG. 14, a perspective view of another
embodiment of a seamless upper for footwear 1400 is depicted. FIG.
14 depicts shoe / footwear 1400 comprising a knitted upper 1401
interconnected to a sole 1403 and frame 1402. The frame 1402 may or
may not be interconnected to the knitted upper 1401. Preferably,
the frame 1402 is one of interconnect or bonded to the frame 1402.
The frame 1402 may comprise any rigid or semi-rigid material. As
used herein "semi-rigid" refers to any material that has at least
some degree of flexibility when a stress is applied but does not
fracture and/or permanently distort due to the stress. The stress
applied being within the stress typically encounter by footwear.
Non-limiting examples of footwear categories are footwear for
street, casual, athletic, industrial, professional, work, dress,
and formal use. Preferably, the frame comprises a polymeric
material.
[0132] In regard to FIGS. 15A-B, cut-away side views of another
embodiment of a seamless upper for footwear 1500 is depicted. FIG.
15 depicts a cross-sectional plan view of shoe/footwear 1500
comprising a sole 1501 and a knitted upper 1502. The knitted upper
1052 has one or more knitted upper voids (not depicted). The sole
1501 comprises at least one arm 105 interconnecting the inner-sole
1503 and outer-sole 1504 elements. The knitted upper is
interconnected to the sole 1501 by passing the inner-sole 1503
element through the one or more knitted upper voids (not depicted).
It can be appreciated that the one or more knitted upper voids are
preferably formed by knitting the one or more voids in the knitted
upper 1502.
[0133] In regard to FIG. 16, a perspective view of another
embodiment of a seamless upper for footwear 1600 is depicted. FIG.
16 depicts a shoe 1600 having a plurality of channels 1602 knitted
in upper 1601. Preferably, each of the plurality of channels 10602
are configured to accept a member 1603. Each of the members 1603
can vary in one or both of shape and physical properties. For
example some members may be more or less flexible and/or rigid than
other members 1603. Furthermore, some members may have a differing
contour, width, length, thickness or combination thereof In some
embodiments, a wearer of the shoe 1600 selects the plurality of
members 1603 to configure the shoe 1600 to his or her needs and/or
foot. The members 1603 can comprise any material. Preferably, the
members 1603 comprise a polymeric material.
[0134] While various embodiment of the present disclosure have been
described in detail, it is apparent that modifications and
alterations of those embodiments will occur to those skilled in the
art. However, it is to be expressly understood that such
modifications and alterations are within the scope and spirit of
the present disclosure, as set forth in the following claims.
[0135] The foregoing discussion of the disclosure has been
presented for purposes of illustration and description. The
foregoing is not intended to limit the disclosure to the form or
forms disclosed herein. In the foregoing Detailed Description for
example, various features of the disclosure are grouped together in
one or more embodiments for the purpose of streamlining the
disclosure. This method of disclosure is not to be interpreted as
reflecting an intention that the claimed disclosure requires more
features than are expressly recited in each claim. Rather, as the
following claims reflect, inventive aspects lie in less than all
features of a single foregoing disclosed embodiment. Thus, the
following claims are hereby incorporated into this Detailed
Description, with each claim standing on its own as a separate
preferred embodiment of the disclosure.
[0136] Moreover, though the present disclosure has included
description of one or more embodiments and certain variations and
modifications, other variations and modifications are within the
scope of the disclosure, e.g., as may be within the skill and
knowledge of those in the art, after understanding the present
disclosure. It is intended to obtain rights which include
alternative embodiments to the extent permitted, including
alternate, interchangeable and/or equivalent structures, functions,
ranges or steps to those claimed, whether or not such alternate,
interchangeable and/or equivalent structures, functions, ranges or
steps are disclosed herein, and without intending to publicly
dedicate any patentable subject matter.
* * * * *