U.S. patent application number 14/026531 was filed with the patent office on 2015-03-19 for article of footwear incorporating a knitted component with monofilament areas.
This patent application is currently assigned to Nike, Inc.. The applicant listed for this patent is Nike, Inc.. Invention is credited to Bruce Huffa, Daniel A. Podhajny.
Application Number | 20150075031 14/026531 |
Document ID | / |
Family ID | 51589507 |
Filed Date | 2015-03-19 |
United States Patent
Application |
20150075031 |
Kind Code |
A1 |
Podhajny; Daniel A. ; et
al. |
March 19, 2015 |
Article Of Footwear Incorporating A Knitted Component With
Monofilament Areas
Abstract
An article of footwear including an upper incorporating a
knitted component having one or more monofilament areas is
described. Monofilament areas are formed by knitting with a
monofilament strand. The monofilament areas are formed of unitary
knit construction with the remaining portions of the knitted
component. An inlaid tensile element can extend through the knitted
component, including portions of the monofilament areas.
Inventors: |
Podhajny; Daniel A.;
(Beaverton, OR) ; Huffa; Bruce; (Encino,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nike, Inc. |
Beaverton |
OR |
US |
|
|
Assignee: |
Nike, Inc.
Beaverton
OR
|
Family ID: |
51589507 |
Appl. No.: |
14/026531 |
Filed: |
September 13, 2013 |
Current U.S.
Class: |
36/45 ;
66/196 |
Current CPC
Class: |
D04B 1/123 20130101;
A43B 23/0245 20130101; D10B 2403/032 20130101; D10B 2501/043
20130101; A43B 23/0205 20130101; D10B 2403/0114 20130101; A43B
1/0072 20130101; A43B 7/085 20130101; A43B 23/0235 20130101; A43B
23/0215 20130101; A43B 1/04 20130101; A43B 23/042 20130101; D04B
1/16 20130101 |
Class at
Publication: |
36/45 ;
66/196 |
International
Class: |
A43B 1/04 20060101
A43B001/04; A43B 23/02 20060101 A43B023/02 |
Claims
1. An article of footwear having an upper and a sole structure
secured to the upper, the upper including a knitted component
comprising: a first portion of the knitted component formed by a
first yarn, the first yarn being a natural or synthetic twisted
fiber yarn; at least one monofilament area disposed on the knitted
component, the at least one monofilament area being formed by a
monofilament strand; wherein the at least one monofilament area is
formed of unitary knit construction with the first portion of the
knitted component such that the knitted component is a one-piece
element.
2. The article of footwear according to claim 1, wherein at least
one course of the first yarn is substantially continuous with at
least one course of the monofilament strand.
3. The article of footwear according to claim 1, wherein the
knitted component includes a plurality of monofilament areas, each
monofilament area being formed by the monofilament strand.
4. The article of footwear according to claim 3, wherein the
plurality of monofilament areas comprise a medial monofilament
portion disposed on a medial side of the upper and a lateral
monofilament portion disposed on a lateral side of the upper.
5. The article of footwear according to claim 4, wherein the
plurality of monofilament areas further comprises a forefoot
monofilament portion disposed in a forefoot region of the
upper.
6. The article of footwear according to claim 5, wherein at least
one of the medial monofilament portion and the lateral monofilament
portion is substantially continuous with the forefoot monofilament
portion.
7. The article of footwear according to claim 5, wherein at least
one of the medial monofilament portion and the lateral monofilament
portion is discontinuous with the forefoot monofilament
portion.
8. The article of footwear according to claim 1, wherein the
monofilament area is substantially surrounded by the first portion
of the knitted component.
9. The article of footwear according to claim 8, wherein the first
portion of the knitted component surrounding the monofilament area
is configured to place the monofilament area under tension.
10. The article of footwear according to claim 1, further
comprising an inlaid tensile element extending through at least one
of the first portion and the monofilament area.
11. The article of footwear according to claim 10, wherein the
inlaid tensile element extends through both the first portion of
the knitted component and the monofilament area.
12. The article of footwear according to claim 1, wherein the
monofilament area comprises two knit layers formed of unitary knit
construction, the two knit layers being overlapping and at least
partially coextensive with each other.
13. The article of footwear according to claim 12, wherein a first
knit layer of the monofilament area is associated with an exterior
surface of the upper and a second knit layer of the monofilament
area is associated with an interior surface of the upper.
14. The article of footwear according to claim 13, wherein the
first knit layer and the second knit layer are both formed by a
monofilament strand.
15. The article of footwear according to claim 13, wherein the
first knit layer is formed by the monofilament strand; and wherein
the second knit layer is formed by the first yarn.
16. An article of footwear having an upper and a sole structure
secured to the upper, the upper including a knitted component
comprising: a knit element including a first yarn, the knit element
defining a portion of an exterior surface of the upper and an
opposite interior surface of the upper, the interior surface
defining a void for receiving a foot, the first yarn being a
natural or synthetic twisted fiber yarn; and at least one
monofilament area comprised of two knit layers, the two knit layers
being overlapping and at least partially coextensive with each
other, each knit layer including a monofilament strand; wherein the
at least one monofilament area is formed of unitary knit
construction with the knit element such that the knitted component
is a one-piece element.
17. The article of footwear according to claim 16, wherein the
knitted component includes a plurality of monofilament areas.
18. The article of footwear according to claim 17, wherein the
plurality of monofilament areas includes at least one monofilament
area of a first type and at least one monofilament area of a second
type.
19. The article of footwear according to claim 18, wherein the
first type of monofilament area includes a first monofilament
strand associated with the exterior surface of the upper and a
second monofilament strand associated with the interior surface of
the upper.
20. The article of footwear according to claim 18, wherein the
second type of monofilament area includes a first monofilament
strand associated with the exterior surface of the upper and a
natural or synthetic twisted fiber yarn associated with the
interior surface of the upper.
21. The article of footwear according to claim 20, wherein the
natural or synthetic twisted fiber yarn of the second type of
monofilament area is the first yarn.
22. The article of footwear according to claim 17, wherein the
plurality of monofilament areas comprise a medial monofilament
portion disposed on a medial side of the upper and a lateral
monofilament portion disposed on a lateral side of the upper.
23. The article of footwear according to claim 22, wherein the
plurality of monofilament areas further includes at least one of a
forefoot monofilament portion disposed in a forefoot region of the
upper and a heel forefoot monofilament portion disposed in a heel
region of the upper.
24. The article of footwear according to claim 23, wherein the
plurality of monofilament areas are continuous between two or more
of the plurality of monofilament areas.
25. The article of footwear according to claim 16, wherein a first
knit layer of the monofilament area is associated with the exterior
surface of the upper and a second knit layer of the monofilament
area is associated with the interior surface of the upper.
26. The article of footwear according to claim 25, wherein the
first knit layer includes the monofilament strand.
27. The article of footwear according to claim 25, wherein the
second knit layer includes one of a monofilament strand and a
natural or synthetic twisted fiber yarn.
28. The article of footwear according to claim 16, further
comprising an inlaid tensile element extending through at least one
of the knit element and the monofilament area.
29. The article of footwear according to claim 28, wherein the
inlaid tensile element extends through both the knit element and
the monofilament area of the knitted component.
30. An article of footwear having an upper and a sole structure
secured to the upper, the upper including a knitted component
comprising: a first portion of the knitted component formed by a
first yarn, the first yarn being a natural or synthetic twisted
fiber yarn; a second portion of the knitted component formed by a
monofilament strand, wherein second portion is formed of unitary
knit construction with the first portion such that the knitted
component is a one-piece element; and an inlaid tensile element
extending through the knitted component, including at least a
portion of the first portion and a portion of the second
portion.
31. The article of footwear according to claim 30, wherein the
first portion comprises at least a portion of an interior surface
of the upper and wherein the second portion comprises at least a
portion of an exterior surface of the upper.
32. The article of footwear according to claim 30, wherein the
first portion comprises a majority of the knitted component; and
wherein the first portion surrounds the second portion.
33. The article of footwear according to claim 30, wherein the
knitted component further comprises a knit element and at least one
monofilament area; and wherein the knit element includes the first
portion; and wherein the at least one monofilament area includes
the second portion.
34. The article of footwear according to claim 33, wherein the
knitted component comprises a plurality of monofilament areas.
35. The article of footwear according to claim 34, wherein the
plurality of monofilament areas are disposed on at least two of a
medial side of the upper, a lateral side of the upper, a forefoot
portion of the upper, and a heel portion of the upper.
36. The article of footwear according to claim 34, wherein the
plurality of monofilament areas are substantially continuous with
each other across the upper.
37. The article of footwear according to claim 34, wherein the
plurality of monofilament areas comprises different types of
monofilament areas, including: a first type of monofilament area
comprising two knit layers formed by the monofilament strand, the
two knit layers being partially co-extensive and overlapping; and a
second type of monofilament area comprising a first knit layer
formed by the monofilament strand and a second knit layer formed by
the first yarn, the first knit layer and the second knit layer
being partially co-extensive and overlapping.
38. The article of footwear according to claim 37, wherein at least
one of the knit layers of the first type of monofilament area and
the second type of monofilament area include the same monofilament
strand.
Description
BACKGROUND
[0001] Conventional articles of footwear generally include two
primary elements, an upper and a sole structure. The upper is
secured to the sole structure and forms a void on the interior of
the footwear for comfortably and securely receiving a foot. The
sole structure is secured to a lower area of the upper, thereby
being positioned between the upper and the ground. In athletic
footwear, for example, the sole structure may include a midsole and
an outsole. The midsole often includes a polymer foam material that
attenuates ground reaction forces to lessen stresses upon the foot
and leg during walking, running, and other ambulatory activities.
Additionally, the midsole may include fluid-filled chambers,
plates, moderators, or other elements that further attenuate
forces, enhance stability, or influence the motions of the foot.
The outsole is secured to a lower surface of the midsole and
provides a ground-engaging portion of the sole structure formed
from a durable and wear-resistant material, such as rubber. The
sole structure may also include a sockliner positioned within the
void and proximal a lower surface of the foot to enhance footwear
comfort.
[0002] The upper generally extends over the instep and toe areas of
the foot, along the medial and lateral sides of the foot, under the
foot, and around the heel area of the foot. In some articles of
footwear, such as basketball footwear and boots, the upper may
extend upward and around the ankle to provide support or protection
for the ankle. Access to the void on the interior of the upper is
generally provided by an ankle opening in a heel region of the
footwear. A lacing system is often incorporated into the upper to
adjust the fit of the upper, thereby permitting entry and removal
of the foot from the void within the upper. The lacing system also
permits the wearer to modify certain dimensions of the upper,
particularly girth, to accommodate feet with varying dimensions. In
addition, the upper may include a tongue that extends under the
lacing system to enhance adjustability of the footwear, and the
upper may incorporate a heel counter to limit movement of the
heel.
[0003] A variety of material elements (e.g., textiles, polymer
foam, polymer sheets, leather, synthetic leather) are
conventionally utilized in manufacturing the upper. In athletic
footwear, for example, the upper may have multiple layers that each
include a variety of joined material elements. As examples, the
material elements may be selected to impart stretch-resistance,
wear-resistance, flexibility, air-permeability, compressibility,
comfort, and moisture-wicking to different areas of the upper. In
order to impart the different properties to different areas of the
upper, material elements are often cut to desired shapes and then
joined together, usually with stitching or adhesive bonding.
Moreover, the material elements are often joined in a layered
configuration to impart multiple properties to the same areas. As
the number and type of material elements incorporated into the
upper increases, the time and expense associated with transporting,
stocking, cutting, and joining the material elements may also
increase. Waste material from cutting and stitching processes also
accumulates to a greater degree as the number and type of material
elements incorporated into the upper increases. Moreover, uppers
with a greater number of material elements may be more difficult to
recycle than uppers formed from fewer types and numbers of material
elements. By decreasing the number of material elements utilized in
the upper, therefore, waste may be decreased while increasing the
manufacturing efficiency and recyclability of the upper.
SUMMARY
[0004] Various configurations of an article of footwear may have an
upper and a sole structure secured to the upper. A knitted
component of the upper includes one or more monofilament areas. The
monofilament areas are formed of unitary knit construction with the
remaining portions of the knitted component.
[0005] In one aspect, the invention provides an article of footwear
having an upper and a sole structure secured to the upper, the
upper including a knitted component comprising: a first portion of
the knitted component formed by a first yarn, the first yarn being
a natural or synthetic twisted fiber yarn; at least one
monofilament area disposed on the knitted component, the at least
one monofilament area being formed by a monofilament strand;
wherein the at least one monofilament area is formed of unitary
knit construction with the first portion of the knitted component
such that the knitted component is a one-piece element.
[0006] In another aspect, the invention provides an article of
footwear having an upper and a sole structure secured to the upper,
the upper including a knitted component comprising: a knit element
including a first yarn, the knit element defining a portion of an
exterior surface of the upper and an opposite interior surface of
the upper, the interior surface defining a void for receiving a
foot, the first yarn being a natural or synthetic twisted fiber
yarn; and at least one monofilament area comprised of two knit
layers, the two knit layers being overlapping and at least
partially coextensive with each other, each knit layer including a
monofilament strand; wherein the at least one monofilament area is
formed of unitary knit construction with the knit element such that
the knitted component is a one-piece element.
[0007] In another aspect, the invention provides an article of
footwear having an upper and a sole structure secured to the upper,
the upper including a knitted component comprising: a first portion
of the knitted component formed by a first yarn, the first yarn
being a natural or synthetic twisted fiber yarn; a second portion
of the knitted component formed by a monofilament strand, wherein
second portion is formed of unitary knit construction with the
first portion such that the knitted component is a one-piece
element; and an inlaid tensile element extending through the
knitted component, including at least a portion of the first
portion and a portion of the second portion.
[0008] Other systems, methods, features and advantages of the
invention will be, or will become, apparent to one of ordinary
skill in the art upon examination of the following figures and
detailed description. It is intended that all such additional
systems, methods, features and advantages be included within this
description and this summary, be within the scope of the invention,
and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention can be better understood with reference to the
following drawings and description. The components in the figures
are not necessarily to scale, emphasis instead being placed upon
illustrating the principles of the invention. Moreover, in the
figures, like reference numerals designate corresponding parts
throughout the different views.
[0010] FIG. 1 is an isometric view of an exemplary embodiment of an
article of footwear incorporating a knitted component with
monofilament areas;
[0011] FIG. 2 is a medial side view of the exemplary embodiment of
an article of footwear incorporating a knitted component with
monofilament areas;
[0012] FIG. 3 is a lateral side view of the exemplary embodiment of
an article of footwear incorporating a knitted component with
monofilament areas;
[0013] FIG. 4 is a top plan view of the exemplary embodiment of an
article of footwear incorporating a knitted component with
monofilament areas;
[0014] FIG. 5 is a cross-sectional view of the exemplary embodiment
of an article of footwear taken along the line shown in FIG. 4;
[0015] FIG. 6 is a top plan view of an exemplary embodiment of the
knitted component with monofilament areas;
[0016] FIG. 7 is a top plan view of the exemplary embodiment of the
knitted component with monofilament areas including enlarged views
of exemplary knit structures;
[0017] FIG. 8 is an isometric view of an exemplary embodiment of an
article of footwear incorporating a knitted component with various
monofilament areas;
[0018] FIG. 9 is a medial side view of the exemplary embodiment of
an article of footwear incorporating a knitted component with
various monofilament areas;
[0019] FIG. 10 is a lateral side view of the exemplary embodiment
of an article of footwear incorporating a knitted component with
various monofilament areas;
[0020] FIG. 11 is a top plan view of the exemplary embodiment of an
article of footwear incorporating a knitted component with various
monofilament areas;
[0021] FIGS. 12A-12C are cross-sectional views of the exemplary
embodiment of an article of footwear taken along different portions
according to the section lines shown in FIG. 11;
[0022] FIG. 13 is a top plan view of an exemplary embodiment of the
knitted component with various monofilament areas;
[0023] FIG. 14 is a top plan view of the exemplary embodiment of
the knitted component with various monofilament areas including
enlarged views of exemplary knit structures;
[0024] FIGS. 15A-15C are cross-sectional views of the exemplary
embodiment of a knitted component taken along different portions
according to the section lines shown in FIG. 14;
[0025] FIG. 16A is an enlarged view of a portion of an exemplary
embodiment of a knitted component including a tensile element;
[0026] FIG. 16B is an enlarged view of a portion of an alternate
embodiment of a knitted component including a tensile element;
and
[0027] FIG. 17 is a representation of a looping diagram for
knitting a knit structure.
DETAILED DESCRIPTION
[0028] The following discussion and accompanying figures disclose a
variety of concepts relating to knitted components and the
manufacture of knitted components. Although the knitted components
may be used in a variety of products, an article of footwear that
incorporates one or more of the knitted components is disclosed
below as an example. FIGS. 1 through 17 illustrate exemplary
embodiments of an article of footwear incorporating a knitted
component including one or more monofilament areas formed of
unitary knit construction with the remaining portions of the
knitted component. The individual features of any of the knitted
components described herein may be used in combination or may be
provided separately in different configurations for articles of
footwear. In addition, any of the features may be optional and may
not be included in any one particular embodiment of a knitted
component.
[0029] FIGS. 1 through 4 illustrate an exemplary embodiment of an
article of footwear 100, also referred to simply as article 100. In
some embodiments, article of footwear 100 may include a sole
structure 110 and an upper 120. Although article 100 is illustrated
as having a general configuration suitable for running, concepts
associated with article 100 may also be applied to a variety of
other athletic footwear types, including soccer shoes, baseball
shoes, basketball shoes, cycling shoes, football shoes, tennis
shoes, training shoes, walking shoes, and hiking boots, for
example. The concepts may also be applied to footwear types that
are generally considered to be non-athletic, including dress shoes,
loafers, sandals, and work boots. Accordingly, the concepts
disclosed with respect to article 100 may be applied to a wide
variety of footwear types.
[0030] For reference purposes, article 100 may be divided into
three general regions: a forefoot region 10, a midfoot region 12,
and a heel region 14, as shown in FIGS. 1, 2, and 3. Forefoot
region 10 generally includes portions of article 100 corresponding
with the toes and the joints connecting the metatarsals with the
phalanges. Midfoot region 12 generally includes portions of article
100 corresponding with an arch area of the foot. Heel region 14
generally corresponds with rear portions of the foot, including the
calcaneus bone. Article 100 also includes a lateral side 16 and a
medial side 18, which extend through each of forefoot region 10,
midfoot region 12, and heel region 14 and correspond with opposite
sides of article 100. More particularly, lateral side 16
corresponds with an outside area of the foot (i.e., the surface
that faces away from the other foot), and medial side 18
corresponds with an inside area of the foot (i.e., the surface that
faces toward the other foot). Forefoot region 10, midfoot region
12, and heel region 14 and lateral side 16, medial side 18 are not
intended to demarcate precise areas of article 100. Rather,
forefoot region 10, midfoot region 12, and heel region 14 and
lateral side 16, medial side 18 are intended to represent general
areas of article 100 to aid in the following discussion. In
addition to article 100, forefoot region 10, midfoot region 12, and
heel region 14 and lateral side 16, medial side 18 may also be
applied to sole structure 110, upper 120, and individual elements
thereof.
[0031] In an exemplary embodiment, sole structure 110 is secured to
upper 120 and extends between the foot and the ground when article
100 is worn. In some embodiments, sole structure 110 may include
one or more components, including a midsole, an outsole, and/or a
sockliner or insole. In an exemplary embodiment, sole structure 110
may include an outsole 112 that is secured to a lower surface of
upper 120 and/or a base portion configured for securing sole
structure 110 to upper 120. In one embodiment, outsole 112 may be
formed from a wear-resistant rubber material that is textured to
impart traction. Although this configuration for sole structure 110
provides an example of a sole structure that may be used in
connection with upper 120, a variety of other conventional or
nonconventional configurations for sole structure 110 may also be
used. Accordingly, in other embodiments, the features of sole
structure 110 or any sole structure used with upper 120 may
vary.
[0032] For example, in other embodiments, sole structure 110 may
include a midsole and/or a sockliner. A midsole may be secured to a
lower surface of an upper and in some cases may be formed from a
compressible polymer foam element (e.g., a polyurethane or
ethylvinylacetate foam) that attenuates ground reaction forces
(i.e., provides cushioning) when compressed between the foot and
the ground during walking, running, or other ambulatory activities.
In other cases, a midsole may incorporate plates, moderators,
fluid-filled chambers, lasting elements, or motion control members
that further attenuate forces, enhance stability, or influence the
motions of the foot. In still other cases, the midsole may be
primarily formed from a fluid-filled chamber that is located within
an upper and is positioned to extend under a lower surface of the
foot to enhance the comfort of an article.
[0033] In some embodiments, upper 120 defines a void within article
100 for receiving and securing a foot relative to sole structure
110. The void is shaped to accommodate the foot and extends along a
lateral side of the foot, along a medial side of the foot, over the
foot, around the heel, and under the foot. Upper 120 includes an
exterior surface 121 and an opposite interior surface 122. Whereas
exterior surface 121 faces outward and away from article 100,
interior surface 122 faces inward and defines a majority or a
relatively large portion of the void within article 100 for
receiving the foot. Moreover, interior surface 122 may lay against
the foot or a sock covering the foot. Upper 120 may also include a
collar 123 that is located in at least heel region 14 and forms a
throat opening 140. Access to the void is provided by throat
opening 140. More particularly, the foot may be inserted into upper
120 through throat opening 140 formed by collar 123, and the foot
may be withdrawn from upper 120 through throat opening 140 formed
by collar 123. In some embodiments, an instep area 150 extends
forward from collar 123 and ankle opening 140 in heel region 14
over an area corresponding to an instep of the foot in midfoot
region 12 to an area adjacent to forefoot region 10.
[0034] In some embodiments, upper 120 may include a tongue portion
152. Tongue portion 152 may be disposed between lateral side 16 and
medial side 18 of upper 120 through instep area 150. In an
exemplary embodiment, tongue portion 152 may be integrally attached
to and formed of unitary knit construction with portions of upper
120 along lateral and medial sides through instep area 150.
Accordingly, as shown in the Figures, upper 120 may extend
substantially continuously across instep area 150 between lateral
side 16 and medial side 18. In other embodiments, tongue portion
152 may be disconnected along lateral and medial sides through
instep area 150 such that tongue portion 152 is moveable within an
opening between a lateral portion and a medial portion on opposite
sides of instep area 150.
[0035] A lace 154 extends through a plurality of lace apertures 153
in upper 120 and permits the wearer to modify dimensions of upper
120 to accommodate proportions of the foot. In some embodiments,
lace 154 may extend through lace apertures 153 that are disposed
along either side of instep area 150. More particularly, lace 154
permits the wearer to tighten upper 120 around the foot, and lace
154 permits the wearer to loosen upper 120 to facilitate entry and
removal of the foot from the void (i.e., through throat opening
140). In addition, tongue portion 152 of upper 120 in instep area
150 extends under lace 154 to enhance the comfort of article 100.
Lace 154 is illustrated with article 100 in FIG. 1, while in FIGS.
2 through 4, lace 154 may be omitted for purposes of clarity. In
further configurations, upper 120 may include additional elements,
such as (a) a heel counter in heel region 14 that enhances
stability, (b) a toe guard in forefoot region 10 that is formed of
a wear-resistant material, and (c) logos, trademarks, and placards
with care instructions and material information.
[0036] In some embodiments, upper 120 may include one or more
portions that include monofilament strands, as will be described in
more detail below. Monofilament strands may be made from a plastic
or polymer material that is extruded to form the monofilament
strand. Generally, monofilament strands may be lightweight and have
a high tensile strength, i.e., are able to sustain a large degree
of stress prior to tensile failure or breaking, so as to provide a
large amount or degree of resistance to stretch to upper 120. In an
exemplary embodiment, portions of upper 120 that include
monofilament strands may be located in one or more monofilament
areas 160.
[0037] In some embodiments, monofilament areas 160 may be located
on various portions of upper 120. In an exemplary embodiment, one
or more monofilament areas 160 may be located on portions of
article 100 where upper 120 will lay generally flat against a foot
of a wearer disposed within upper 120. In this embodiment,
monofilament areas 160 include a medial monofilament portion 162
disposed on medial side 18 of upper 120 and a lateral monofilament
portion 166 disposed on lateral side 16 of upper 120. Medial
monofilament portion 162 and lateral monofilament portion 166 may
be generally located in midfoot region 12. In some embodiments,
monofilament areas 160 may further include a forefoot monofilament
portion 164 that is disposed forward of instep area 150 in forefoot
region 10 of upper 120.
[0038] In some embodiments, monofilament areas 160 may be
substantially continuous between each monofilament area 160 across
upper 120. For example, in one embodiment, medial monofilament
portion 162 may be continuous with forefoot monofilament portion
164, and lateral monofilament portion 166 may also be continuous
with forefoot monofilament portion 164. With this configuration,
monofilament areas 160 may form a substantially continuous zone
extending across upper 120 from lateral side 16 across forefoot
region 10 to medial side 18. In other embodiments, each
monofilament area 160, including medial monofilament portion 162,
forefoot monofilament portion 164, and/or lateral monofilament
portion 166, may be discontinuous with other monofilament areas 160
disposed on upper 120. In embodiments where monofilament areas 160
are discontinuous, each monofilament area 160, for example, medial
monofilament portion 162, forefoot monofilament portion 164, and/or
lateral monofilament portion 166, may be surrounded or
circumscribed by the remaining portions of upper 120.
[0039] Many conventional footwear uppers are formed from multiple
material elements (e.g., textiles, polymer foam, polymer sheets,
leather, synthetic leather) that are joined through stitching or
bonding, for example. In contrast, in some embodiments, a majority
of upper 120 is formed from a knitted component 130, which will be
discussed in more detail below. Knitted component 130 may, for
example, be manufactured through a flat knitting process and
extends through each of each of forefoot region 10, midfoot region
12, and heel region 14, along both lateral side 16 and medial side
18, over forefoot region 10, and around heel region 14. In an
exemplary embodiment, knitted component 130 forms substantially all
of upper 120, including exterior surface 121 and a majority or a
relatively large portion of interior surface 122, thereby defining
a portion of the void within upper 120. In some embodiments,
knitted component 130 may also extend under the foot. In other
embodiments, however, a strobel sock or thin sole-shaped piece of
material is secured to knitted component 130 to form a base portion
of upper 120 that extends under the foot for attachment with sole
structure 110. In addition, a seam 129 extends vertically through
heel region 14, as depicted in FIG. 4, to join edges of knitted
component 130.
[0040] Although seams may be present in knitted component 130, a
majority of knitted component 130 has a substantially seamless
configuration. Moreover, knitted component 130 may be formed of
unitary knit construction. As utilized herein, a knitted component
(e.g., knitted component 130) is defined as being formed of
"unitary knit construction" when formed as a one-piece element
through a knitting process. That is, the knitting process
substantially forms the various features and structures of knitted
component 130 without the need for significant additional
manufacturing steps or processes. A unitary knit construction may
be used to form a knitted component having structures or elements
that include one or more courses of yarn, strands, or other knit
material that are joined such that the structures or elements
include at least one course in common (i.e., sharing a common yarn)
and/or include courses that are substantially continuous between
each of the structures or elements. With this arrangement, a
one-piece element of unitary knit construction is provided.
[0041] Although portions of knitted component 130 may be joined to
each other (e.g., edges of knitted component 130 being joined
together) following the knitting process, knitted component 130
remains formed of unitary knit construction because it is formed as
a one-piece knit element. Moreover, knitted component 130 remains
formed of unitary knit construction when other elements (e.g., a
lace, logos, trademarks, placards with care instructions and
material information, structural elements) are added following the
knitting process.
[0042] Knitted component 130 may incorporate various types of yarn
that impart different properties to separate areas of upper 120.
That is, one area of knitted component 130 may be formed from a
first type of yarn that imparts a first set of properties, and
another area of knitted component 130 may be formed from a second
type of yarn that imparts a second set of properties. In this
configuration, properties may vary throughout upper 120 by
selecting specific yarns for different areas of knitted component
130. The properties that a particular type of yarn will impart to
an area of knitted component 130 partially depend upon the
materials that form the various filaments and fibers within the
yarn. Cotton, for example, provides a soft hand, natural
aesthetics, and biodegradability. Elastane and stretch polyester
each provide substantial stretch and recovery, with stretch
polyester also providing recyclability. Rayon provides high luster
and moisture absorption. Wool also provides high moisture
absorption, in addition to insulating properties and
biodegradability. Nylon is a durable and abrasion-resistant
material with relatively high strength. Polyester is a hydrophobic
material that also provides relatively high durability. In addition
to materials, other aspects of the yarns selected for knitted
component 130 may affect the properties of upper 120. For example,
a yarn forming knitted component 130 may be a monofilament yarn or
a multifilament yarn. The yarn may also include separate filaments
that are each formed of different materials. In addition, the yarn
may include filaments that are each formed of two or more different
materials, such as a bicomponent yarn with filaments having a
sheath-core configuration or two halves formed of different
materials. Different degrees of twist and crimping, as well as
different deniers, may also affect the properties of upper 120.
Accordingly, both the materials forming the yarn and other aspects
of the yarn may be selected to impart a variety of properties to
separate areas of upper 120.
[0043] In some configurations of knitted component 130, materials
forming yarns may be non-fusible or fusible. For example, a
non-fusible yarn may be substantially formed from a thermoset
polyester material and fusible yarn may be at least partially
formed from a thermoplastic polyester material. When a fusible yarn
is heated and fused to non-fusible yarns, this process may have the
effect of stiffening or rigidifying the structure of knitted
component 130. Moreover, joining portions of non-fusible yarn using
fusible yarns may have the effect of securing or locking the
relative positions non-fusible yarns within knitted component 130,
thereby imparting stretch-resistance and stiffness. That is,
portions of non-fusible yarn may not slide relative to each other
when fused with the fusible yarn, thereby preventing warping or
permanent stretching of knitted component 130 due to relative
movement of the knit structure. Another feature of using fusible
yarns in portions of knitted component 130 relates to limiting
unraveling if a portion of knitted component 130 becomes damaged or
one of the non-fusible yarns is severed. Accordingly, areas of
knitted component 130 may be configured with both fusible and
non-fusible yarns within the knit structure.
[0044] In an exemplary embodiment, upper 120 may include a first
type of yarn that is knitted to form portions of knitted component
130 other than monofilament areas 160. Monofilament areas 160 on
upper 120 may be formed by knitting with a monofilament strand to
form knitted component 130 of unitary knit construction with the
portions knitted with the first type of yarn. That is, monofilament
areas 160 are formed of unitary knit construction with the
remaining portions of knitted component 130 so as to be a one-piece
element.
[0045] In some embodiments, knitted component 130 may include one
or more boundary zones. Boundary zones define the portion of
knitted component 130 where the yarn used to knit knitted component
130 transitions from one yarn type to another yarn type. For
example, knitted component 130 may transition from a first type of
yarn to a monofilament strand forming monofilament areas 160 at one
or more boundary zones on upper 120. In an exemplary embodiment,
the first type of yarn transitions from a natural or synthetic
twisted fiber yarn to the monofilament strand at one or more
boundary zones associated with each of monofilament areas 160. In
this embodiment, medial monofilament portion 162 includes a rear
medial boundary 200 disposed towards heel region 14 of upper 120
where a monofilament strand forming medial monofilament portion 162
transitions to the first type of yarn used to form the remaining
portions of knitted component 130. Medial monofilament portion 162
may further include a top medial boundary 204 and a bottom medial
boundary 206. In one embodiment, top medial boundary 204 is located
along medial side 18 of upper 120 and may be spaced apart from
collar 123 and throat opening 140 by a first distance D1. In one
embodiment, bottom medial boundary 206 is also located along medial
side 18 of upper 120 and may be spaced apart from sole structure
110 by a second distance D2.
[0046] In some embodiments, forward medial boundary 202 may define
a forward location of medial monofilament portion 162 on upper 120.
In embodiments where monofilament areas 160 are substantially
continuous, forward medial boundary 202 may simply transition into
forefoot monofilament portion 164. In embodiments where each
monofilament area 160 is discontinuous, however, forward medial
boundary 202 may define the transition from the monofilament strand
back to the first yarn type. It should be understood that in such
discontinuous embodiments, forefoot monofilament portion 164 will
be defined by another boundary zone where the yarn again
transitions back to the monofilament strand.
[0047] Continuing along upper 120, forefoot monofilament portion
164 may include a rear forefoot boundary 208 and a forward forefoot
boundary 209. In one embodiment, rear forefoot boundary 208 may be
located forward of instep area 150 and spaced apart by a third
distance D3. Similarly, forward forefoot boundary 209 may be
located near a toe end of article 100 and spaced apart by a fourth
distance D4. In this embodiment, lateral monofilament portion 166
includes a rear lateral boundary 210 disposed towards heel region
14 of upper 120 where a monofilament strand forming lateral
monofilament portion 166 transitions to the first type of yarn used
to form the remaining portions of knitted component 130. Lateral
monofilament portion 166 may further include a top lateral boundary
214 and a bottom lateral boundary 216. In one embodiment, top
lateral boundary 214 is located along lateral side 16 of upper 120
and may be spaced apart from collar 123 and throat opening 140 by a
fifth distance D5. In one embodiment, bottom lateral boundary 216
is also located along lateral side 16 of upper 120 and may be
spaced apart from sole structure 110 by a sixth distance D6.
[0048] In different embodiments, the distances associated with
first distance D1, second distance D2, third distance D3, fourth
distance D4, fifth distance D5, and/or sixth distance D6 may vary.
For example, in some cases, first distance D1 and fifth distance D5
may vary from 1 cm to 4 cm. In an exemplary embodiment, first
distance D1 and fifth distance D5 may be approximately 2 cm to 3
cm. In some cases, second distance D2 and sixth distance D6 may
vary from 0.1 cm to 1 cm. In an exemplary embodiment, second
distance D2 and sixth distance D6 may be approximately 0.25 cm to
0.5 cm. In some cases, third distance D3 may vary from 1 cm to 4
cm. In one embodiment, third distance D3 may be approximately 2 cm
to 3 cm. In some cases, fourth distance D4 may vary from 2 cm to 6
cm. In one embodiment, fourth distance D4 may be approximately 3 cm
to 5 cm. In other cases, the distances associated with first
distance D1, second distance D2, third distance D3, fourth distance
D4, fifth distance D5, and/or sixth distance D6 may be larger or
smaller to provide monofilament areas 160 of varying shapes and/or
sizes.
[0049] In some embodiments, a forward lateral boundary 212 may
define a forward location of lateral monofilament portion 166 on
upper 120. Similar to forward medial boundary 202, in embodiments
where monofilament areas 160 are substantially continuous, forward
lateral boundary 212 may simply transition into forefoot
monofilament portion 164. In embodiments where each monofilament
area 160 is discontinuous, however, forward lateral boundary 212
may define the transition from the monofilament strand back to the
first yarn type. It should be understood that in such discontinuous
embodiments, forefoot monofilament portion 164 will be defined by
another boundary zone where the yarn again transitions back to the
monofilament strand.
[0050] In some embodiments, medial monofilament portion 162 and
lateral monofilament portion 166 may have similar arrangements on
each of medial side 18 and lateral side 16 so as to be
approximately symmetric. In these embodiments, first distance D1
and fifth distance D5 may be approximately equal. Similarly, in
second distance D2 and sixth distance D6 may also be approximately
equal. In other embodiments, however, each of medial side 18 and
lateral side 16 may have monofilament areas 160 that are different
between each side. Accordingly, in such other embodiments, each of
first distance D1 and fifth distance D5 may be different and/or
second distance D2 and sixth distance D6 may be different to locate
medial monofilament portion 162 and lateral monofilament portion
166 farther or closer to collar 123 and/or sole structure 110. In
still other embodiments, only one of medial side 18 or lateral side
16 may include monofilament areas 160. It should be understood that
other configurations of monofilament areas 160 of varying size,
shape, and/or location may be arranged according to the processes
described herein.
[0051] In some embodiments, monofilament areas 160 on upper 120 may
be transparent, translucent, or opaque depending on the
characteristics or properties of the material used to make the
monofilament strand forming the respective monofilament area 160.
In one embodiment, a single monofilament strand having a diameter
of approximately 0.114 mm may be used for forming monofilament
areas 160, including each of medial monofilament portion 162,
forefoot monofilament portion 164, and lateral monofilament portion
166. A monofilament strand having a larger or smaller diameter may
be used in other embodiments. Additionally, in other embodiments,
different monofilament strands may be used for each separate
monofilament area 160 on upper 120 so as to provide different
properties or characteristics to the respective monofilament area
160.
[0052] By incorporating knitted component 130 with monofilament
areas 160 into upper 120 for article 100, monofilament areas 160
may provide strength, stretch resistance, reduced weight, and/or
assist with airflow through upper 120 to provide ventilation to the
interior of article 100. For example, as shown in FIG. 5, medial
monofilament portion 162 and lateral monofilament portion 166 are
disposed along each of medial side 18 and lateral side 16 of upper
120 in midfoot region 12. With this configuration, medial side 18
and lateral side 16 of upper 120 may have increased strength and
resistance to stretch in these areas. Additionally, the structure
of medial monofilament portion 162 and lateral monofilament portion
166 allows air to easily pass through upper 120 into the interior
of article 100. For example, when a foot of a wearer is disposed
along a base portion 500 of upper 120 within the interior of
article 100, air may circulate into and out of upper 120 to assist
with providing ventilation to article 100.
[0053] Moreover, by forming upper 120 with one or more monofilament
areas 160, the overall weight of upper 120 may be significantly
reduced compared with an upper formed wholly of a natural or
synthetic twisted fiber yarn. For example, in one embodiment, an
upper for an adult men's size 8 may weigh approximately 49 grams
when knitted with a natural or synthetic twisted fiber yarn. In
contrast, upper 120 with monofilament areas 160 may weigh only 29
grams for a similar size. Therefore, the weight savings associated
with using the monofilament strand for monofilament areas 160 in
upper 120 may be lighter by at least 40%. In addition, by varying
the number, shape, and/or size of monofilament areas 160 on upper
120, additional weight savings to increase the reduction in weight
to more than 40% may be achieved.
[0054] Referring now to FIGS. 6 and 7, an exemplary embodiment of
knitted component 130 is shown in a planar or flat configuration.
In this embodiment, knitted component 130 has a generally Y-shaped
configuration that is outlined by an outer perimeter edge 600. In
this embodiment, outer perimeter edge 600 extends around knitted
component 130 from lateral side 16 to medial side 18. The outer
perimeter of knitted component 130 also includes a pair of heel
edges 602 disposed on each of lateral side 16 and medial side 18.
In an exemplary embodiment, knitted component 130 may further
include an inner perimeter edge along collar 123 that will be
associated with and define throat opening 140, described above.
When incorporated into an article of footwear, including article
100, outer perimeter edge 600 and at least a portion of heel edges
602 may lay against an upper surface of sole structure 110 as base
portion 500, shown in FIG. 5. In other embodiments, knitted
component 130 may be joined to a strobel sock or sockliner for
attachment to sole structure 110. In addition, heel edges 602 are
joined to each other and extend vertically in heel region 14 of
article 100 to form seam 129. In some embodiments of an article of
footwear, a material element may cover seam 129 between heel edges
602 to reinforce seam 129 and enhance the aesthetic appeal of the
article.
[0055] Knitted component 130 may include instep area 150 that is
formed of unitary knit construction with the remaining portion of
upper 120, as described above. In some embodiments, instep area 150
includes plurality of lace apertures 153 disposed in knitted
component 130. Lace apertures 153 may extend through knitted
component 130 from exterior surface 121 to interior surface 122 and
are configured to receive a lace, including lace 154. In an
exemplary embodiment, lace apertures 153 may be formed directly
into knitted component 130 by knitting. In other embodiments,
however, lace apertures 153 may include additional reinforcing
elements added to knitted component 130.
[0056] In various embodiments, knitted component 130 may
incorporate various types of yarn that impart different properties
to separate areas of upper 120. For example, one area of knitted
component 130 may be formed from a first type of yarn that imparts
a first set of properties, and another area of first knitted
component 130 may be formed from a second type of yarn that imparts
a second set of properties. In this configuration, properties may
vary throughout upper 120 by selecting specific yarns for different
areas of knitted component 130. In an exemplary embodiment, knitted
component 130 includes monofilament areas 160, as described above.
In one embodiment, monofilament areas 160 may include medial
monofilament portion 162, forefoot monofilament portion 164, and/or
lateral monofilament portion 166. As described above, knitted
component 130 is formed of unitary knit construction such that each
of the areas of knitted component 130, including monofilament areas
160, are knitted as a one-piece element.
[0057] Referring now to FIG. 7, enlarged views of portions of
monofilament areas 160 along various boundary zones are illustrated
to show the unitary knit construction of knitted component 130. As
described above, boundary zones on knitted component 130 define the
portion of knitted component 130 where the yarn used to knit
knitted component 130 transitions from one yarn type to another
yarn type. For example, knitted component 130 may transition from a
first type of yarn 700 to a monofilament strand 701 forming
monofilament areas 160 at one or more boundary zones on upper 120.
In an exemplary embodiment, first type of yarn 700 transitions from
a natural or synthetic twisted fiber yarn to monofilament strand
701 at one or more boundary zones associated with each of
monofilament areas 160.
[0058] As shown in FIG. 7, at forward forefoot boundary 209 in
forefoot region 10 of knitted component 130, knitted component 130
transitions from forefoot monofilament portion 164 formed by
monofilament strand 701 to the remaining portion of knitted
component 130 formed by first type of yarn 700. In this embodiment,
a course of monofilament strand 701 is joined (e.g., by
interlooping) to an adjacent course of first type of yarn 700. That
is, a course formed by knitting monofilament strand 701 is
substantially continuous with a course formed by knitting first
type of yarn 700. With this configuration, monofilament areas 160
may be formed of unitary knit construction with knitted component
130.
[0059] Similarly, adjacent wales of knitted component 130 may also
transition from one type of yarn to a different type of yarn at
boundary zones. As shown in FIG. 7, at top medial boundary 204,
knitted component 130 transitions from a portion formed by first
type of yarn 700 to medial monofilament portion 162 formed by
monofilament strand 701. In this embodiment, wales of first type of
yarn 700 are joined to an adjacent wale of monofilament strand 701.
In one embodiment, monofilament areas 160 may be knit using an
intarsia knitting technique to transition between yarn types along
boundary zones. For example, wales of first type of yarn 700 may
joined to adjacent wales of monofilament strand 701 by using
intarsia knit construction techniques. With this configuration,
monofilament areas 160 may be formed of unitary knit construction
with knitted component 130.
[0060] By forming knitted component 130 with monofilament areas 160
of unitary knit construction, monofilament areas 160 may be
surrounded or circumscribed by the remaining portions of knitted
component 130 so as to place monofilament areas 160 under tension.
That is, first type of yarn 700 may be configured to surround
monofilament areas 160 formed by monofilament strand 701. Because
first type of yarn 700 may have a smaller stretch resistance than
monofilament strand 701, which is non-elastic and resists stretch,
knitted component 130 may stretch in the portions surrounding
monofilament areas 160 so as to apply a slight tensioning force on
monofilament areas 160. With this configuration, the tensioning
force applied on monofilament areas 160 by the surrounding portion
of knitted component 130 may assist with preventing or reducing
kinks or sharp bends in monofilament strand 701 in monofilament
areas 160 that may produce an uncomfortable feeling to a foot of a
wearer.
[0061] In different embodiments, an article of footwear
incorporating a knitted component having different features may be
provided. In some embodiments, an article of footwear may be
configured with a knitted component having different types of
monofilament areas on an upper. Depending on the desired type and
location, monofilament areas may be varied to provide different
properties to an upper. For example, in some embodiments, a
monofilament area with a natural or synthetic twisted fiber yarn
interior layer may be configured to provide comfort to a foot of a
wearer. FIGS. 8 through 17 illustrate another exemplary embodiment
of an article of footwear 800, also referred to simply as article
800, with multiple types of monofilament areas 860. In some
embodiments, article of footwear 800 may include an upper 820 that
is attached to sole structure 110, described above. In an exemplary
embodiment, upper 820 may include multiple types of monofilament
areas 860.
[0062] In some embodiments, upper 820 may include multiple
components that are substantially similar to components of upper
120, described above. For example, upper 820 may include an
exterior surface 821 and an opposite interior surface 822 that are
substantially similar to exterior surface 121 and interior surface
122, described above. Upper 820 may also include a collar 823 that
is substantially similar to collar 123 and that is located in at
least heel region 14 and forms a throat opening 840, which provides
access to the interior of upper 820. Additionally, upper 820 may
also include an instep area 850 that is substantially similar to
instep area 150, described above.
[0063] In some embodiments, instep area 850 may further include a
tongue portion 852 that is disposed between lateral side 16 and
medial side 18 of upper 820 through instep area 850. In an
exemplary embodiment, tongue portion 852 may be substantially
similar to tongue portion 152, described above, and may be
integrally attached to and formed of unitary knit construction with
portions of upper 820 along lateral and medial sides through instep
area 850. As with tongue portion 152, in other embodiments, tongue
portion 852 may be similarly disconnected along lateral and medial
sides through instep area 850 such that tongue portion 852 is
moveable within an opening between a lateral portion and a medial
portion on opposite sides of instep area 850.
[0064] Article 800 may further be used with lace 154, described
above, that extends through a plurality of lace apertures 853 in
upper 820 and permits the wearer to modify dimensions of upper 820
to accommodate proportions of the foot. In some embodiments, lace
154 may extend through lace apertures 853 that are disposed along
either side of instep area 850. In some embodiments, lace apertures
853 may be lace-receiving members formed by a looped portion of an
inlaid tensile element 832, as will be further described below.
More particularly, lace 154 permits the wearer to tighten upper 820
around the foot, and lace 154 permits the wearer to loosen upper
820 to facilitate entry and removal of the foot from the void
(i.e., through throat opening 840). In addition, tongue portion 852
of upper 820 in instep area 850 extends under lace 854 to enhance
the comfort of article 800. Lace 154 is illustrated with article
800 in FIG. 8, while in FIGS. 9 through 11, lace 154 may be omitted
for purposes of clarity. In further configurations, upper 820 may
include additional elements, such as (a) a heel counter in heel
region 14 that enhances stability, (b) a toe guard in forefoot
region 10 that is formed of a wear-resistant material, and (c)
logos, trademarks, and placards with care instructions and material
information.
[0065] In some embodiments, upper 820 may include one or more
portions that include monofilament strands, as described above. In
an exemplary embodiment, portions of upper 820 that include
monofilament strands may be located in one or more monofilament
areas 860. In this embodiment, monofilament areas 860 may include
two or more different types of monofilament areas. For example, in
one embodiment, different monofilament areas may have different
knit structures. In another embodiment, different monofilament
areas may be formed using a combination of monofilament strands and
natural or synthetic twisted fiber yarns.
[0066] As with monofilament areas 160, described above,
monofilament areas 860 may be located on various portions of upper
820. In an exemplary embodiment, one or more monofilament areas 860
may be located on portions of article 800 where upper 820 will lay
generally flat against a foot of a wearer disposed within upper
820. In this embodiment, monofilament areas 860 include a medial
monofilament portion 862 disposed on medial side 18 of upper 820
and a lateral monofilament portion 866 disposed on lateral side 16
of upper 820. Medial monofilament portion 862 and lateral
monofilament portion 866 may be generally located in midfoot region
12. In some embodiments, monofilament areas 860 may further include
a forefoot monofilament portion 864 and a heel monofilament portion
868. Forefoot monofilament portion 864 is disposed forward of
instep area 850 in forefoot region 10 of upper 820 and heel
monofilament portion 868 is disposed in heel region 14. In an
exemplary embodiment, heel monofilament portion 868 may extend
substantially continuously around heel region 14 of upper 820
between lateral side 16 and medial side 18.
[0067] In some embodiments, monofilament areas 860 may be
substantially continuous between each monofilament area 860 across
upper 820. For example, in one embodiment, medial monofilament
portion 862 may be continuous with forefoot monofilament portion
864, and lateral monofilament portion 866 may also be continuous
with forefoot monofilament portion 864. Similarly, lateral
monofilament portion 866 may be continuous with heel monofilament
portion 868 and medial monofilament portion 862 may also be
continuous with at least a portion of heel monofilament portion
868. With this configuration, monofilament areas 860 may form a
substantially continuous zone extending across upper 820 from
lateral side 16 across forefoot region 10 to medial side 18 in the
front portion of article 100 and may also form a substantially
continuous zone extending across upper 820 from lateral side across
heel region 14 to medial side in the rear portion of article
100.
[0068] In other embodiments, each monofilament area 860, including
medial monofilament portion 862, forefoot monofilament portion 864,
lateral monofilament portion 866, and/or heel monofilament portion
868 may be discontinuous with other monofilament areas 860 disposed
on upper 820. In embodiments where monofilament areas 860 are
discontinuous, each monofilament area 860 may be entirely
surrounded or circumscribed by the remaining portions of upper
820.
[0069] Knitted component 830 shown in FIGS. 8 through 16 may
include additional structures or elements as compared with knitted
component 130, described above. In an exemplary embodiment, the
primary elements of knitted component 830 are a knit element 831
and an inlaid tensile element 832. Knit element 831 may be formed
from at least one yarn that is manipulated (e.g., with a knitting
machine) to form a plurality of intermeshed loops that define a
variety of courses and wales. That is, knit element 831 has the
structure of a knit textile. Inlaid tensile element 832 extends
through knit element 831 and passes between the various loops
within knit element 831. Although inlaid tensile element 832
generally extends along courses within knit element 831, inlaid
tensile element 832 may also extend along wales within knit element
831. Inlaid tensile element 832 may impart stretch-resistance and,
when incorporated into article 800, operates in connection with
lace 154 to enhance the fit of article 800. In an exemplary
embodiment, inlaid tensile element 832 may pass through one or more
portions of knit element 831, including portions of one or more
monofilament areas 860.
[0070] In some embodiments, inlaid tensile element 832 may extend
upwards through knit element 831 in a vertical direction from sole
structure 110 towards instep area 850. In an exemplary embodiment,
portions of inlaid tensile element 832 may form a loop that serves
as lace aperture 853 and then may extend downwards back in the
vertical direction from instep area 850 towards sole structure 110.
In addition, when article 800 is provided with lace 154, inlaid
tensile element 832 may be tensioned when lace 154 is tightened,
and inlaid tensile element 832 resists stretch in upper 820.
Moreover, inlaid tensile element 832 assists with securing upper
820 around the foot and operates in connection with lace 154 to
enhance the fit of article 800. In some embodiments, inlaid tensile
element 832 may exit knit element 831 at one or more portions,
including along medial and lateral sides of instep area 850 so as
to be exposed on exterior surface 821 of upper 820.
[0071] As described above with reference to knitted component 130,
knitted component 830 may similarly include yarns formed of
different materials, including any of the suitable materials for
forming a yarn described above. In some embodiments, knitted
component 830 may further include non-fusible yarns and fusible
yarns, as described above. When a fusible yarn is heated and fused
to non-fusible yarns, this process may have the effect of
stiffening or rigidifying the structure of knitted component 830.
Moreover, by joining (a) one portion of a non-fusible yarn to
another portion of a non-fusible yarn, and/or (b) non-fusible yarn
and inlaid tensile element 832 to each other has the effect of
securing or locking the relative positions of non-fusible yarns and
inlaid tensile element 832, thereby imparting stretch-resistance
and stiffness. That is, portions of non-fusible yarns may not slide
relative to each other when fused with fusible yarns, thereby
preventing warping or permanent stretching of knit element 831 due
to relative movement of the knit structure. Additionally, inlaid
tensile element 832 may not slide relative to knit element 831,
thereby preventing portions of inlaid tensile element 832 from
pulling outward from knit element 831. Accordingly, areas of
knitted component 830 may be configured with both fusible and
non-fusible yarns within knit element 831.
[0072] In some embodiments, knitted component 830 may include knit
element 831 with multiple knit layers. Knit layers associated with
knitted component 830 may be partially co-extensive and overlapping
portions of knit element 831 that include at least one common yarn
or monofilament strand that passes back and forth between the knit
layers so as to join and interlock the layers to each other. With
this configuration, the knit layers together form a single knit
textile formed of unitary knit construction.
[0073] In an exemplary embodiment, knit element 831 may include at
least two knit layers interlocked with each other at one or more
portions to form knitted component 830. In one embodiment, a first
knit layer may form a majority of a first side of knitted component
830 and a second knit layer may form a majority of a second side of
knitted component 830. In some embodiments, the first knit layer
may be associated with a majority of exterior surface 821 and the
second knit layer may be associated with a majority of interior
surface 822. In an exemplary embodiment, inlaid tensile element 832
may extend through portions of the first knit layer, the second
knit layer, and/or through portions of knit element 831 between the
first knit layer and the second knit layer.
[0074] In some embodiments, knitted component 830 may include one
or more boundary zones, as described above with reference to
knitted component 130. Boundary zones define the portion of knitted
component 830 where the yarn used to knit a portion of knitted
component 830 transitions from one yarn type to another yarn type.
For example, knitted component 830 may transition from a first type
of yarn to a monofilament strand forming monofilament areas 860 at
one or more boundary zones on upper 820. Additionally, in
embodiments where knitted component 830 may further have the
configuration of multiple knit layers, boundary zones may
transition yarn types at only one of the first knit layer and the
second knit layer, or may transition yarn types at both the first
knit layer and the second knit layer. That is, the boundary zone
may apply at the level of individual knit layers of knit element
831.
[0075] In an exemplary embodiment, the first type of yarn
transitions from a natural or synthetic twisted fiber yarn to the
monofilament strand at one or more boundary zones associated with
each of monofilament areas 860. In this embodiment, medial
monofilament portion 862 includes a rear medial boundary 900
disposed along a portion of upper 820 on medial side 18 towards
heel region 14 where at least one monofilament strand forming one
knit layer of medial monofilament portion 862 transitions to the
first type of yarn in at least one knit layer of knit element 831
used to form the remaining portions of knitted component 830.
Medial monofilament portion 862 may further include a top medial
boundary 904 and a bottom medial boundary 906. In one embodiment,
top medial boundary 904 is located along medial side 18 of upper
820 and may be spaced apart from collar 823 and throat opening 840
by first distance D1 and bottom medial boundary 906 is also located
along medial side 18 of upper 820 and may be spaced apart from sole
structure 110 by second distance D2, described above.
[0076] In some embodiments, forward medial boundary 902 may define
a forward location of medial monofilament portion 862 on upper 820.
In embodiments where monofilament areas 860 are substantially
continuous, forward medial boundary 902 may simply transition into
forefoot monofilament portion 864. In embodiments where each
monofilament area 860 is discontinuous, however, forward medial
boundary 902 may define the transition from the monofilament strand
back to the first yarn type for both knit layers forming knit
element 831. It should be understood that in such discontinuous
embodiments, forefoot monofilament portion 864 will be defined by
another boundary zone where the yarn again transitions back to the
monofilament strand for forming at least one knit layer.
[0077] Continuing along upper 820, forefoot monofilament portion
864 may include a rear forefoot boundary 908 and a forward forefoot
boundary 909. In one embodiment, rear forefoot boundary 908 may be
located forward of instep area 850 and spaced apart by third
distance D3 and forward forefoot boundary 909 may be located near a
toe end of article 800 and be spaced apart by fourth distance D4,
described above. In this embodiment, lateral monofilament portion
866 includes a rear lateral boundary 910 disposed on lateral side
16 of upper 820 towards heel region 14 at least one monofilament
strand forming one knit layer of lateral monofilament portion 866
transitions to the first type of yarn in at least one knit layer of
knit element 831 used to form the remaining portions of knitted
component 830. Lateral monofilament portion 866 may further include
a top lateral boundary 914 and a bottom lateral boundary 916. In
one embodiment, top lateral boundary 914 is located along lateral
side 16 of upper 820 and may be spaced apart from collar 823 and
throat opening 840 by fifth distance D5 and bottom lateral boundary
916 may also be located along lateral side 16 of upper 820 and may
be spaced apart from sole structure 110 by sixth distance D6,
described above.
[0078] In some embodiments, a forward lateral boundary 912 may
define a forward location of lateral monofilament portion 866 on
upper 820. Similar to forward medial boundary 902, in embodiments
where monofilament areas 860 are substantially continuous, forward
lateral boundary 912 may simply transition into forefoot
monofilament portion 864. In embodiments where each monofilament
area 860 is discontinuous, however, forward lateral boundary 912
may define the transition from the monofilament strand back to the
first yarn type for both knit layers forming knit element 831. It
should be understood that in such discontinuous embodiments,
forefoot monofilament portion 864 will be defined by another
boundary zone where the yarn again transitions back to the
monofilament strand for forming at least one knit layer.
[0079] In some embodiments, medial monofilament portion 862 and
lateral monofilament portion 866 may have similar arrangements on
each of medial side 18 and lateral side 16 so as to be
approximately symmetric, as described in reference to knitted
component 130 above. In these embodiments, first distance D1 and
fifth distance D5 may be approximately equal. Similarly, in second
distance D2 and sixth distance D6 may also be approximately equal.
In other embodiments, however, each of medial side 18 and lateral
side 16 may have monofilament areas 860 that are different between
each side. Accordingly, in such other embodiments, each of first
distance D1 and fifth distance D5 may be different and/or second
distance D2 and sixth distance D6 may be different to locate medial
monofilament portion 862 and lateral monofilament portion 866
farther or closer to collar 823 and/or sole structure 110. In still
other embodiments, only one of medial side 18 or lateral side 16
may include monofilament areas 860. It should be understood that
other configurations of monofilament areas 860 of varying size,
shape, and/or location may be arranged according to the processes
described herein.
[0080] Additionally, in an exemplary embodiment, knitted component
830 may further include boundary zones associated with heel
monofilament portion 868. In this embodiment, heel monofilament
portion 868 may include a top heel boundary 920 and a bottom heel
boundary 922. Top heel boundary 920 may be spaced apart from collar
823 and throat opening 840 in heel region 14 of upper 820 and
bottom heel boundary 922 may be spaced apart from sole structure
110. In some embodiments, top heel boundary 920 may be spaced apart
from collar 823 by a substantially similar distance as top medial
boundary 904 and/or top lateral boundary 914 and bottom heel
boundary 922 may be spaced apart from sole structure 110 by a
substantially similar distance as bottom medial boundary 906 and/or
bottom lateral boundary 916. In other embodiments, the spacing of
top heel boundary 920 and/or bottom heel boundary 922 may vary.
[0081] As described above, in some embodiments, knitted component
830 may include multiple types of monofilament areas 860 having
different structures. For example, in an exemplary embodiment,
monofilament areas 860 may include a first type of monofilament
area formed from two knit layers knit with monofilament strands and
a second type of monofilament area formed from two knit layers knit
with a monofilament strand and natural or synthetic twisted fiber
yarns. In an exemplary embodiment, monofilament areas 860 of the
first type, i.e., two knit layers of monofilament strands, may be
disposed along each of lateral side 16 and medial side 18. In this
embodiment, medial monofilament portion 862 and/or lateral
monofilament portion 866 may be monofilament areas of the first
type. That is, medial monofilament portion 862 and/or lateral
monofilament portion 866 may include a first knit layer formed of a
first monofilament strand and a second knit layer formed of a
second monofilament strand.
[0082] In an exemplary embodiment, portions of knitted component
830 that are configured to rest against the toes and heel of a foot
of a wearer when disposed within upper 820 may be configured with
monofilament areas 860 of the second type, i.e., two knit layers
having one knit layer formed of a monofilament strand and one knit
layer formed of natural or synthetic twisted fiber yarns. In this
embodiment, forefoot monofilament portion 864 and/or heel
monofilament portion 868 may be monofilament areas of the second
type. That is, forefoot monofilament portion 864 and/or heel
monofilament portion 868 may include a first knit layer formed of a
monofilament strand and a second knit layer formed of natural or
synthetic twisted fiber yarns.
[0083] In an exemplary embodiment, the first knit layer formed of
the monofilament strand in forefoot monofilament portion 864 and/or
heel monofilament portion 868 may be associated with exterior
surface 821 of upper 820 and the second knit layer formed of
natural or synthetic twisted fiber yarns in forefoot monofilament
portion 864 and/or heel monofilament portion 868 may be associated
with interior surface 822 of upper 820. For example, in one
embodiment, the second knit layer associated with interior surface
822 may be made from a polyester yarn in forefoot monofilament
portion 864 and/or heel monofilament portion 868. With this
configuration, the second knit layer of polyester yarn may provide
a smooth and soft interior surface 822 for a foot of a wearer
disposed within upper 820. Additionally, the second knit layer may
provide protection to the foot from sharp edges or bent portions of
the first knit layer formed of the monofilament strand in forefoot
monofilament portion 864 and/or heel monofilament portion 868.
[0084] In another embodiment, the second knit layer associated with
interior surface 822 may be made from a combination of polyester
yarn and fusible yarn in forefoot monofilament portion 864 and/or
heel monofilament portion 868. With this configuration, the fusible
yarn portion associated with the second knit layer may be
configured to assist with setting forefoot monofilament portion 864
and/or heel monofilament portion 868 in place within knitted
component 830 when heated, as described above.
[0085] By incorporating knitted component 830 with different types
of monofilament areas 860 into upper 820 for article 800,
monofilament areas 860 may provide strength, stretch resistance,
reduced weight, and/or assist with airflow through upper 820 to
provide ventilation to the interior of article 800, as described
above. Additionally, by varying the two knit layer configuration of
monofilament areas 860, upper 820 may provide these features while
also remaining comfortable to a foot of a wearer. Referring now to
FIGS. 12A through 12C, cross-sectional views of article 800 having
upper 820 incorporating knitted component 830 with different types
of monofilament areas 860 are illustrated.
[0086] FIG. 12A shows a cross-section view of forefoot region 10
taken across upper 820. In this embodiment, forefoot monofilament
portion 864 is disposed along a top portion of upper 820. In an
exemplary embodiment, forefoot monofilament portion 864 may be a
monofilament area 860 of the second type, described above. In this
embodiment, forefoot monofilament portion 864 includes two knit
layers, including a first knit layer formed by a monofilament
strand that is associated with exterior surface 821 of knitted
component 830 and a second knit layer formed by a natural or
synthetic twisted fiber yarn that is associated with interior
surface 822. In some embodiments, the second knit layer of forefoot
monofilament portion 864 may be made from the same yarn as the
remaining portion of knit element 831 forming knitted component
830.
[0087] With this configuration, when a foot of a wearer is disposed
along a base portion 1200 of upper 820 within the interior of
article 800, air may circulate into and out of upper 820 to assist
with providing ventilation to article 800 and forefoot monofilament
portion 864 may include a softer knit layer along interior surface
822 to provide a comfortable feel to the foot.
[0088] FIG. 12B shows a cross-section view of midfoot region 12
taken across upper 820. In this embodiment, medial monofilament
portion 862 and lateral monofilament portion 866 are disposed along
each of medial side 18 and lateral side 16 of upper 820 in midfoot
region 12. In an exemplary embodiment, medial monofilament portion
862 and/or lateral monofilament portion 866 may be a monofilament
area 860 of the first type, described above. In this embodiment,
medial monofilament portion 862 and/or lateral monofilament portion
866 includes two knit layers, including a first knit layer formed
by a first monofilament strand that is associated with exterior
surface 821 of knitted component 830 and a second knit layer formed
by a second monofilament strand that is associated with interior
surface 822. With this configuration, medial side 18 and lateral
side 16 of upper 820 may have increased strength and resistance to
stretch in these areas.
[0089] FIG. 12C shows a cross-section view of heel region 14 taken
across upper 820. In this embodiment, heel monofilament portion 868
is disposed along lateral side 16 and medial side 18 of upper 820.
In an exemplary embodiment, heel monofilament portion 868 may be a
monofilament area 860 of the second type, described above. In this
embodiment, heel monofilament portion 868 may have a substantially
similar structure as forefoot monofilament portion 864, including a
first knit layer formed by a monofilament strand that is associated
with exterior surface 821 of knitted component 830 and a second
knit layer formed by a natural or synthetic twisted fiber yarn that
is associated with interior surface 822. In some embodiments, the
second knit layer of heel monofilament portion 868 may be made from
the same yarn as the remaining portion of knit element 831 forming
knitted component 830.
[0090] Additionally, in this embodiment, portions of inlaid tensile
element 832 are shown extending through portions of knitted
component 830, including knit element 831, as well as through
monofilament areas 860, for example, heel monofilament portion
868.
[0091] Referring now to FIGS. 13 and 14, an exemplary embodiment of
knitted component 830 is shown in a planar or flat configuration.
As described above, knitted component 830 includes knit element 831
and inlaid tensile element 832. In this embodiment, knitted
component 830 may have an oblong offset configuration that is
outlined by a top forefoot perimeter edge 1300, a top side
perimeter edge 1302, a pair of heel edges, including a medial heel
edge 1304 and a lateral heel edge 1314, a bottom side perimeter
edge 1312, and a bottom forefoot perimeter edge 1310. In addition,
knit element 831 has a first side forming a portion of exterior
surface 821 of upper 820 and an opposite second side that may form
a portion of interior surface 822 of upper 820, thereby defining at
least a portion of the void within upper 820. In many
configurations, inlaid tensile element 832 may extend through
portions of knit element 831, including portions of monofilament
areas 860, between the first side and the second side of knit
element 831.
[0092] As shown in FIGS. 13 and 14, inlaid tensile element 832
repeatedly extends from top side perimeter edge 1302 toward instep
area 850, where a portion of inlaid tensile element 832 forms a
loop to serve as lace aperture 853, and back to top side perimeter
edge 1302. Inlaid tensile element 832 may follow a similar path on
the opposite side of knitted component 830. In this embodiment,
inlaid tensile element 832 repeatedly extends from bottom side
perimeter edge 1312 toward instep area 850, where a portion of
inlaid tensile element 832 forms a loop to serve as lace aperture
853, and back to bottom side perimeter edge 1312. In some
embodiments, portions of inlaid tensile element 832 may angle
rearwards and extend to medial heel edge 1304 and/or lateral heel
edge 1314. Additionally, inlaid tensile element 832 may pass
through one or more monofilament areas 860 of knitted component
830, including portions of medial monofilament portion 862 and/or
lateral monofilament portion 866, as inlaid tensile element 832
extends towards or away from top side perimeter edge 1302 and/or
bottom side perimeter edge 1312. Similarly, inlaid tensile element
832 may also pass through portions of forefoot monofilament portion
864 and/or heel monofilament portion 868 as inlaid tensile element
832 extends towards or away from medial heel edge 1304 and/or
lateral heel edge 1314.
[0093] In comparison with knit element 831, inlaid tensile element
832 may exhibit greater stretch-resistance. That is, inlaid tensile
element 832 may stretch less than knit element 831. Given that
numerous sections of inlaid tensile element 832 extend through knit
element 831, inlaid tensile element 832 may impart
stretch-resistance to portions of upper 820 between instep area 850
and a lower area adjacent to sole structure 110. Moreover, placing
tension upon lace 154 may impart tension to inlaid tensile element
832, thereby inducing the portions of upper 820 between instep area
850 and the lower area to lay against the foot. Additionally, given
that numerous sections of inlaid tensile element 832 extend toward
medial heel edge 1304 and/or lateral heel edge 1314, inlaid tensile
element 832 may impart stretch-resistance to portions of upper 820
in heel region 14. Moreover, placing tension upon lace 154 may
induce the portions of upper 820 in heel region 14 to lay against
the foot. For example, inlaid tensile element 832 may assist with
locating monofilament areas 860 along lateral side 16 and medial
side 18 of upper 820 to lay flat against a foot of a wearer. As
such, inlaid tensile element 832 operates in connection with lace
154 to enhance the fit of article 800.
[0094] Knit element 831 may incorporate any of the various types of
yarn discussed above for knitted component 130. In some
embodiments, the configuration of inlaid tensile element 832 may
vary significantly. In addition to yarn, inlaid tensile element 832
may have the configurations of a filament (e.g., a monofilament),
thread, rope, webbing, cable, or chain, for example. In comparison
with the yarns forming knit element 831, the thickness of inlaid
tensile element 832 may be greater. In some configurations, inlaid
tensile element 832 may have a significantly greater thickness than
the yarns of knit element 831. Although the cross-sectional shape
of inlaid tensile element 832 may be round, triangular, square,
rectangular, elliptical, or irregular shapes may also be utilized.
Moreover, the materials forming inlaid tensile element 832 may
include any of the materials for the yarn within knit element 831,
such as cotton, elastane, polyester, rayon, wool, and nylon. As
noted above, inlaid tensile element 832 may exhibit greater
stretch-resistance than knit element 831. As such, suitable
materials for inlaid tensile element 832 may include a variety of
engineering filaments that are utilized for high tensile strength
applications, including glass, aramids (e.g., para-aramid and
meta-aramid), ultra-high molecular weight polyethylene, and liquid
crystal polymer. As another example, a braided polyester thread may
also be utilized as inlaid tensile element 832.
[0095] U.S. Patent Application Publication 2012/0233882 to Huffa,
et al., the disclosure of which is incorporated herein in its
entirety, provides a discussion of the manner in which a knitted
component (e.g., knitted component 130, 830) may be formed,
including the process of inlaying or otherwise locating inlaid
tensile element within a knit element.
[0096] In an exemplary embodiment, one or more of the perimeter
edges of knitted component 830 may be joined to form upper 820. In
this embodiment, knitted component 830 may be folded at a folding
point 1306 between top forefoot perimeter edge 1300 and bottom
forefoot perimeter edge 1310 to place top forefoot perimeter edge
1300 and bottom forefoot perimeter edge 1310 in contact with each
other. Similarly, top side perimeter edge 1302 may be placed in
contact with bottom side perimeter edge 1312 and pair of heel
edges, medial heel edge 1304 and lateral heel edge 1314, may be
placed in contact with each other. In an exemplary embodiment,
medial heel edge 1304 and lateral heel edge 1314 may be joined
along seam 829 disposed along medial side 18 of upper 820 in heel
region 14. In addition, seam 829 may further extend along and
connect each of top forefoot perimeter edge 1300 and bottom
forefoot perimeter edge 1310 and top side perimeter edge 1302 and
bottom side perimeter edge 1312 to form upper 820.
[0097] Referring now to FIG. 14, enlarged views of portions of
knitted component, including knit element 831 and different types
of monofilament areas 860, are illustrated to show the unitary knit
construction of knitted component 830. As described above,
monofilament areas 860 of knitted component 830 may include
multiple types of monofilament areas 860 having different
structures. For example, in an exemplary embodiment, monofilament
areas 860 may include a first type of monofilament area formed from
two knit layers knit with monofilament strands and a second type of
monofilament area formed from two knit layers knit with a
monofilament strand and natural or synthetic twisted fiber yarns.
In this embodiment, medial monofilament portion 862 and/or lateral
monofilament portion 866 may be monofilament areas of the first
type. That is, medial monofilament portion 862 and/or lateral
monofilament portion 866 may include a first knit layer formed of a
first monofilament strand 1400 and a second knit layer formed of a
second monofilament strand 1401. Thus, as may be seen in FIG. 15B,
monofilament areas 860 of this first type include knit layers
formed of monofilament strands on both exterior surface 821 and
interior surface 822 of upper 820.
[0098] In this embodiment, forefoot monofilament portion 864 and/or
heel monofilament portion 868 may be monofilament areas of the
second type. That is, forefoot monofilament portion 864 and/or heel
monofilament portion 868 may include a first knit layer formed of
monofilament strand 1400 and a second knit layer formed of a
natural or synthetic twisted fiber yarn 1403. In an exemplary
embodiment, as may be seen in FIG. 15A, the first knit layer formed
of monofilament strand 1400 may be associated with exterior surface
821 of knitted component 830 and the second knit layer formed of
natural or synthetic twisted fiber yarn 1403 may be associated with
interior surface 822.
[0099] Additionally, in embodiments where inlaid tensile element
832 extends through portions of knitted component 830 that include
monofilament areas 860, inlaid tensile element 832 may be located
between exterior surface 821 and interior surface 822 of upper 820.
As shown in FIG. 15C, inlaid tensile element 832 extends through
heel monofilament portion 868 between the first knit layer formed
of monofilament strand associated with exterior surface 821 and the
second knit layer formed of natural or synthetic twisted fiber yarn
associated with interior surface 822. In some configurations,
portions of inlaid tensile element 832 may be visible through one
or both of surfaces. In other embodiment, portions of inlaid
tensile element 832 may lay against one of exterior surface 821
and/or interior surface 822, or knit element 831 may form
indentations or apertures through which inlaid tensile element 832
passes.
[0100] In the remaining portions of knitted component 830 not
including monofilament areas 860, knit element 831 may have a
similar two knit layer structure. For example, as shown in FIG. 14,
a portion of knit element 831 may include a first knit layer formed
of a first natural or synthetic twisted fiber yarn 1402 and a
second knit layer formed of a second natural or synthetic twisted
fiber yarn 1403. In an exemplary embodiment, the first knit layer
formed of first natural or synthetic twisted fiber yarn 1402 may be
associated with exterior surface 821 of knitted component 830 and
the second knit layer formed of second natural or synthetic twisted
fiber yarn 1403 may be associated with interior surface 822. In an
exemplary embodiment, the same second natural or synthetic twisted
fiber yarn 1403 may be used to knit monofilament areas 860 of the
second type and the remaining portions of knitted component 830
that also include second natural or synthetic twisted fiber yarn
1403.
[0101] By forming knitted component 830 with monofilament areas 860
of unitary knit construction, monofilament areas 860 may be
surrounded or circumscribed by the remaining portions of knitted
component 830 so as to place monofilament areas 860 under tension,
as described above with reference to knitted component 130. With
this configuration, the tensioning force applied on monofilament
areas 860 by the surrounding portion of knitted component 830 may
assist with preventing or reducing kinks or sharp bends in
monofilament strands in monofilament areas 860 that may produce an
uncomfortable feeling to a foot of a wearer.
[0102] Referring now to FIG. 16A, a portion of knitted component
830 that includes medial monofilament portion 862 is illustrated.
In this embodiment, inlaid tensile element 832 extends through knit
element 831 and medial monofilament portion 862. In an exemplary
embodiment, the portion of knitted component 830 at bottom medial
boundary 906 may transition from monofilament strand 1400 forming
medial monofilament portion 862 to natural or synthetic twisted
fiber yarn 1402 forming the remaining portion of knit element 831,
as described above. As shown in the enlarged view of FIG. 16A, a
first course 1600 of knitted component 830 and a fourth course 1606
of knitted component 830 transition from monofilament strand 1400
forming medial monofilament portion 862 to natural or synthetic
twisted fiber yarn 1402 at bottom medial boundary 906. In one
embodiment, a second course 1602 and a third course 1604 of knitted
component 830 also include inlaid tensile element 832. In this
embodiment, second course 1602 and third course 1604 also
transition from monofilament strand 1400 to natural or synthetic
twisted fiber yarn 1402, or another different type of yarn, at
bottom medial boundary 906, as with first course 1600 and fourth
course 1606.
[0103] In an exemplary embodiment, second course 1602 and third
course 1604 may correspond with inlaid tensile element 832 as
inlaid tensile element 832 extends through knit element 831. With
this configuration, inlaid tensile element 832 may extend through
monofilament strand 1400 in medial monofilament portion 862, and
continue extending through natural or synthetic twisted fiber yarn
1402 in the remaining portion of knit element 831. Accordingly,
natural or synthetic twisted fiber yarn 1402 may substantially
surround portions of inlaid tensile element 832 as it extends
through the remaining portions of knit element 831 outside of
medial monofilament portion 862. With this configuration, inlaid
tensile element 832 may be hidden from view on exterior surface 821
of knitted component 830 outside of monofilament areas 860.
[0104] In other embodiments, one or more courses of knitted
component 830 that include a monofilament strand may extend along
through the remaining portions of knit element 831 beyond
monofilament areas 860. Referring now to FIG. 16B, an optional
configuration for a portion of knitted component 830 that includes
medial monofilament portion 862 is illustrated. As with FIG. 16A,
inlaid tensile element 832 extends through knit element 831 and
medial monofilament portion 862. In this embodiment, however, one
or more courses formed by a monofilament strand, for example
monofilament strand 1400, described above, may further extend
through knit element 831 outside of medial monofilament portion 862
together with inlaid tensile element 832.
[0105] In an exemplary embodiment, the portion of knitted component
830 at bottom medial boundary 906 may transition from monofilament
strand 1400 forming medial monofilament portion 862 to natural or
synthetic twisted fiber yarn 1402 forming the remaining portion of
knit element 831, as described above. As shown in the enlarged view
of FIG. 16B, a first course 1600 of knitted component 830 and a
fourth course 1606 of knitted component 830 transition from
monofilament strand 1400 forming medial monofilament portion 862 to
natural or synthetic twisted fiber yarn 1402 at bottom medial
boundary 906. In one embodiment, a second course 1602 and a third
course 1604 of knitted component 830 do not transition from
monofilament strand 1400 to natural or synthetic twisted fiber yarn
1402, or another different type of yarn, at bottom medial boundary
906. Instead, second course 1602 and third course 1604 continue in
a substantially continuous manner to be formed with the same
monofilament strand 1400 forming medial monofilament portion
862.
[0106] In this embodiment, second course 1602 and third course 1604
knit with monofilament strand 1400 may correspond with inlaid
tensile element 832 as inlaid tensile element 832 extends through
knit element 831. With this configuration, inlaid tensile element
832 may extend through monofilament strand 1400 in medial
monofilament portion 862, as well as through the remaining portion
of knit element 831. Accordingly, monofilament strand 1400 may
substantially surround portions of inlaid tensile element 832 as it
extends through the remaining portions of knit element 831 outside
of medial monofilament portion 862. In other embodiments, one or
more courses of monofilament strands may extend outside of each
monofilament areas 860, including medial monofilament portion 862,
forefoot monofilament portion 864, lateral monofilament portion
866, and/or heel monofilament portion 868, to follow and correspond
with the path of inlaid tensile element 832 throughout knitted
component 830. By enclosing or surrounding inlaid tensile element
832 with monofilament strand 1400, additional strength and support
may be provided to inlaid tensile element 832.
[0107] In some embodiments, monofilament areas 860 of the second
type, i.e., two knit layers having one knit layer formed of a
monofilament strand and one knit layer formed of natural or
synthetic twisted fiber yarns, may be knit with a knit structure
that forms plurality of indentations during the knitting process in
the knit layer formed of natural or synthetic twisted fiber yarns.
Such a configuration may further provide ventilation to the
interior of upper 820 while still providing a comfortable feel to a
foot of a wearer along interior surface 822.
[0108] A suitable knit structure for forming monofilament areas 860
of the second type includes a 1.times.1 inverted mock mesh knit
structure or 2.times.2 inverted mock mesh structure. In contrast
with a mesh knit structure, which may be used to form apertures
that extend fully through a knit element, including both a first
knit layer and a second knit layer, an inverted mock mesh knit
structure forms indentations in second knit layer, i.e., the layer
associated with interior surface 822 of upper 820. An exemplary
embodiment of a looping diagram 1700 for knitting an inverted
2.times.2 mock mesh structure is illustrated. In this embodiment,
looping diagram 1700 illustrates the sequence of stitches and
movements performed by a knitting machine, for example, a
flat-knitting machine, to form an inverted 2.times.2 mock mesh
structure making up a portion of monofilament areas 860 of the
second type. As shown in FIG. 17, the spaced apart dots represent
the needles of a knitting machine and the illustrated steps
represent the direction of movement of a yarn or strand between the
needles of each of a front bed and a back bed of a knitting
machine.
[0109] As shown in FIG. 17, monofilament strand 1400 may be used to
knit the first knit layer of monofilament area 860 that is
associated with exterior surface 821 of upper 820, while natural or
synthetic twisted fiber yarn 1403 may be used to knit the second
knit layer of monofilament area 860 that is associated with
interior surface 822 of upper 820. In contrast to the first knit
layer, the second knit layer includes a number of tuck stitches
performed with or natural or synthetic twisted fiber yarn 1403. In
this embodiment, the width or gap in second knit layer is
associated with 2 needles to form the inverted 2.times.2 mock mesh
structure. For example, such an inverted 2.times.2 mock mesh
structure may be used to form one or more of forefoot monofilament
portion 864 and/or heel monofilament portion 868, described above.
In other embodiments, however, a larger or smaller knit structure
may be provided by making the gap associated with a larger or
smaller number of needles. For example, an inverted 3.times.3 mock
mesh structure may be formed by increasing the gap to 3 needles and
an inverted 1.times.1 mock mesh structure may be formed by
decreasing the gap to a single needle.
[0110] FIG. 17 illustrates one exemplary embodiment of a knit
structure that may be used with knitted component 830 to form a
portion of monofilament areas 860. Mesh knit structures, mock mesh
knit structures, and other suitable knit structures with
accompanying loop diagrams for knitting such knit structures for
use in the present embodiments are described in U.S. Patent
Application Publication 2012/0233882 to Huffa et al., which was
referenced above and incorporated herein.
[0111] While various embodiments of the invention have been
described, the description is intended to be exemplary, rather than
limiting and it will be apparent to those of ordinary skill in the
art that many more embodiments and implementations are possible
that are within the scope of the invention. Accordingly, the
invention is not to be restricted except in light of the attached
claims and their equivalents. Also, various modifications and
changes may be made within the scope of the attached claims.
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