U.S. patent application number 17/527881 was filed with the patent office on 2022-05-19 for double knit upper comprising functional tucked-in yarns.
The applicant listed for this patent is adidas AG. Invention is credited to Florin FILIPESCU, Florian GODENBERG, Matthias LINZ, Florian POEGL.
Application Number | 20220151341 17/527881 |
Document ID | / |
Family ID | |
Filed Date | 2022-05-19 |
United States Patent
Application |
20220151341 |
Kind Code |
A1 |
FILIPESCU; Florin ; et
al. |
May 19, 2022 |
DOUBLE KNIT UPPER COMPRISING FUNCTIONAL TUCKED-IN YARNS
Abstract
A double layer knitted element includes a first layer comprising
a first yarn, a second layer comprising a second yarn, and a third
yarn arranged at least in part between the first and second layer.
The third yarn is attached to at least one of the first layer and
the second layer by a plurality of tuck stitches, wherein there is
at least one miss stitch between two successive tuck stitches of
the third yarn.
Inventors: |
FILIPESCU; Florin;
(Herzogenaurach, DE) ; POEGL; Florian; (Fuerth,
DE) ; LINZ; Matthias; (Scheinfeld, DE) ;
GODENBERG; Florian; (Neustadt an der Aisch, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
adidas AG |
Herzogenaurach |
|
DE |
|
|
Appl. No.: |
17/527881 |
Filed: |
November 16, 2021 |
International
Class: |
A43B 23/02 20060101
A43B023/02; A43B 1/04 20060101 A43B001/04; A43B 23/04 20060101
A43B023/04; D04B 21/20 20060101 D04B021/20 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 17, 2020 |
DE |
10 2020 214 449.4 |
Claims
1. A double layer knitted element comprising: a first layer
comprising a first yarn; a second layer comprising a second yarn;
and a third yarn arranged at least in part between the first and
second layer, wherein the third yarn is attached to at least one of
the first layer and the second layer by a plurality of tuck
stitches, and wherein there is at least one miss stitch between two
successive tuck stitches of the third yarn.
2. The double layer knitted element of claim 1, wherein the third
yarn comprises a functional yarn.
3. The double layer knitted element of claim 2, wherein the
functional yarn is at least one of a melting yarn, thermoplastic
polyurethane yarn, water repellent yarn, volume yarn, puff yarn,
natural fiber yarn, cellulose yarn, hybrid yarn, anti-microbial
yarn, or a conductive yarn.
4. The double layer knitted element of claim 2, wherein the
functional yarn is a yarn with at least one of the following
properties: heat resistance, UV protection, moisture absorbance,
water resistance, heat retention, chemical resistance, flame
resistance, or moisture wicking capability.
5. The double layer knitted element of claim 2, wherein the
functional yarn is a yarn with at least one of the following
properties: compression, shrinkability, cushioning, conduction,
insulation, or durability.
6. The double layer knitted element of claim 1, wherein the third
yarn is attached to only one of the first and second layer by tuck
stitches in the respective layer.
7. The double layer knitted element of claim 1, wherein the third
yarn is attached to at least one of the first and the second layer
by immediately successive tuck stitches.
8. The double layer knitted element of claim 1, wherein a ratio
between the number of tuck stitches and the number of miss stitches
varies within a course.
9. The double layer knitted element of claim 1, wherein the ratio
between the number of tuck stitches and the number of miss stitches
is 1:1, 1:2, or 1:3.
10. The double layer knitted element of claim 1, wherein a distance
between two successive tuck stitches is less than 2.54 cm.
11. The double layer knitted element of claim 1, wherein the first
yarn of the first layer is attached to the second layer by tuck or
loop stitches, or the second yarn of the second layer is attached
to the first layer by tuck or loop stitches.
12. The double layer knitted element of claim 1, wherein the third
yarn is knitted at least twice in between two knitting rows.
13. The double layer knitted element of claim 1, wherein the third
yarn is partially knitted in a certain portion of the knitting
row.
14. The double layer knitted element of claim 1, wherein the third
yarn is attached to the first layer by a plurality of tuck
stitches, and wherein the third yarn is not visible at the second
layer.
15. The double layer knitted element of claim 1, wherein the
thickness of the third yarn varies within the knitted element.
16. The double layer knitted element of claim 1, wherein the third
yarn is provided in repetitive structures, jacquard structures, or
in spacer-based structures.
17. The double layer knitted element of claim 1, wherein the
element is manufactured by intarsia, interlock, plating, inverted
plating, or inlay techniques.
18. An upper for a shoe comprising a double layer knitted element
of claim 1.
19. A shoe comprising: the upper of claim 18; and a sole attached
to the upper.
20. A method of manufacturing a double layer knitted element, the
method comprising the steps of: providing a first layer comprising
a first yarn; providing a second layer comprising a second yarn;
and arranging a third yarn at least in part between the first and
second layer, wherein the third yarn is attached to at least one of
the first and second layer by a plurality of tuck stitches, and
wherein there is at least one miss stitch between two successive
tuck stitches of the third yarn.
Description
TECHNICAL FIELD
[0001] Embodiments of the present invention relate to a double
knitted element, in particular a sports article, and to a method of
manufacturing such a double knitted element.
BACKGROUND
[0002] In order to provide a knitted element with desired
functional properties such as stiffness, stretch, recovery or
compression properties through knitting, there exists various
manufacturing methods.
[0003] In particular, stiffness is usually achieved by plating a
melting yarn together with a base yarn (e.g. polyester) or just
mixing melting yarns with the base yarn into the same yarn feeder.
Another possibility to achieve stiffness is provided by knitting
thermoplastic polyurethane (TPU) yarns or by knitting hybrid yarns,
which represent a mixture of polyester and melting yarn.
Furthermore, stretch, recovery or compression properties are
usually achieved by in-laying covered elastic yarns, by plating or
mixing spandex yarns together with the base yarn (e.g. natural
fiber, artificial, synthetic) directly into the feeder or by
knitting covered elastic yarns.
[0004] Tucked-in yarns are usually used on a single layer knit
base, for example in fleece fabrics. In these fabrics, the yarns
that are too thick for regular knitting are thus inserted into the
fabric by tucking. Furthermore, an elastic yarn may be used as an
inlay or even in a tuck-float structure for sock knitting, but this
use is only known for a single jersey or a single knit layer.
[0005] When using plating or mixing to achieve stiffness, the
melting yarn follows the same knitting sequence as the base yarn.
Further, the amount of melting yarn is difficult to control as it
depends on the knitting structure. In addition, if the melting yarn
is only needed on one side of the fabric, then the knitting
sequence needs to be modified accordingly, which results in a
different visual appearance or property of the fabric. When the
melting yarn is mixed together with the base yarn it is impossible
to control which of the two yarns will show up on the surface of
the fabric. Plating the melting yarn can improve this shortcoming,
but it is usually difficult or time consuming to set it up on the
knitting machine. In particular, plating is usually difficult to
adjust on the knitting machine.
[0006] When using elastic yarns to achieve stretch, recovery or
compression as in-laid yarns, there is always a risk of pulling out
the elastic yarn because it is not connected to the fabric. In
particular, the in-laid yarn is just a long float inside the double
layer knit.
[0007] US 2017/0029989 A1 relates to textile constructions formed
with fusible filaments. In particular, the document is directed to
a textile construct wherein thermoplastic yarns or fibers are
melted to form a fused film on one side or layer of the construct
while another side or layer is maintained in a discrete knitted
structure. The fused film may provide a membrane side or layer that
has desired attributes, such as one or more of waterproofness,
water resistance, wind resistance, and breathability.
SUMMARY OF THE INVENTION
[0008] The above-outlined problems are addressed and are at least
partly solved by the different aspects of the present disclosure,
which provides a knit fabric and a respective manufacturing method
to achieve enhanced functional properties in the knit fabric. In
particular, there is a need to create functional properties in the
knit independently of the knitting sequence, to avoid the
possibility of pulling out the in-laid threads, to keep the
appearance of the fabric as it is, but with added functional
properties, and/or to activate the melting yarn at targeted
locations of the knit fabric.
[0009] According to a first aspect, the above problem is solved by
a double layer knitted element, in particular for a sports article.
The double layer knitted element comprises a first layer comprising
a first yarn, a second layer comprising a second yarn and a third
yarn arranged at least in part between the first and second layer,
wherein the third yarn is attached to at least one of the first and
second layer by a plurality of tuck stitches, wherein there is at
least one miss stitch between two successive tuck stitches of the
third yarn.
[0010] In some embodiments, the third yarn is locked to the fabric
because of the tucks. Compared to the tucked-in third yarn of the
present disclosure, inlay strands are free floating inside the
double layer fabric and could be removed from the knitted fabric if
pulled.
[0011] In some embodiments, the third yarn is independent of the
main knitting structure and does not influence it, but further
enhances the properties of the knit. In fact, the tuck stitches
that are visible on the surface of one of the knitted layers are
minimalistic so they do not significantly affect the surface finish
of that knitted layer. In addition, as the third yarn is sandwiched
in between the two layers, additional protection of the third yarn
is provided. This means that yarns that would fail testing
(abrasion, color migration etc.) could be still tucked in and
provide extra function to a double layer knitted element.
[0012] In some embodiments, the third yarn of the double knitted
element may comprise a functional yarn. The use of a functional
yarn as the third yarn allows to create functional properties in
the knit independent of the knitting sequence.
[0013] In some embodiments. the first yarn of the first layer and
the second yarn of the second layer may be a same type of yarn but
it can also be two different types of yarns.
[0014] In some embodiments, the functional yarn may be at least one
of a melting yarn, thermoplastic polyurethane (TPU) yarn, water
repellent yarn, volume/puff yarn, natural fiber yarn (e.g. wool and
cotton), cellulose yarn, hybrid yarn, anti-microbial
(anti-bacterial) yarn (e.g. copper, zinc, silver, etc.), elastic
yarn, conductive yarn, or at least one of a yarn with at least one
of a heat resistance, UV protection, heat retention, moisture
absorbance, water resistance, chemical resistance, flame
resistance, moisture wicking capability, or at least one of a yarn
with a compression, shrinkability, cushioning, conductive,
insulation, or durability property.
[0015] Advantageously, by using a functional yarn as the third
yarn, the double layer knitted element can be provided with
different properties, depending on the functionality of the yarn.
For example, stretch, recovery, or compression properties of the
double layer knitted element can be influenced by using an elastic
yarn as a functional yarn. On the other hand, stiffness can be
achieved by using melting yarn, TPU yarn, or hybrid yarn as a
functional yarn. For example, melting or TPU functional yarns can
be used to stiffen the heel and toe cap areas of an upper, wherein
elastic functional yarns can be used to create stretch or recovery
in the instep area or in the collar of a fabric. In general, using
elastomeric material generates reinforced areas after an
application of heat.
[0016] An additional advantage is that the use of plating or mixing
the functional yarn with the base yarn into the yarn feeder or the
use of in-laid functional yarns is not necessary.
[0017] In some embodiments, the third yarn may be attached to only
one of the first and second layer by tuck stitches in the
respective layer.
[0018] In some embodiments, when the third yarn is attached to only
one of the first or second layer by using tuck stitches, the third
yarn is not visible at the respective other layers. Thus, the
appearance of the top of the one layer is kept as it is, wherein
desired functional properties are provided by the third yarn.
Further, the tuck stitches that are visible on the surface of one
of the knitted layers are minimalistic so they do not significantly
affect the surface finish of that knitted layer. In fact, the third
yarn is more or less independent of the main knitting structure and
does not influence it. Rather, the tuck stitches that are visible
on the surface of one of the knitted layers are minimalistic so
they do not significantly affect the surface finish of that knitted
layer, at the same time the surface finish of the other knitted
layer is completely unaffected.
[0019] In addition, in some embodiments, if a melting yarn is
provided between the first and second layer and attached only to
one layer, it is possible to activate the melting yarn only on the
inner side of one of the two layers. For example, if the melting
yarn is connected (tucked) to the back side layer, after thermal
activation, the melting yarn will be absorbed mostly by the back
side layer, but the external side of the front layer may not show
any traces of the melting yarn. Thus, further post processes can be
applied to the top side of the fabric, without using or
reactivating the melted yarn.
[0020] In some embodiments, the third yarn may be attached to at
least one of the first and the second layer by immediately
successive tuck stitches.
[0021] In some embodiments, a ratio between the number of tuck
stitches and the number of miss stitches may be variable within a
course or a row.
[0022] In particular, the amount of support in a respective area of
the double layer knitted element, can be engineered by the
tuck-miss ratio. More tucks close to one another will add more yarn
in the respective area. Changing the tuck-miss ratio of the third
yarn in different areas can provide different stretch or stiffness
properties. In contrast to that, an inlay strand would have the
same property along its width.
[0023] In some embodiments, the ratio between the number of tuck
stitches and the number of miss stitches can be at least one of
1:1, 1:2, or 1:3. One miss stitch means one needle is skipped in
the needle bed and the third yarn is floated over that one needle
between two tuck stitches. Thus, a tuck-miss ratio of 1:2, for
example, means that two needles are skipped and the third yarn is
floated over those two needles between two tuck stitches.
[0024] In some embodiments, the support of a double layer knitted
element can be engineered by the tuck-miss ratio. More tucks close
one to another provides a higher amount of the third yarn. Thus, a
tuck-miss ratio of 1:1 provides a higher support than 1:2, wherein
1:2 provides a higher support than 1:3 and so on.
[0025] In some embodiments, a distance between two successive tuck
stitches may be less than 2.54 cm.
[0026] In general, 2.54 cm of a needle bed of a knitting machine
corresponds to 14 needles on a gauge 14 machine or 7 needles on a
gauge 7 machine, wherein the gauge of a knitting machine
corresponds to the number of needles in 2.54 cm (one inch). For
safety reasons, floats are usually kept shorter than 2.54 cm. If
the floats are longer, there is the risk that the needles are not
catching the yarn.
[0027] In some embodiments, the first yarn of the first layer may
be attached to the second layer, and/or the second yarn of the
second layer may be attached to the first layer by tuck or loop
stitches.
[0028] In some embodiments, the third yarn may be knitted at least
twice in between two knitting rows. In other words, there are at
least two courses of the third yarn knitted in between two knitting
rows.
[0029] Thus, an increased support may be provided by keeping the
same tuck-miss ratio but knitting the third yarn multiple times in
between two knitting rows. For example, knitting the third yarn
several times between two knitting rows can be used to increase the
stiffness in a particular area of a fabric (for example in the heel
of an upper).
[0030] In some embodiments. the third yarn may be partially knitted
in between two knitting rows.
[0031] Partially knitting allows the third yarn to be provided in a
different amount in different areas of the double layer knitting
element. In particular, when the third yarn is partially knitted
multiple times in between two knitting rows. Thus, different
support may be provided in different areas, depending on the amount
of the third yarn. Thus, the provided support of a certain area or
zone can be engineered by keeping the same tuck-miss ratio but
partially knitting the third yarn one or multiple times in a
certain area.
[0032] Further, partially knitting the third yarn is technically
easier compared to an inlay strand. The reason is that the third
yarn is connected by tuck to the fabric and it will not jump out
when the knitting direction is changed.
[0033] In some embodiments, the thickness of the third yarn may
vary within the knitted element. By varying the thickness of the
third yarn, the support of the double layer knitted element can
also be influenced.
[0034] In some embodiments, the third yarn may be provided in
repetitive structures, jacquard structures, or in spacer-based
structures.
[0035] Thus, structures like repetitive structures, jacquard
structures, or spacer-based structures may be engineered by using a
functional yarn, wherein the appearance of at least one layer of
the structures remains the same.
[0036] In some embodiments, the element may be manufactured by
intarsia, interlock, plating, inverted plating, and/or inlay
techniques.
[0037] Thus, various double-layer elements with different
structures and functional properties can be provided by the present
disclosure.
[0038] A further aspect of the present disclosure is directed to an
upper for a shoe, in particular a sports shoe, comprising a double
layer knitted element as described herein.
[0039] A further aspect of the present disclosure is directed to a
shoe, in particular a sports shoe, comprising an upper as described
herein, i.e. with a knitted element according to the present
disclosure, and a sole attached to the upper.
[0040] Thus, an upper or a shoe are provided, which comprise the
previously described beneficial properties of the double layer
knitted element.
[0041] According to another aspect of the present disclosure, a
method of manufacturing a double layer knitted element in
accordance with one of the previous aspects is provided. In
particular, the method comprises the steps of providing a first
layer comprising a first yarn, providing a second layer comprising
a second yarn, and arranging a third yarn at least in part between
the first and second layer, wherein the third yarn is attached to
at least one of the first and second layer by a plurality of tuck
stitches, wherein there is at least one miss stitch between two
successive tuck stitches of the third yarn.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Aspects of the present disclosure will be described in more
detail with reference to the following figures:
[0043] FIGS. 1A-C show a knitting scheme for a double layer knitted
element with two layers and a third tucked-in yarn according to
some embodiments.
[0044] FIG. 2 shows a knitting scheme for a double layer knitted
element with two layers and a third tucked-in yarn knitted twice in
between two knitting rows according to some embodiments.
[0045] FIGS. 3A-B show a knitting scheme for a double layer knitted
element with two layers and a third tucked-in yarn with a different
ratio between the number of tuck stitches and the number of miss
stitches according to some embodiments.
[0046] FIG. 4 shows a knitting scheme for a double layer knitted
element with a third tucked-in yarn knitted twice in between two
knitting rows according to some embodiments.
[0047] FIG. 5 shows a knitting scheme for a double layer knitted
element with jacquard structures and a third tucked-in yarn
according to some embodiments.
[0048] FIGS. 6A-C show a knitting scheme for a double layer knitted
element using different knitting techniques according to some
embodiments.
[0049] FIG. 7 shows a knitting scheme for a double layer knitted
element with a spacer and a third tucked-in yarn according to some
embodiments.
[0050] FIG. 8 shows a knitting scheme for a double layer knitted
element and a third tucked-in yarn with a varying ratio between the
number of tuck stitches and the number of miss stitches within the
same course according to some embodiments.
[0051] FIG. 9 shows a knitting scheme for a double layer knitted
element and a partially tucked-in third yarn according to some
embodiments.
[0052] FIGS. 10A-B show a knitting scheme and section of a double
layer knitted element and a tucked-in third yarn using Intarsia
knitting technique according to some embodiments.
[0053] FIG. 11 shows a flow diagram illustrating a method of
manufacturing a double layer knitted element of the present
disclosure according to some embodiments.
[0054] FIG. 12 shows an isometric view of a shoe having a double
layer knitted element according to some embodiments.
DETAILED DESCRIPTION
[0055] In the following, embodiments of the present disclosure are
described in more detail referring to a double layer knitted
element, in particular for a sports article. While specific
combinations of features are described in relation to the exemplary
embodiments of the present disclosure, it is to be understood that
the disclosure is not limited to such embodiments. In particular,
not all features need to be present in order to realize the present
disclosure, and the embodiments may be modified by combining
certain features of one embodiment with one or more features of
another embodiment. For example, the present disclosure can be used
for a shoe upper, clothing, or accessories where various functional
properties like stiffness, elasticity, stretch, recovery or
compression are required, without influencing the appearance.
[0056] The use of a third tucked-in yarn enables a double knitted
element that comprises desired functional properties while it still
has an uninfluenced outward appearance. The various functional
properties comprise stiffness, elasticity, stretch, recovery, or
compression, for example. The techniques used in order to achieve
such properties or functions will be described in the
following.
[0057] The described techniques include suitable knitting
techniques comprising different combinations of the number of tuck
and miss stitches of the third yarn, as well as the selection of
fibers and yarns. These and other techniques will be explained in
the following, before embodiments of shoe uppers will be described
in which these techniques are applied.
[0058] FIGS. 1A-C show knitting schemes of a double layer knitted
structure, wherein the dots represent the needle positions of a
knitting machine in a knitting row. In particular, the knitting
scheme of FIGS. 1A-C comprises two lines of needles provided within
a row.
[0059] FIG. 1A illustrates a first layer 100 (e.g. the front layer)
comprising a first yarn 110, a second layer 200 (e.g. the back
layer) comprising a second yarn 210, and a third yarn 310 arranged
at least in part between the first layer 100 and the second 200
layer, wherein the third yarn 310 is attached to the second 200
layer by a plurality of tuck stitches 311. In some embodiments, the
third yarn 310 may be attached to the first layer 100 by a
plurality of tuck stitches 311. As illustrated in FIG. 1A there is
at least one miss stitch 312 between two successive tuck stitches
311 of the third yarn 310. In some embodiments, for example in FIG.
1A, the ratio between the number of tuck stitches and the number of
miss stitches, which corresponds to the tuck-miss ratio, is
1:1.
[0060] In some embodiments, the main double layer knit structure is
independent of the tucked-in yarn. The tucked-in yarn is an
addition to the existing structure and is sandwiched in between the
two layers.
[0061] FIG. 1A illustrates that the third yarn 310 is only attached
to the second layer 200 by immediately successive tuck stitches
311, wherein the third yarn 310 is not attached to the first layer
100.
[0062] In some embodiments, when using melt or TPU yarns as the
third yarn 310, stiffness can be applied to only one of the two
layers.
[0063] In some embodiments, stiffness is achieved within the fabric
without affecting its external appearance.
[0064] In some embodiments, the first 110 and second 210 yarns may
be different. In some embodiments, the first 110 and second 210
yarns may be equal.
[0065] In some embodiments, as illustrated in FIG. 1A, the first
layer 100 is connected to the second layer 200 by tuck
stitches.
[0066] FIG. 1B illustrates a section of a front layer 100 of an
exemplary double knitted element comprising a first yarn 110,
wherein FIG. 1C illustrates a section of a back layer 200
comprising a second yarn 210. In FIGS. 1B and 1C, a melting yarn
310 is connected (tucked) to the back layer 200. In particular, the
melting yarn 310 is absorbed mostly by the back layer 200 (a bit
also by the inner side of the front layer 100) after thermal
activation. The external side of the front layer 100 does not
present melting yarn 310 (e.g., melting yarn 310 is not exposed at
the front layer 100), as shown in FIG. 1B. Thus, further post
processes can be applied to the front side of the fabric, without
using or reactivating the melted yarn 310 underneath the front
layer 100. As shown, for example, in FIG. 1C, the first yarn 110 of
the front layer 100 may be attached to the back layer 200 by tuck
or loop stitches.
[0067] In some embodiments, the third yarn is locked to the fabric
because of the tucks. Compared to the tucked-in third yarn of the
present disclosure, inlay strands would be free floating inside the
double layer fabric and could be removed from the knitted fabric if
pulled.
[0068] Further, in various embodiments of the present disclosure,
the third yarn may comprise a functional yarn.
[0069] In some embodiments, the functional yarn can be at least one
of a melting yarn, thermoplastic polyurethane (TPU) yarn, water
repellent yarn, volume/puff yarn, natural fiber yarn (e.g. wool and
cotton), cellulose yarn, hybrid yarn, anti-microbial
(anti-bacterial) yarn (e.g. copper, zinc, silver, etc.), elastic
yarn, conductive yarn, or at least one of a yarn with at least one
of a heat resistance, UV protection, heat retention, moisture
absorbance, water resistance, chemical resistance, flame
resistance, moisture wicking capability, or at least one of a yarn
with a compression, shrinkability, cushioning, conductive,
insulation, durability property.
[0070] In some embodiments, applications of knitting a conductive
yarn could be heating certain parts of the upper or for
transferring electricity to LED lights in the upper or tooling,
wherein wool yarns can heat up the upper and cotton yarns can
absorb moisture.
[0071] FIG. 2 shows an exemplary embodiment wherein the third yarn
310a can be tucked in the first layer 100, e.g. on the front
stitches from row 110, in a first knitting step, and the third yarn
310b can be tucked in the second layer 200, e.g. on the back
stitches from the previous row 210, not shown here, in a second
knitting step, by immediately successive tuck stitches.
[0072] FIGS. 3A and 3B illustrate knitting schemes having different
ratios between the number of tuck stitches and the number of miss
stitches of the third yarn 310.
[0073] In some embodiments, for example as illustrated in FIG. 3A,
there are two miss stitches 312 between two successive tuck
stitches 311 of the third yarn 310, wherein the ratio between the
number of tuck stitches 311 and the number of miss stitches 312 is
1:2. FIG. 3B shows a knitting scheme, with three miss stitches 312
between two successive tuck stitches 311 of the third yarn 310,
wherein the ratio between the number of tuck stitches 311 and the
number of miss stitches 312 is 1:3.
[0074] In some embodiments, the support (with respect to stiffness
or stretch properties) of a double layer knitted element can be
engineered by the tuck-miss ratio. More tucks close to one another
provide a higher amount of the third yarn 310. Thus, a tuck-miss
ratio of 1:1 provides a higher support than 1:2, wherein 1:2
provides a higher support compared to 1:3 and so on.
[0075] In some embodiments, a distance between two successive tuck
stitches may be less than 2.54 cm (one inch). In particular, 2.54
cm of the needle bed of a knitting machine corresponds to 14
needles on a gauge 14 machine or 7 needles on a gauge 7 machine,
wherein the gauge of a knitting machine corresponds to the number
of needles in 2.54 cm which corresponds to 1 inch. For safety
reasons, floats are usually kept shorter than 2.54 cm. If the
floats are longer, there is the risk that the needles are not
catching the yarn.
[0076] In some embodiments, for example as shown in FIGS. 3A and
3B, the first layer 100 is attached to the second layer 200 by loop
stitches. In some embodiments, for example as shown in FIGS. 3A and
3B, the third yarn 310 is only attached to the second layer 200 by
immediately successive tuck stitches 311 to the second layer 200,
i.e. there are no tuck stitches of the third yarn 310 in the first
layer 100.
[0077] In some embodiments, the third yarn is attached to at least
one of the first and the second layer by tuck stitches. For
example, the third yarn 310 may be tucked to the first layer 100
and the second layer 200. In some embodiments, the third yarn may
be tucked to only the first layer by immediately successive tuck
stitches.
[0078] In some embodiments, as shown for example in FIG. 4, the
third yarn 310 is knitted at least twice in between two knitting
rows. In this embodiment, there are at least two courses of the
third yarn 310 knitted in between two knitting rows. In particular,
the third yarn 310 is knitted in a first knitting sequence 301 (for
example tuck-miss going to right) and in a second knitting sequence
302 (miss-tuck going to the left), which increases the support of
the third yarn 310 on the double layer knitted element.
[0079] In some embodiments, knitting the third yarn 310 several
times in between two knitting rows can be used for example to
increase the stiffness of a fabric.
[0080] In some embodiments, the amount of support can also be
engineered by using finer or thicker yarns (150 den to 900 den). In
some embodiments, a melt yarn can have a thickness of 2,000 den and
for sock knit even more is possible. In particular, higher denier
means thicker yarns.
[0081] In some embodiments, as shown for example in FIG. 4, the
first layer 100 is attached to the second layer 200 by loop
stitches.
[0082] In some embodiments, as shown for example in FIG. 4, the
third yarn 310 is only attached to the second layer 200 by
immediately successive tuck stitches 311 to the second layer 200
and not to the first layer.
[0083] In some embodiments, not explicitly shown here, the third
yarn 310 may be tucked only to the first layer 100, or tucked to
the first layer 100 and the second layer 200 by using tuck
stitches.
[0084] In some embodiments, the third yarn is independent of and
can be combined with all double knit structures. That means that
the structure can stay the same, but with function (e.g., stretch,
stiffness, and conductive yarn) being applied in various places of
the upper.
[0085] In some embodiments, the third yarn can be inserted in
repetitive structures as shown for example in FIGS. 1-4 or in
jacquard structures, as shown in FIG. 5.
[0086] In some embodiments, the tucked-in third yarn may be
combined with knitting techniques such as partial knitting,
intarsia (zone knitting), plating, inverted plating, devore, inlay,
etc.
[0087] In some embodiments, as shown for example in FIGS. 6A-C,
knitting structures using a functional third yarn 310 illustrates
an interlock structure with a third yarn.
[0088] In some embodiments, the third yarn can also be inserted in
spacer-based structures, as shown, for example, in FIG. 7. In FIG.
7, a spacer layer 400 and the third yarn 310 are alternately
knitted in between two knitting rows of the first layer 100 and the
second 200 layer.
[0089] FIG. 8 illustrates an embodiment of the present disclosure,
wherein the ratio between the number of tuck stitches and the
number of miss stitches is variable within a course or a row. In
particular, the amount of support in different portions (510, 520)
within the same row of the knitting element, can be engineered by
the tuck-miss ratio. In some embodiments, as shown for example in
FIG. 8, a first portion (510) includes a tuck-miss ratio of 1:3 and
a second portion (520) includes a tuck-miss ratio of 1:1. More
tucks close to one another will add more yarn in that specific
portion.
[0090] A variation of the tuck-miss ratio of the third yarn in
different areas can provide different stretch or stiffness
properties in the respective areas. In contrast to that, an inlay
strand has the same property along its width.
[0091] In some embodiments, the ratio between the number of tuck
stitches and the number of miss stitches can be at least one of
1:1, 1:2, or 1:3.
[0092] In some embodiments, as shown for example in FIG. 9, the
third yarn 310 is partially knitted in a certain portion of a
knitting row. In FIG. 9, the third yarn 310 is provided once in a
first portion 530, wherein the third yarn is provided multiple
(e.g. three) times in another portion 540.
[0093] In some embodiments, partial knitting of the third yarn, as
shown for example in FIG. 9, can provide different support by
keeping the same tuck-miss ratio but knitting different amounts of
the third yarn 310 in a certain portion of the knitting row or area
of the double layer element.
[0094] Further, partially knitting the third yarn is technically
easier compared to an inlay strand. The reason is that the third
yarn is connected by tuck to the fabric and it will not jump out
when the knitting direction is changed.
[0095] FIGS. 10A-B illustrate an embodiment with an efficient
placement of a third yarn 310 in a double-knitted element by using
Intarsia knitting. In some embodiments, special zones can be
engineered on the knitted element to have special properties
through intarsia. In some embodiments, as shown for example in FIG.
10A, the third yarn 310 is knitted, in a double-jersey knit,
multiple times in immediately successive courses in a portion of
the knitted element between the front 100 and back layers 200. In
addition, the third yarn 310 is attached to the first 100 and the
second 200 layer by alternating tuck-miss stitches.
[0096] In some embodiments, a third yarn 310 with an elastomer
material may be used to generate reinforced areas after the
application of heat. Besides elastomer, other polymer based yarns
can also be used that provide a reinforcing effect on application
of heat, pressure or other treatments.
[0097] Further, due to the knitting method, no pre-twisting of
materials is needed and manual labor is reduced and
high-performance upper materials can be created.
[0098] FIG. 10B shows a section of a double-knitted element by
using Intarsia knitting, in a double-jersey knit, wherein the third
yarn 310 is attached to the first 100 and the second 200 layer by
alternating tuck-miss stitches. By using tuck-stiches of the third
yarn 310 to both layers, the third yarn 310 is visible in both
layers (e.g. first layer 100 of FIG. 10B).
[0099] In some embodiments, as shown, for example, in FIG. 12, an
upper 15 for a shoe 10, in particular a sports shoe, may be
provided, which comprises a double layer knitted element 20
according to the present disclosure.
[0100] In some embodiments, a shoe 10, in particular a sports shoe,
may comprise an upper 15, which comprises a double layer knitted
element 20 of the present disclosure and a sole 25, which is
attached to the upper 15.
[0101] FIG. 11 shows a flow diagram illustrating a method of
manufacturing a double layer knitted element according to the
present disclosure and as described in more detail above. In step
1110, a first layer comprising a first yarn is provided. In step
1120, a second layer comprising a second yarn is provided. In step
1130, a third yarn is at least in part arranged between the first
and second layer, wherein the third yarn is attached to at least
one of the first and second layer by a plurality of tuck stitches,
wherein there is at least one miss stitch between two successive
tuck stitches of the third yarn.
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