U.S. patent application number 17/838991 was filed with the patent office on 2022-09-29 for artile of footwear incorporating a knitted component having floated portions.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to Adrian Meir.
Application Number | 20220304422 17/838991 |
Document ID | / |
Family ID | 1000006391264 |
Filed Date | 2022-09-29 |
United States Patent
Application |
20220304422 |
Kind Code |
A1 |
Meir; Adrian |
September 29, 2022 |
ARTILE OF FOOTWEAR INCORPORATING A KNITTED COMPONENT HAVING FLOATED
PORTIONS
Abstract
An article of footwear may include an upper incorporating a
knitted component formed of unitary knit construction. The knitted
component includes portions having extended floated portions to
distribute forces acting on the knitted component and resist
stretching of the knitted component when the article of footwear is
worn during a sport or athletic activity.
Inventors: |
Meir; Adrian; (Portland,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
1000006391264 |
Appl. No.: |
17/838991 |
Filed: |
June 13, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16778575 |
Jan 31, 2020 |
11375772 |
|
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17838991 |
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15094547 |
Apr 8, 2016 |
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16778575 |
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62148531 |
Apr 16, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 23/0205 20130101;
A43B 23/026 20130101; D04B 1/102 20130101; A43B 23/0245 20130101;
D10B 2501/043 20130101; D04B 1/22 20130101 |
International
Class: |
A43B 23/02 20060101
A43B023/02; D04B 1/10 20060101 D04B001/10; D04B 1/22 20060101
D04B001/22 |
Claims
1. An upper for an article of footwear, the upper comprising: a
knitted component having a first portion proximate an ankle collar
of the article of footwear, a second portion proximate a sole
portion of the article of footwear, and a joining area
transitioning between the first portion and the second portion,
wherein: the first portion comprises a first knit structure having
a plurality of knitted loops; the second portion comprises a second
knit structure that is different from the first knit structure and
that comprises a plurality of floated portions.
2. The upper of claim 1, wherein the first knit structure comprises
a series of knitted loops that uninterruptedly extend from the
joining area to the ankle collar.
3. The upper of claim 1, wherein the second knit structure
comprises a first tuck stitch and a second tuck stitch.
4. The upper of claim 3, wherein the first tuck stitch is
positioned adjacent the joining area and the second tuck stitch is
positioned adjacent the sole portion of the article of
footwear.
5. The upper of claim 4, wherein the plurality of floated portions
comprises a floated portion extending between the first tuck stitch
and the second tuck stitch.
6. The upper of claim 1, wherein the first portion further
comprises a first plurality of courses, and the second portion
further comprises a second plurality of courses.
7. The upper of claim 6, wherein each course of the second
plurality of courses comprises a first tuck stitch positioned
adjacent to the joining area and a second tuck stitch positioned
adjacent to the sole portion of the article of footwear.
8. The upper of claim 7, wherein the first tuck stitches are in a
first wale and the second tuck stitches are in a second wale.
9. The upper of claim 6, wherein the first plurality of courses
includes a first yarn and the second plurality of courses includes
a second yarn.
10. The upper of claim 9, wherein the first yarn has a lower
elasticity than the second yarn.
11. An upper for an article of footwear, comprising: a knitted
component having a first portion, a second portion, and a joining
area transitioning between the first portion and the second
portion, wherein: the first portion comprises a first knit
structure having a first plurality of courses; and the second
portion comprises a second knit structure that is different from
the first knit structure, the second knit structure having a second
plurality of courses.
12. The upper of claim 11, wherein the first portion further
comprises a plurality of knitted loops, and the second portion
comprises a plurality of floated portions.
13. The upper of claim 11, wherein the first plurality of courses
includes a first yarn and the second plurality of courses includes
a second yarn.
14. The upper of claim 13, wherein the first yarn has a lower
elasticity than the second yarn.
15. The upper of claim 13, wherein the first yarn has a greater
elasticity than the second yarn.
16. The upper of claim 11, wherein the first knit structure
comprises a series of knitted loops that uninterruptedly extend
from the joining area to an ankle collar.
17. The upper of claim 11, wherein the second knit structure
comprises a first tuck stitch and a second tuck stitch.
18. The upper of claim 17, wherein the first tuck stitch is
positioned adjacent the joining area and the second tuck stitch is
positioned adjacent the sole portion of the article of
footwear.
19. The upper of claim 18, wherein the plurality of floated
portions comprises a floated portion extending between the first
tuck stitch and the second tuck stitch.
20. The upper of claim 11, wherein the first plurality of courses
and the second plurality of courses include separate strands.
Description
RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 16/778,575 (filed Jan. 31, 2020, and entitled
"ARTICLE OF FOOTWEAR INCORPORATING A KNITTED COMPONENT HAVING
FLOATED PORTIONS"), which is a continuation application of U.S.
patent application Ser. No. 15/094,547 (filed Apr. 8, 2016, and
entitled "ARTICLE OF FOOTWEAR INCORPORATING A KNITTED COMPONENT
HAVING FLOATED PORTIONS"), which claims the benefit of U.S.
Provisional Application Ser. No. 62/148,531 (filed Apr. 16, 2015).
Each application listed in this paragraph is hereby incorporated by
reference in its entirety.
BACKGROUND
[0002] Conventional articles of footwear generally include two
primary elements, an upper and a sole structure. The upper and the
sole structure, at least in part, define a foot-receiving chamber
that may be accessed by a user's foot through a foot-receiving
opening.
[0003] The upper is secured to the sole structure and forms a void
on the interior of the footwear for receiving a foot in a
comfortable and secure manner. The upper member may secure the foot
with respect to the sole member. The upper may extend around the
ankle, over the instep and toe areas of the foot. The upper may
also extend along the medial and lateral sides of the foot as well
as the heel of the foot. The upper may be configured to protect the
foot and provide ventilation, thereby cooling the foot. Further,
the upper may include additional material to provide extra support
in certain areas.
[0004] The sole structure is secured to a lower area of the upper,
thereby positioned between the upper and the ground. 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 chamber, 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.
[0005] 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 includes 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 layered
configuration to impart multiple properties to the same areas.
[0006] 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
number of material elements. Further, multiple pieces that are
stitched together may cause a greater concentration of forces in
certain areas. The stitch junctions may transfer stress at an
uneven rate relative to other parts of the article of footwear
which may cause failure or discomfort. Additional material and
stitch joints may lead to discomfort when worn. By decreasing the
number of material elements utilized in the upper, therefore, waste
may be decreased while increasing the manufacturing efficiency, the
comfort, performance, and the recyclability of the upper.
SUMMARY
[0007] In one aspect, an article of footwear includes an upper and
a sole structure secured to the upper. The upper includes a knitted
component. The knitted component includes a first course and a
second course. The first course extends from a first area of the
knitted component to a second area of the knitted component along a
first knitting direction. The first course includes a first loop
and a second loop. The first loop and the second loop are separated
by a plurality of loops. The second course extends from the first
area to the second area. The second course includes a first tuck
stitch and a second tuck stitch. The first tuck stitch interacts
with the first loop. The second tuck stitch interacts with the
second loop. The second course includes a floated portion that
extends from the first tuck stitch to the second tuck stitch. The
floated portion extends over the plurality of loops of the first
course. And, the second course is configured to resist stretch in
at least a first portion of the upper.
[0008] In another aspect, an article of footwear includes an upper
and a sole structure secured to the upper. The upper incorporates a
knitted component. The knitted component includes a stretch
resistant area formed of a plurality of courses. At least a first
course incorporates a floated portion. A first loop being located
at a first end of the floated portion, a second loop being located
at a second end of the floated portion.
[0009] In another aspect, a method of making an article of footwear
having an upper and a sole structure secured to the upper is
disclosed. The upper incorporates a knitted component. The knitted
component is formed by knitting a first course and a second course.
The first course extending from a first area of the knitted
component to a second area of the knitted component along a first
knitting direction. The first course including a first loop located
in the first area and a second loop located in the second area. The
first loop and the second loop being separated by a plurality of
loops. The second course extending from the first area to the
second area. The second course including a first tuck stitch and a
second tuck stitch. The first tuck stitch interacting with the
first loop. The second tuck stitch interacting with the second
loop. The second course including a floated portion extending from
the first tuck stitch to the second tuck stitch. The floated
portion extending over the plurality of loops of the first course.
And, the second course being configured to resist stretch in at
least a first area of the upper.
[0010] Other systems, methods, features and advantages of the
embodiments 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
embodiments, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] 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.
[0012] FIG. 1 is a side view of an exemplary embodiment of an
article of footwear;
[0013] FIG. 2 is a side view of an exemplary embodiment of an
article of footwear including varying knit structures;
[0014] FIG. 3 is a schematic view of an embodiment of an upper
incorporating a large floated portion and tuck stitches;
[0015] FIG. 4 is a schematic view of an embodiment of an upper
incorporating tuck stitches and large floated portions;
[0016] FIG. 5 is a schematic view of an alternate embodiment of an
upper incorporating tuck stitches and large floated portions;
[0017] FIG. 6 is a schematic view of an alternate embodiment of an
upper incorporating tuck stitches and large floated portions;
[0018] FIG. 7 is a schematic view of an embodiment of an article of
footwear incorporating large floated portions;
[0019] FIG. 8 is a schematic view of an alternate embodiment of an
article of footwear incorporating large floated portions;
[0020] FIG. 9 is a schematic view of an alternate embodiment of an
article of footwear incorporating large floated portions;
[0021] FIG. 10 is a schematic view of an embodiment of a knitted
component incorporating large floated portions;
[0022] FIG. 11 is a schematic view of an alternate embodiment of a
knitted component incorporating large floated portions;
[0023] FIG. 12 is a schematic view of an alternate embodiment of a
knitted component incorporating large floated portions;
[0024] FIG. 13 is a view of an embodiment of a course incorporating
a tuck stitch and large floated portions;
[0025] FIG. 14 is a schematic view of the course from FIG. 7
subjected to a tensile force;
[0026] FIG. 15 is a schematic view of an embodiment of a course
incorporating multiple loops;
[0027] FIG. 16 is a schematic view of the course from FIG. 9
subjected to a tensile force;
[0028] FIG. 17 is a schematic view of an alternate embodiment of an
article of footwear incorporating multiple layers;
[0029] FIG. 18 is a top view of an embodiment of an article of
footwear incorporating a large floated portion;
[0030] FIG. 19 is a representational view of an athlete standing
with an enlarged cross-sectional view of a forefoot portion of an
embodiment of an article;
[0031] FIG. 20 depicts an athlete making a lateral maneuver with an
enlarged cross-regional view of a forefoot portion of an embodiment
of an article of footwear;
[0032] FIG. 21 is a representational view of an athlete making a
lateral maneuver with an enlarged cross-regional view of a forefoot
portion of an embodiment of an article of footwear that
incorporates tuck stitches and large floated portions;
[0033] FIG. 22 illustrates a force acting on an embodiment of a
knitted component that incorporates tuck stitches and large floated
portions;
[0034] FIG. 23 illustrates a force acting on an embodiment of a
knitted component that does not include tuck stitches and large
floated portions;
[0035] FIG. 24 depicts an exemplary looping diagram incorporating
tuck stitches and a floated portion;
[0036] FIG. 25 is a perspective view of an embodiment of a knitting
machine;
[0037] FIG. 26 is a schematic view of an exemplary embodiment of a
knitted component during an aspect of the knitting process;
[0038] FIG. 27 is looping diagram of the knitted component depicted
in FIG. 26;
[0039] FIG. 28 is a schematic view of an exemplary embodiment of a
knitted component during another aspect of the knitting
process;
[0040] FIG. 29 is a schematic view of an exemplary process of a
feeder passing yarn to the needles;
[0041] FIG. 30 is a schematic view of an exemplary process of
needles intertwining the yarn with loops;
[0042] FIG. 31 is a looping diagram of the knitted component
depicted in FIG. 30;
[0043] FIG. 32 is a schematic view of an exemplary process of a
plurality of needles extending and accepting yarn from a
feeder;
[0044] FIG. 33 is a schematic view of an exemplary process of
needles retracting and intertwining the yarn with the previous
intermeshed loops;
[0045] FIG. 34 is a looping diagram of the knitted component
depicted in FIG. 33.
DETAILED DESCRIPTION
[0046] 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 utilized in a variety of products, an article of footwear
that incorporates one of the knitted components is disclosed below
as an example. In addition to footwear, the knitted components may
be utilized in other types of apparel (e.g., shirts, pants, socks,
jackets, undergarments), athletic equipment (e.g., golf bags,
baseball and football gloves, soccer ball restriction structures),
containers (e.g., backpacks, bags), and upholstery for furniture
(e.g., chairs, couches, car seats). The knitted components may also
be utilized in bed coverings (e.g., sheets, blankets), table
coverings, towels, flags, tents, sails, and parachutes. The knitted
components may be utilized as technical textiles for industrial
purposes, including structures for automotive and aerospace
applications, filter materials, medical textiles (e.g. bandages,
swabs, implants), geotextiles for reinforcing embankments,
agrotextiles for crop protection, and industrial apparel that
protects or insulates against heat and radiation. Accordingly, the
knitted components and other concepts disclosed herein may be
incorporated into a variety of products for both personal and
industrial purposes.
[0047] Footwear Configuration
[0048] An article of footwear 100 is depicted in FIGS. 1-2 as
including a sole structure 102 and an upper 104. Although article
of footwear 100, also referred to hereafter as simply article 100,
is illustrated as having a general configuration suitable for
running, concepts associated with footwear may also be applied to a
variety of other athletic footwear types, including baseball shoes,
basketball shoes, cycling shoes, football shoes, tennis shoes,
soccer 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 footwear apply to a wide variety of
footwear types.
[0049] As best shown in FIGS. 1-2, article 100 may be divided into
three general regions: a forefoot region 10, a midfoot region 12,
and a heel region 14. 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 forefoot region 10, midfoot region 12, and heel
region 14, and correspond with opposite sides of footwear. More
particularly, lateral side 16 corresponds with an outside area of
the 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, heel region 14, lateral side 16, and
medial side 18 are not intended to demarcate precise areas of
footwear. Rather, forefoot region 10, midfoot region 12, heel
region 14, lateral side 16, and 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, heel region 14, lateral side 16, and medial side 18 may
also be applied to sole structure 102, upper 104, and individual
elements thereof.
[0050] Further, reference may be made to directional descriptions.
"Longitudinal" as used throughout this detailed description and in
the claims refers to a direction extending the length of an article
or component or portions thereof. In some cases, the longitudinal
direction may extend from forefoot region 10 to heel region 14 or
portions. The term "lateral" as used throughout this detailed
description and in the claims refers to a direction extending a
width of an article or portions thereof. In other words, the
lateral direction may extend between lateral side 16 and medial
side 18 of an article. Furthermore, the term "vertical" as used
throughout this detailed description and in the claims refers to a
direction generally perpendicular to a lateral and longitudinal
direction.
[0051] In an embodiment, sole structure 102 is secured to upper 104
and extends between the foot and the ground when article 100 is
worn. In some embodiments, the primary elements of sole structure
102 may include a midsole, an outsole, and a sockliner. In an
exemplary embodiment, sole structure 102 may include an outsole. In
an embodiment, outsole may be secured to a lower surface of upper
104. The outsole may also be secured to a base portion configured
for securing sole structure 102 to upper 104. Although the
configuration for sole structure 102 provides an example of a sole
structure that may be used in connection with upper 104, many other
conventional or nonconventional configurations for sole structure
102 may be utilized. Accordingly, the features of sole structure
102, or any sole structure used with upper 104, may vary in other
embodiments.
[0052] For example, in other embodiments, sole structure 102 may
include a midsole and/or a sockliner. The midsole may be secured to
a lower surface of an upper and 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
configurations, 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 article of footwear 100.
[0053] In some embodiments, upper 104 defines a void within article
100 for receiving and securing a foot relative to sole structure
102. The void is shaped to accommodate a foot and extends along the
lateral side of the foot, along a medial side of the foot, over the
foot, around the heel, and under the foot. Access to the void is
provided by an ankle opening 118 located in at least the heel
region 14. The foot may be inserted into upper 104 through ankle
opening 118 formed by collar 120. The foot may be withdrawn from
upper 104 through ankle opening 118 formed by collar 120. In some
embodiments, an instep area 122 may extend forward from ankle
opening 118 and collar 120 over an area corresponding to an instep
of the foot in midfoot region 12 to the forefoot region 10.
[0054] In some embodiments, upper 104 may include a tongue portion
124. Tongue portion 124 may be disposed between lateral side 16 and
medial side 18 of upper 104 through the instep area 122. Tongue
portion 124 may be integrally attached to upper 104. In some
embodiments, tongue portion 124 may be formed of a unitary knit
construction, which is defined in further detail below, with
portions of upper 104. Accordingly, upper 104 may extend
substantially continuously across instep area 122 between lateral
side 16 and medial side 18. In some embodiments, tongue portion 124
may be attached along lateral side 16 and medial side 18 of instep
area 122. In other embodiments, tongue portion 124 may be
disconnected along the sides of instep area 122 allowing for tongue
portion 124 to be moveable between the sides of instep area
122.
[0055] A lace 126 may extend through various lace apertures 128 to
enhance the comfort of article 100. Lace 126 may allow for the
wearer to modify the dimensions of upper 104 to accommodate
proportions of the foot. In some embodiments, lace 126 may extend
through lace apertures 128 that are disposed along either side of
instep area 122. In some embodiments, lace apertures 128 are
integrally formed within upper 104. In some embodiments, an inlaid
strand or tensile element may form lace aperture 128. Lace 126 may
permit the wearer to tighten upper 104 around the foot. Lace 126
may also permit the wearer to loosen upper 104 to facilitate entry
and removal of the foot from the void. In addition, tongue portion
124 of upper 104 in instep area 122 extends under lace 126 to
enhance the comfort of article 100. In some embodiments, lace
apertures 128 may be formed from another material. In further
configurations, upper 104 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 wear-resistant
material, and (c) logos, trademarks, and placards with care
instructions and material information.
[0056] 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 104 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 one of more of forefoot region 10, midfoot region
12, and heel region 14 along both lateral side 16 and medial side
18. In some embodiments, knitted component 130 forms substantially
all of upper 104 including an exterior surface and a majority or a
relatively large portion of an interior surface thereby defining a
portion of the void within upper 104. 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
104 that extends under the foot for attachment with sole structure
102.
[0057] 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.
[0058] Knitted component 130 may incorporate various types of yarn
that impart different properties to separate areas of upper 104.
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 104 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 104. 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 104.
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 104.
[0059] Knitting direction, as discussed throughout the description
and claims, refers to the orientation of interlooped yarns or
strands forming a course or row of loops that are being joined to
successive courses through a knitting process. The knitting
direction may be generally defined relative to the direction of the
knit material being formed during the knitting process. For
example, during a flat knitting process, successive courses of
interlooped yarns are joined together to form a knit element by
manipulating a yarn through knitting a course or row along a
generally horizontal direction to increase the size of the knitted
component along a generally vertical direction.
[0060] Reference may be made to courses which form the knitted
component. A "technical course" is used to refer to a row of needle
loops produced by adjacent needles during the same knitting cycle.
Each technical course refers to a pass of yarn along the knitting
direction that interacts with at least one needle. In some
embodiments, multiple technical courses may interact with one
another to form a visual course. A "visual course" refers to a
course as seen along the knitting direction. The height of a visual
course is generally the same height as a needle loop within the
visual course. A visual course may include multiple technical
courses. For example, a visual course may include a first technical
course that is formed of multiple jersey loops and a second
technical course that is formed of tuck stitches and floated
portions. The second technical course may interact with the first
technical course, however, the tuck stitches of the second
technical course may not extend beyond the height of the jersey
loops of the first technical course. That is, the loops of the
first technical course and the loops of the second technical course
may interact with the same needles at the same time. Therefore, the
height or length of a knitted component that incorporates the first
technical course may not increase by the addition of the second
technical course.
[0061] In some embodiments, knitted component 130 may incorporate
courses that utilize differing stitch configurations. In some
embodiments, knitted component 130 may utilize jersey stitches. In
other embodiments, knitted component 130 may incorporate float
stitches, tuck stitches, jacquard stitches, and other knit
stitches.
[0062] In some embodiments, various stitches may be particularly
located to take advantage of the properties of a particular stitch
or loop. For example, a stretch resistant stitch may be located in
an area of an article where stretch is undesirable, whereas a
stitch that allows for stretch may be located in an area where
stretch is desirable. Additionally, multiple stitches may be
combined to achieve a particular property.
[0063] Referring to FIG. 1, the lateral side of an article of
footwear is depicted. Upper 104 of article 100 may be formed
utilizing knitted component 130. The technical aspects of knitted
component 130 are depicted in technical component 132 and technical
component 134 for ease of description and discussion in relation to
this Detailed Description. Technical component 132 and technical
component 134 are used to depict the technical placement and
orientation of individual courses, however, when assembled,
technical component 132 and technical component 134 may appear as
does knitted component 130. Additionally, it should be recognized
that knitted component 130 may be located throughout any one or
more portions of upper 104.
[0064] In some embodiments, knitted component 130 may include
various courses configured to impart particular properties to upper
104 using the material properties of the courses. In some
embodiments, the courses may be formed of differing materials. For
example, in some embodiments, knitted component 130 may include
courses formed of stretch-resistant material. In other embodiments,
knitted component 130 may include courses formed of elastic
material. In still further embodiments, knitted component 130 may
include courses formed from both elastic material and
stretch-resistant material.
[0065] In some embodiments, knitted component 130 may include
courses configured to impart various properties to upper 104
through the configuration of the courses. In some embodiments,
courses may be configured to resist stretch. In some embodiments, a
tensile course may be utilized to resist stretch. In some
embodiments, a tensile course may incorporate large floated
portions to resist stretch in particular areas of upper 104. In
this Detailed Description, a floated portion refers to the piece of
yarn or thread that joins one weft knitted loop or stitch to the
next loop or stitch. Additionally, the tensile course may
incorporate tuck stitches, minimizing the length of material used
to form the tensile course. In other embodiments, the tensile
course may incorporate a jersey loop.
[0066] As depicted, technical component 132 includes different
stitches or loops in different areas of article 100. For example,
referring to technical course 150, jersey loops are used from the
sole portion to a lace portion of the upper. As shown, technical
course 150 does not change its configuration based on location
within upper 104. Rather, technical course 150 uses jersey loops or
stitches throughout the length of technical course 150. In
contrast, technical tensile course 152 utilizes different stitches
depending on where in article 100 technical tensile course 152 is
located. In the embodiment shown in FIGS. 1 and 2, technical
tensile course 152 includes a large floated portion adjacent sole
structure 102.
[0067] In some embodiments, courses may incorporate stitches or
loops that are stretch resistant in an area of upper 104 that may
experience higher magnitudes of force during use of article 100. In
some embodiments, an area of upper 104 adjacent to the sole
structure 102 may experience higher magnitudes of force during use
of article 100 as opposed to other areas of article 100. As a user
cuts or moves laterally, the foot of the user may press against the
portion of upper 104 adjacent sole structure 102. In order to
counteract the elevated levels of force in various locations within
article 100, different configurations of stitches may be utilized.
As shown in FIG. 1, stretch resistant area 140 of upper 104 is
configured to resist stretch. In some embodiments, a jersey loop
may be utilized along with a large floated portion to counteract
elevated forces in this area. In other embodiments, a tuck stitch
along with a large floated portion may be utilized to counteract
the elevated forces that this area of upper 104 may experience
during use of article 100. Additionally, by utilizing particular
stitches, a foot may be restricted from movement within article
100, securing the foot in relation to the sole structure 102. As
shown, technical tensile course 152 extends from sole structure 102
to instep area 122 and lace apertures 128. Technical tensile course
152 of knitted component 130 extends along the stretch resistant
area 140 of upper 104 from a lower area 142 to an upper area 144.
Adjacent sole structure 102 is lower area 142. Technical tensile
course 152 utilizes a tuck stitch 160 in lower area 142. As
technical tensile course 152 extends from lower area 142 to upper
area 144, technical tensile course 152 utilizes a large floated
portion 162. At upper area 144, technical tensile course 152 again
utilizes another tuck stitch 164. Tuck stitch 160 and tuck stitch
164 may be used to secure large floated portion 162 of technical
tensile course 152. In other embodiments, other types of loops such
as jersey loops may be utilized. Detailed aspects relating to tuck
stitches and floated portions will be discussed in detail later in
the Detailed Description.
[0068] Although stretch resistant area 140 of upper 104 appears to
be demarcated in FIG. 1, in some embodiments the stretch resistant
area 140 of upper 104 may not be visually different than other
areas of upper 104. In other embodiments, the stretch resistant
area 140 of upper 104 may be demarcated indicating the location of
stretch-resistant material. In other embodiments, the knit
structure of stretch resistant area 140 of upper 104 may alter the
appearance of stretch resistant area 140 such that when viewed,
stretch resistant area 140 of upper 104 may be visually different
than other areas of article 100.
[0069] Referring to FIG. 2, a lateral side view of article 100 is
depicted. Additionally, enlarged portions of knitted component 130
incorporated into upper 104 of article 100 are shown. Referring to
the enlarged portion 200, a swatch of knitted component 130
incorporating a jersey knit stitch is shown. It should be clear
that although jersey stitch is shown throughout the Detailed
Description, other stitches may be utilized.
[0070] Referring to enlarged portion 200, a jersey loop
configuration is depicted. As shown, course 202 interacts and
interloops with the loops of course 204. Both course 202 and course
204 are formed in a jersey loop orientation. Additionally, each
course within enlarged portion 200 contributes to the width of the
swatch.
[0071] Referring to enlarged portion 210, various stitches may be
used to form enlarged portion 210. As shown, enlarged portion 210
includes at least two different types of stitches. Additionally,
enlarged portion 210 is located in stretch resistant area 140 of
upper 104. Enlarged portion 210 includes jersey loops as well as
tuck stitches in combination with large floated portions. As shown,
technical course 212 includes jersey loops that interact with
jersey loops of technical course 214. In this manner, enlarged
portion 210 is similar to enlarged portion 200. Additionally,
floated portion 216 of technical tensile course 218 extends behind
technical course 214. Tuck stitch 220 of technical tensile course
218 extends along loop 222 of technical course 212. Tuck stitch 220
therefore interacts with loop 224 of technical course 214 as well
as loop 222 of technical course 212. In this manner, tuck stitch
220 does not increase the width of enlarged portion 210. Rather,
tuck stitch 220 extends either into an interior void of article 100
or extends outward away from the interior void of article 100. Tuck
stitch 220 and floated portion 216 therefore may add depth or
thickness to enlarged portion 210. In other embodiments, technical
tensile course 218 may include jersey loops. In such embodiments,
the jersey loops may contribute to the width of enlarged portion
210.
[0072] Referring to FIG. 3, a schematic view of an upper
incorporating a knitted component including jersey stitches, tuck
stitches, and large floated portions is depicted. Additionally, an
enlarged portion of an upper is depicted that shows the interaction
of various courses of the knitted component. Technical course 301,
technical tensile course 302 and technical course 303 extend from
medial side 18 to lateral side 16. Technical course 301 and
technical course 303 depict jersey loop structures over the length
of technical course 301 and technical course 303. Although depicted
with few loops, it should be recognized that the number of loops in
technical course 301 and in technical course 303 may be greater
than the number of loops represented in FIG. 3. For example,
technical course 301 and technical course 303 each may incorporate
between ten loops and fifty or seventy-five or one hundred loops or
more. Technical course 301 and technical course 303 of the knitted
component incorporated into upper 300 extend generally across a
vamp portion of upper 300.
[0073] Referring to upper 300, different locations of the knitted
component incorporated into upper 300 may include large floated
portions. Technical tensile course 302 of the knitted component
extends generally across the vamp portion of upper 300. Technical
tensile course 302, however, does not interact with technical
course 301 and technical course 303 in the same way that technical
course 301 and technical course 303 interact with each other. In
some embodiments, technical tensile course 302 may include a tuck
stitch located near perimeter edge 304 along medial side 18. The
tuck stitch may be used to secure technical tensile course 302 from
translating or slipping within the knitted component incorporated
into upper 300. As shown, tuck stitch 320 is oriented to interact
with loop 321 of technical course 301. Additionally, tuck stitch
320 may be layered or plaited with loop 322 of technical course
303. An enlarged view of the junction of tuck stitch 320 is
depicted in enlarged portion 350. In other embodiments, technical
tensile course 302 may include jersey loops. In such embodiments,
technical tensile course 302 may interact with technical course 301
and technical course 303 in the same or similar manner that
technical course 301 and technical course 303 interact with one
another.
[0074] Technical course 303 as depicted includes multiple loops.
Each of the loops interacts with loops of technical course 301.
Loop 322 includes a foot 331, leg 332, head 333, leg 334, and foot
335. Leg 332 extends over foot 361 of loop 321. Head 333 extends
behind leg 362 of loop 321, and additionally extends behind leg 363
of loop 321. Leg 334 of loop 322 extends over foot 364. In this
manner loop 322 is interlooped with loop 321. Additionally, the
strand that forms loop 322 extends from loop 322 to an additional
loop 390 within technical course 303. This area is referred to as
floated loop 374.
[0075] In some embodiments, a separate course may be interlooped
between technical course 303 and technical course 301. In some
embodiments, the course may interact with various loops in each of
technical course 303 and technical course 301. In some embodiments,
the separate course may interloop with particular loops of
technical course 301 and technical course 303. As shown, tuck
stitch 320 interloops with loop 321. Tuck stitch 320 may be visibly
different than both loop 321 and loop 322. Tuck stitch 320,
however, largely follows the same path as does loop 322. That is,
leg 351 of tuck stitch 320 extends over foot 361 of loop 321.
Additionally, head 352 passes behind leg 362 and leg 363 of loop
321. Further, leg 353 extends over foot 364 of loop 321. In this
sense, tuck stitch 320 largely follows the path of loop 322. The
floated portion of tuck stitch 320, however, does not extend toward
an immediately adjacent loop. Rather, floated portion 329 extends
behind loop 390 toward another tuck loop. Additionally, in contrast
to loop 321 and loop 322, the legs of tuck stitch 320 do not
intertwine with another loop. For example, loop 321 interloops with
loop 322. Head 333 and leg 332 and leg 334 of loop 322 restrict the
motion of loop 321 by limiting the movement of leg 362 and leg 363.
In contrast, tuck stitch 320 is not interlooped with another loop
that limits the motion of leg 351 and leg 353. This configuration
is referred to as a tuck stitch. In other embodiments, a jersey
loop may be incorporated on either side of floated portion 329 in
contrast to the depiction of FIG. 3.
[0076] In some embodiments, the floated portion located in the
tensile course may span or extend along many wales of the knitted
component. "Wales" as used in this Detailed Description refers to
the columns of loops that may extend along multiple courses. Wales
extend perpendicular to the knitting direction. "Courses" refers to
rows of loops formed from a strand that extend along the knitting
direction. Additionally, some embodiments may refer to needles to
discuss the width dimension. For example, a floated portion may
extend over multiple needles of a knitting machine which may be
holding loops. In other embodiments, the needles may not be holding
loops. The distance that a floated portion extends through the
knitted component may therefore be referred to as a needle width,
measured in reference to the number of needles on the needle bed of
the knitting machine, or needle, or may also be referred to in
terms of number of wales of the knitted component. In some
embodiments wales and needle widths may be interchangeable.
However, in half-gauge configurations, a needle width of forty may
correspond to a smaller distance than forty wales. That is because
"wales" refers to the loops formed from the needles that may be
altered, while "needle widths" refers to the width of needles that
are located on a knitting machine. Reference may be made to various
portions of courses extending over wales or needles in this
detailed description.
[0077] In some embodiments, floated portion 329 may extend along
technical course 303 passing multiple wales or needles while not
interacting with loops of either technical course 301 or loops of
technical course 303. In some embodiments, floated portion 329 may
extend past ten wales. In other embodiments, floated portion 329
may extend past twenty wales. In still further embodiments, floated
portion 329 may extend past seventy-five wales. In other
embodiments, floated portion 329 may extend past a number of wales
between about ten wales and about seventy-five wales.
[0078] In some embodiments, floated portion 329 may pass from one
side of upper 300 to the other side of upper 300. By varying the
length of floated portion 329, particularized stretch resistance
may be achieved. For example, a floated portion that extends past
ten wales may provide stretch resistance in a particularized area
of a knitted component, while allowing another area of the knitted
component to have elasticity. A floated portion that extends past
seventy-five wales may provide stretch resistance over a greater
portion of a knitted component. In other embodiments, a floated
portion may extend over a portion of upper 300. In some
embodiments, a floated portion may extend from a sole structure to
an instep area.
[0079] The size of a stretch resistant area of an upper having a
knitted component utilizing a tuck stitch and large floated portion
configuration may correspond to the number of wales that a floated
portion extends past or the widths of the needles that the floated
portion extends past. For example, a floated portion that extends
from lateral side 16 to medial side 18 of an article may extend
past seventy-five wales. In contrast, a floated portion that
extends from lateral side 16 to a central portion of an article may
pass a fewer number of wales. Additionally, the size of a floated
portion may correspond to the size and shape of the stretch
resistant area. For example, an embodiment that includes a stretch
resistant area associated with only a lateral side of an article
may include a shorter or smaller floated portion than an embodiment
that includes a stretch resistant area that extends from a lateral
side to a medial side.
[0080] In some embodiments, technical tensile course 302 may
include a mechanism for securing the course in place. In some
embodiments, technical tensile course 302 may include another tuck
stitch on the lateral side 16 of upper 300. Tuck stitch 340 may be
another tuck stitch that is located on lateral side 16 of upper
300. Tuck stitch 340 may assist in securing the orientation of
technical tensile course 302 with respect to technical course 301
and technical course 303 within the knitted component.
Additionally, tuck stitch 340 may prevent technical tensile course
302 from unraveling and may lock the orientation of technical
tensile course 302 in place within the knitted component. Tuck
stitch 340 may be intertwined and interlooped with loops of
technical course 301 and loops of technical course 303 in a similar
manner as depicted in enlarged portion 350. Tuck stitch 320 and
tuck stitch 340 may therefore secure technical tensile course 302
in place. Further, tuck stitch 320 and tuck stitch 340 may assist
in securing floated portion 329.
[0081] In some embodiments, technical tensile course 302 may be
formed from various materials. In some embodiments, technical
tensile course 302 may be formed from a stretch-resistant material.
In some embodiments, the stretch-resistant material may have a high
tensile strength. In some embodiments, the stretch-resistant
material may comprise Kevlar, carbon fiber, or other materials.
[0082] Referring to upper 300, other areas of upper 300 may include
portions of knitted component having courses incorporating large
floated portions in combination with jersey loop formations and
stitches. In some embodiments, floated portions may extend from a
first side of an upper to an interior edge 344. In some
embodiments, interior edge 344 may define ankle opening 118.
Additionally, interior edge 344 may define an area encompassing a
tongue portion of upper 300. In some embodiments, lace apertures
128 may be located adjacent interior edge 344. For example,
technical course 381 extends from medial side 18 to interior edge
344. As depicted, technical course 381 includes a first tuck stitch
382 adjacent perimeter edge 304. A second tuck stitch 384 is
located adjacent interior edge 344. A floated portion 383 extends
from first tuck stitch 382 to second tuck stitch 384. In some
embodiments, floated portion 383 may not interloop with loops of
adjacent technical course 380. In some embodiments, a large floated
portion such as floated portion 383 may be used to control stretch
in a midfoot area within an article of footwear.
[0083] Comparing floated portion 383 to floated portion 329, there
is a difference in the length of floated portion 383 and floated
portion 329. Floated portion 329 extends from medial side 18 to
lateral side 16 of article 300. In this configuration, floated
portion 329 may resist stretch along floated portion 329 from
medial side 18 to lateral side 16. Floated portion 383, by
comparison extends from medial side 18 to interior edge 344. In
this configuration floated portion 383 may resist stretch over a
shorter distance. Additionally, floated portion 383 extends past a
fewer number of wales than does floated portion 329. Therefore, the
length of the floated portions may be adjusted for a particular
stretch-resistant property in a particular area within an
article.
[0084] In some embodiments, an article may include different areas
of stretch resistance. In some embodiments, a first area or zone
may be configured to resist stretch and a second area may be
configured to be more flexible or stretchable than the first area.
In some embodiments, the first area may incorporate large floated
portions, and the second area may incorporate a different
combination of stitches and loops. Thus, in some embodiments, areas
with floated portions can have higher stretch resistance than areas
with stitches and loops. However, in some embodiments, the article
can include an area with large floated portions and other areas
with stitches and loops, wherein both areas substantially resist
stretching.
[0085] Furthermore, in some embodiments, the first area may
incorporate a greater number of floated portions than the second
area causing the areas to have different stretch resistances from
each other. In some embodiments, the first area may be more
resistant to stretch than the second area due to the greater
overall length of floated portions in the first area. Also, the
stretch resistance of each area may be determined by the
orientation and placement of the floated portions throughout the
first area and the second area.
[0086] In other embodiments, the area or distance encompassed by
floated portions in the first area may be larger than the area or
distance encompassed by floated portions in the second area. For
example, in some embodiments, the first area may include a floated
portion that extends over ten needles widths. The second area may
include two floated portions that each extends over two needle
widths. In this configuration, the two floated portions of the
second area extend over a total of four needle widths. In this
configuration, the floated portion of the first area that extends
over ten needles widths encompasses a greater distance or area than
the two floated portions that each extends over two needle
widths.
[0087] Referring to FIG. 4, an alternate embodiment of an upper is
depicted. As shown, large floated portions extend from medial side
18 toward interior edge 444. Additionally, large floated portions
extend from lateral side 16 toward interior edge 444. This is
similar to the configuration as depicted in upper 300 in FIG.
3.
[0088] In some embodiments, a tensile course may have varying
configurations. In some embodiments, a tensile course may include a
floated portion that extends from one side of an upper to another
side of the upper. In other embodiments, the tensile course may
include a floated portion that extends partly across an upper, and
also incorporates jersey loops or other loops. Various combinations
of floated portions and other loops may be combined within the
tensile course to achieve a particular stretch resistance in
particular locations. By varying the type of stitch or loop
configuration within the tensile course, the properties of stretch
resistance may be varied through each individual course. By varying
the type of stitch, flexibility in design may be achieved because
each strand need not have the same properties along each course.
For example, a course may be stretch resistant in a first region,
and elastic in a second region. Technical tensile course 401, for
example, has various knit loop configurations as the strand that
forms technical tensile course 401 extends from medial side 18 to
lateral side 16.
[0089] Upper 400 may be separated into regions in order to aid in
the description of the components of upper 400. The regions are not
meant to be a precise demarcation; rather the regions are used for
convenience is describing upper 400. Each course may be split into
different regions for purposes of this discussion: medial region
410, central region 411 and lateral region 412. Medial region 410
of technical tensile course 401 may include a tuck stitch 421, a
large floated portion 422, and another tuck stitch 423. Central
region 411 of technical tensile course 401 may include a plurality
of jersey loops as well as other loop configurations. Lateral
region 412 of technical tensile course 401 may be configured
similarly to medial region 410.
[0090] As depicted, medial region 410 may be configured to resist
stretch. The combination of tuck stitches and a large floated
portion may allow for this region of technical tensile course 401
to resist stretching. Referring to central region 411, jersey loops
are utilized. Central region 411 may be therefore configured to
allow for stretch. Additionally, lateral region 412 may be
configured for stretch-resistance. As depicted, technical tensile
course 401 therefore includes three regions with differing loop
configurations to provide different levels of support and
stretch-resistance to the knitted component incorporated into upper
400. In this configuration stretch is limited along lateral side 16
and stretch is limited along medial side 18. Additionally, a
central portion of upper 400 may be configured to stretch to a
greater degree than medial region 410 and lateral region 412 when
subjected to the same tensile force.
[0091] In some embodiments, the central region of the tensile
course may be varied in size. In some embodiments, central region
411 may be wide and encompass a greater percentage of technical
tensile course 401. In such embodiments, a greater portion of
technical tensile course 401 may be stretchable. By varying the
size of central region 411, the relative sizes of medial region 410
and lateral region 412 may be altered. By increasing the size of
central region 411, the size of medial region 410 and the size of
lateral region 412 may be reduced. The smaller size of medial
region 410 and lateral region 412 may form smaller areas of stretch
resistance in upper 400. In other embodiments, central region 411
may be reduced. In such embodiments, medial region 410 and lateral
region 412 may be increased and form larger areas of stretch
resistance in upper 400. By varying the relative size of different
regions of technical tensile course 401 within upper 400, different
levels of stretch resistance may be located over different
distances of a tensile course.
[0092] Additionally, by varying the length of floated portions
within technical tensile course 401, various stretch-resistant
zones or areas may be formed. For example, floated portion 422
extends from medial side 18 toward central region 411. In other
embodiments, floated portion 422 may extend into central region 411
and provide stretch resistant within central region 411. In other
embodiments, floated portion 422 may extend over a fewer number of
wales and provide stretch resistance over a portion of medial
region 410. The size of each stretch-resistant area may be
configured by allowing floated portion 422 to pass over greater or
fewer wales during the manufacturing process.
[0093] Referring to FIG. 5, an alternate embodiment of an upper
incorporating large floated portions is depicted. In this
embodiment, multiple tensile courses are incorporated into a vamp
area of upper 500. As shown, upper 500 includes technical course
501, technical tensile course 502, technical course 503, technical
tensile course 504, technical course 505 and technical tensile
course 506. Technical course 501, technical course 503 and
technical course 505 are all configured using jersey loops from
medial side 18 across upper 500 to lateral side 16. Technical
tensile course 502, technical tensile course 504, and technical
tensile course 506 incorporate tuck stitches and large floated
portions. Some of the tensile courses also include jersey loops.
Various configurations of tensile courses may be utilized in
conjunction with one another in order to achieve different
stretch-resistant properties in different areas of upper 500.
[0094] Upper 500 may be separated into regions in order to aid in
the description of the components of upper 500. The regions are not
meant to be a precise demarcation; rather the regions are used for
convenience is describing upper 500. Lateral region 512 may refer
to an area located on the lateral side of upper 500. Central region
511 refers to a middle portion of upper 500 that extends between
lateral region 512 and medial region 510. Medial region 510 refers
to an area located on the medial side of upper 500.
[0095] Referring to technical tensile course 502 and technical
tensile course 504, each tensile course is configured in a similar
manner as technical tensile course 401 as depicted in FIG. 4. That
is, technical tensile course 502 and technical tensile course 504
each include a tuck stitch adjacent medial side 18 of upper 500. A
floated portion extends from medial side 18 toward central region
511. Technical tensile course 502 and technical tensile course 504
additionally include a second tuck stitch located adjacent central
region 511. Technical tensile course 502 includes jersey loops in
central region 511. Technical tensile course 502 additionally
includes a tuck stitch adjacent lateral side 16. A floated portion
extends from the tuck stitch toward central region 511 where
another tuck stitch is located. The tuck stitch on either side of
lateral region 512 may secure technical tensile course 502 in a
particular orientation with respect to other courses and upper
500.
[0096] Upper 500 may additionally incorporate a knitted component
having other tensile courses arranged in different configurations.
For example, technical tensile course 506 may include a different
configuration of tuck stitches and floated portions than the
configuration of technical tensile course 504 and the configuration
of technical tensile course 502. As shown, technical tensile course
506 includes a tuck stitch adjacent to medial side 18. Another tuck
stitch is located adjacent to lateral side 16. A larger floated
portion extends from the first tuck stitch to the second tuck
stitch when compared to the floated portions of technical tensile
course 502 and technical tensile course 504. The configuration of
technical tensile course 506 may provide greater stretch resistance
over the entire width of article 500 than compared with technical
tensile course 502 and technical tensile course 504.
[0097] The configuration of upper 500 depicts the use of various
configurations of tensile courses within a single upper. By varying
the configuration of tensile courses throughout a knitted
component, different areas of upper 500 may have different levels
of stretch resistance. The tensile courses can be configured to
resist stretch within desired locations of upper 500.
[0098] In some embodiments, technical tensile course 502, technical
tensile course 504 and technical tensile course 506 may be formed
from a continuous strand. In other embodiments, the various tensile
courses may be formed from individual strands. For example, the
strand that forms technical tensile course 506 may extend out of
article 500 and continue as technical tensile course 504. In other
embodiments, each technical course may be a separate strand.
[0099] Referring to FIG. 6, an alternate embodiment of an upper
incorporating a knitted component having a large floated portion is
depicted. Upper 600 may be separated into regions in order to aid
in the description of the components of upper 600. The regions are
not meant to be a precise demarcation; rather the regions are used
for convenience is describing upper 600. Medial region 610 may
refer to an area located on the medial side of upper 600. Central
region 611 refers to a middle portion of upper 600 that extends
between medial region 610 and medial region 610. Lateral region 612
may refer to an area located on the lateral side of upper 600.
[0100] In some embodiments, particular regions of upper 600
incorporating a knitted component may incorporate large floated
portions to resist stretch. In some embodiments, the floated
portion may extend from one region to another region. In other
embodiments, the floated portion may be formed in a single region.
As depicted in FIG. 6, the knitted component of upper 600 includes
technical tensile course 602. Technical tensile course 602
incorporates tuck stitch 620 adjacent to medial side 18. Tensile
course additionally includes tuck stitch 624 adjacent central
region 611. Floated portion 622 extends between tuck stitch 620 and
tuck stitch 624. From central region 611 to lateral region 612,
technical tensile course 602 is formed from jersey loops. In this
configuration, technical tensile course 602 may be configured to
resist stretch in medial region 610 while allowing for other areas
of upper 600 to stretch to a greater degree.
[0101] The configuration of the knitted component incorporated into
upper 600 may be used to counteract typical forces that may be
exerted throughout upper 600 during use. Typical forces are forces
that may occur in an article of footwear that is used for a
particular purpose, for example, an article of footwear configured
for a sport or other athletic activity. The typical motions for a
player or participant of a sport or athletic activity cause force
to be exerted on an upper of the article in certain areas. Typical
forces may be forces that extend through an article as a foot
presses against upper 600. The foot may stretch or deform upper 600
as the foot extends into upper 600. By placing large floated
portions in particular locations in the knitted component
incorporated into the upper, the floated portions may be used to
counteract the forces from a foot and assist with securing the foot
within the article of footwear and resist deformation of upper
600.
[0102] Referring to FIGS. 7-9, various articles of footwear are
depicted that incorporate different configurations of floated
portions. Although each of the articles depicted includes areas
that do not show jersey loops, or other loops, it should be
recognized that the floated portions of each of the articles may
interact with adjacent loops as depicted in the previous Figures.
Referring particularly to FIG. 7, an article of footwear 50 is
depicted incorporating large floated portions along a lateral side
16. It should be recognized that although depicted along lateral
side 16, floated portions may be oriented along medial side 18 or
within other areas of article 50. Area 51 that incorporates the
large floated portions may be configured to resist stretch.
Additionally, area 52 may include a different knit structure than
area 51. In some embodiments, area 52 may be configured to allow
for greater stretch than area 51. In some embodiments, area 52 may
include jersey loops or other various loops.
[0103] Referring to floated portion 53, floated portion 53 may
extend from sole structure 54 to a joining area 55. Joining area 55
may represent the area between area 51 that is configured for
stretch resistance and area 52 that is configured to be less stress
resistant than area 51. In some embodiments, joining area 55 may
have some of the characteristic of area 51 and some of the
characteristics of area 52. For example, in some embodiments,
joining area 55 may incorporate portions of the floated portions of
area 51 as well as some portions of a jersey knit or other knit
configuration of area 52.
[0104] In some embodiments, floated portions of area 51 may be
formed of a single thread or yarn. For example, floated portion 53
may be formed from the same thread that is floated portion 56. In
other embodiments, floated portion 53 and floated portion 56 may be
formed from separate yarns or thread.
[0105] Referring to FIG. 8, an alternate embodiment of an article
that incorporates a knitted component is depicted. In some
embodiments, a portion of the knitted component may interact with
laces of an article of footwear. As depicted in FIG. 8, lace 126
extends through a loop formed by tensile strand 60. In some
embodiments, tensile strand 60 may be used to form floated portion
and floated portion 62. In some embodiments, tensile strand 60 may
extend from sole structure 63 toward an ankle opening or instep
area.
[0106] In some embodiments, a portion of tensile strand 60 may
extend away from the exterior surface of the knitted component.
That is, in some embodiments, loop 64 may extend out of the surface
of the knitted component incorporated into article 65. In some
embodiments, lace 126 may extend through loop 64. In some
embodiments, lace 126 may extend through multiple loops.
[0107] In some embodiments, a tensile strand may form a loop within
the knitted component. For example, loop 66 may be positioned
within the knitted component incorporated into article 65. In some
embodiments, loop 66 may extend around a lace aperture 67. In some
embodiments, lace 126 may pass through lace aperture 67.
[0108] In the configuration depicted in FIG. 8, loops form by
tensile strands may assist in tightening and adjusting the fit and
feel of article 65 as lace 126 is adjusted. As lace 126 is
tightened, the tensile strand may also tighten and cause the upper
of article 65 tighten.
[0109] Referring to FIG. 9, in some embodiments, tensile courses
may utilize specific configurations. In some embodiments, tensile
courses may be arranged such that junctions are not aligned with
one another. For example, in some embodiments, adjacent tensile
courses may be oriented such that the loops of adjacent tensile
courses are not aligned with each other. In some embodiments, as a
floated portion extends over multiple needle widths, the floated
portion may move or slide along the knitted component. In some
embodiments, the floated portions may be able to be snagged or
caught on an external item. In order to avoid the tensile courses
from becoming snagged, additional loops may be integrated into the
floated portions to reduce the length of the floated portions.
[0110] In some embodiments, the loops or tuck stitches that secure
floated portions may be specifically located within each tensile
course. When tensioned, tensile courses may extend a small amount
around the area of each tensile course that includes a loop or tuck
stitch. By varying the location of each of the tuck stitches or
loops that are used to secure tensile courses, the stretch
resistance of the tensile courses may be controlled. For example,
referring to tensile course 70, tensile course 70 includes a first
tuck stitch 72 and a second tuck stitch 73. Located adjacent
tensile course 70 is tensile course 71. Tensile course 71 includes
third tuck stitch 74, fourth tuck stitch 75, and fifth tuck stitch
76. As shown in FIG. 9, first tuck stitch 72 and second tuck stitch
73 are offset from third tuck stitch 74, fourth tuck stitch 75, and
fifth tuck stitch 76. For example, first tuck stitch 72 may be
located in a first wale position. The wale position refers to the
loop location along the course with respect to the needles used to
form each loop. Fourth tuck stitch 75 may be located in a second
wale position that is different than the first wale position. That
is, the needle used to form fourth tuck stitch 75 may be different
than the needle used to form first tuck stitch 72. In this
configuration, therefore, fourth tuck stitch 75 and first tuck
stitch 72 may be offset from one another.
[0111] In this configuration, as tensile course 76 and tensile
course 70 are subjected to a force, each of the tensile courses may
stretch or extend at different locations. By offsetting the loops
or tuck stitches within each tensile course, the areas when each
tensile course may stretch may be spread out. For example, there
may not be a concentrated portion of the stretch-resistant area of
the knitted component integrated into article 77 that may stretch
or extend. By varying the location of each of the loops or tuck
stitches, the stretch of the tensile courses may be muted, less
noticeable, or spread over a larger portion of the
stretch-resistant area.
[0112] In some embodiments, a floated portion may be located
adjacent to jersey loops or other loops within the knitted
component integrated into article 77. For example, in some
embodiments, a floated portion may not extend directly from a sole
structure or direction across an article of footwear. Tensile
course 78 includes a jersey loop portion 79, a floated portion 80,
and another jersey loop portion 81. As shown, floated portion 80
does not extend directly from sole structure 82 and additionally
does not extend completely to the ankle opening of article 77. In
this configuration, floated portion 80 may resist stretch while
jersey loop portion 79 and jersey loop portion 81 may be more
stretchable than floated portion 80. Additionally, other portions
such as jersey loop portion 79 and jersey loop portion 81 may be
utilized to offset the tuck stitches or other loops between
adjacent tensile courses or other courses. By utilizing the jersey
loop portions in conjunction with floated portions, the areas of
stretch within adjacent floated portions may be reduced.
[0113] Referring to FIGS. 10-12 various configurations of tensile
courses incorporated into knitted components are depicted. In some
embodiments, tensile courses may be oriented in order to counteract
or direct forces that particular articles of footwear may
experience during normal use. For example, a wearer participating
in football may cut laterally during normal play such that
particular forces may be exerted upon the upper of an article of
footwear. In other embodiments, an article used for playing
basketball may include tensile courses oriented at different angles
to counteract the forces that may be exerted upon the upper during
use. Additionally, an article designed for track or running may
include tensile courses oriented at other angles.
[0114] Referring to FIG. 10, tensile courses 91 of knitted
component 90 may angle around a vamp area of knitted component 90.
In this embodiment, tensile courses 91 may be oriented to
counteract particular lateral and vertical forces. Referring to
FIG. 11, knitted component 92 includes tensile courses 93 that are
oriented differently than the tensile courses of knitted component
90. In this depiction, tensile courses 93 may be oriented at less
of an angle than the tensile courses of knitted component 90. The
tensile courses may be orientated at various angles depending on
the type of sport or activity the article is designed for.
Referring to FIG. 12, knitted component 94 is depicted and includes
tensile courses 95. Knitted component 94 may be incorporated into
an article that may be used for track or for running. As running
does not typically involve a cutting motion, tensile course 95 may
extend laterally.
[0115] The embodiments described herein can make use of any of the
apparatus or structures described in Meir, U.S. patent Ser. No.
______, filed as U.S. application Ser. No. 14/445,835 on Jul. 29,
2014 and entitled "Article of Footwear Incorporating an Upper with
a Shifted Knit Structure," the entirety of which is hereby
incorporated by reference.
[0116] Referring to FIGS. 13-16, various stitch configurations are
depicted. Tensile technical tensile course 302 and technical course
301 from upper 300 are depicted in isolation from other courses
within upper 300. Technical tensile course 302 includes tuck stitch
320 and tuck stitch 340. Floated portion 329 extends between and
connects tuck stitch 320 to tuck stitch 340. In contrast, technical
course 301 includes a plurality of loops 910. FIGS. 13-16 are used
to demonstrate the relative length of each of the courses within
upper 300.
[0117] Referring to FIG. 13, technical tensile course 302 is
depicted in isolation from other courses of the knitted component
incorporated into upper 300. Technical tensile course 302 includes
tuck stitch 320, floated portion 329 and tuck stitch 340. As
technical tensile course 302 is subjected to a tensile force 800,
the length of technical tensile course 302 may extend. As depicted
in FIG. 14, technical tensile course 302 is fully expanded to the
full length of the strand that forms technical tensile course 302.
In this configuration, tuck stitch 320 and tuck stitch 340 are
flattened. The yarn or material from the tuck stitches extends the
length of technical tensile course 302 a distance 802.
[0118] It should be recognized that along with the physical and
geometric configuration of technical tensile course 302, changing
the material properties of the strand may contribute to the
stretchability of each course. For example, by using a stretchable
material, tensile technical course 302 may be able to extend a
greater distance than distance 802. Unless otherwise specified in
this Detailed Description, when discussing the distance that a
configuration may extend this Detailed Description relates to the
physical or geometric configuration of structure rather than the
material properties of the material used to form the structure.
[0119] Due to the geometric configuration of technical tensile
course 302, floated portion 329 encompasses a large percentage of
technical tensile course 302. Because floated portion 329
encompasses a large percentage of technical tensile course 302,
when subjected to tension, technical tensile course 302 does not
extend by a large degree. Floated portion 329 in a non-tensioned
state is a generally straight area of technical tensile course 302
that does not include additional loops. Therefore, when technical
tensile course 302 is tensioned, floated portion 329 does not add
to the length of technical tensile course 302. The extension of
technical tensile course 302 to a flat linear course as depicted in
FIG. 14 is used as a representation to depict the amount of yarn
used to form technical tensile course 302 in comparison to other
courses. It should be recognized that during use within an upper,
technical tensile course 302 may not fully extend to a completely
linear configuration as depicted in FIG. 14; rather, technical
tensile course 302 may extend a lesser amount than other courses
that have different configurations. For example, technical tensile
course 302 may extend a lesser amount than technical course 301
when subjected to an equal force.
[0120] Referring to FIGS. 15 and 16, technical course 301 is
depicted in isolation in a tensioned state and a non-tensioned
state. In FIG. 15, technical course 301 is in a non-tensioned
state. In contrast, in FIG. 16, technical course 301 is subjected
to a tensile force 1000. As shown, technical course 301 extends a
distance 1002 when subjected to tensile force 1000. As technical
course 301 is subjected to tensile force 1000, the strand or
material used to form plurality of loops 910 is flattened and
contributes to the length of technical course 301. Because there
are a large number of loops in technical course 301, the length of
technical course 301 may increase a large amount in comparison to
technical tensile course 302. For example, distance 1002 may be
larger than distance 802. When used in conjunction with other
jersey loops, a course of the configuration of technical course 301
may be relatively elastic. Technical tensile course 302, by
contrast, uses a fewer number of loops. Therefore, technical
tensile course 302 may form a course that is relatively stretch
resistance compared to technical course 301. As discussed with
relation to technical tensile course 302, tensile course 301 may
not completely flatten when incorporated into an upper as depicted
in FIG. 16; rather, the loops of technical course 301 may diminish
in size and contribute to the length of technical course 301.
[0121] In some embodiments, tensile courses may be used in
conjunction with jersey loop courses. By using tensile courses in
conjunction with jersey loop courses, the stretch of the jersey
loop courses may be controlled and limited. For example, by
interacting and interlooping technical tensile course 302 with
technical course 301, the stretchability of technical course 301
may be limited. As interlooped technical tensile course 302 and
technical course 301 are subjected to a tensile force, each may
begin to extend. Because technical tensile course 302 may extend a
shorter distance than technical course 301, technical tensile
course 302 may restrict technical course 301 from extending a large
distance. For example, the maximum distance that the combined
course of technical course 301 and technical tensile course 302 may
extend based on the physical and geometric configuration of the
combined course is distance 802. The reason for this property is
because technical tensile course 302 cannot draw on any additional
loops beyond tuck stitch 320 and tuck stitch 340 to extend the
length of technical tensile course 302. Although technical course
301 may be able to extend a greater amount in isolation, by
interacting technical tensile course 302 with tensile course 301,
the distance that tensile course 301 is able to extend may be
limited by technical tensile course 302. In this manner, technical
tensile courses may be used throughout an article or component to
limit stretch in particular areas.
[0122] Referring to FIG. 17, an alternate embodiment of an article
of footwear is depicted. Article 1100 includes upper 1104 and sole
structure 1102. Additionally article 1100 includes collar 1120,
tongue 1124 and instep area 1122. Further, article 1100 includes
lace 1126 which may pass through lace apertures 1128. Upper 1104
may be formed from knitted component 1130. Knitted component 1130
may be formed in largely the same manner as knitted component 130
discussed previously. Further, article 1100 may include a stretch
resistant area 1140. Stretch resistant area 1140 may resist stretch
in an area that may be predefined prior to completion of article
1100. For example, the structure of stretch resistant area 1140 may
be formed during a knitting process during the formation of upper
1104.
[0123] In some embodiments, article 1100 may be formed using
multiple layers. In some embodiments, the multiple layers may
include knit structures. As shown in FIG. 17, article 1100 includes
two layers, interior layer 1160 and exterior layer 1162 including
knit structures.
[0124] In some embodiments, article 1100 may incorporate
cross-stitching. "Cross-stitching" as discussed in this Detailed
Description relates to stitching extending between layers of
fabric. In some embodiments, cross-stitching may be utilized such
that a first layer of fabric and a second layer of fabric are
spaced from one another. That is, in some embodiments, the thread
used to form the cross-stitch may form a filler or spacer material
between layers of fabric. In some embodiments, a specific type of
cross-stitching may be used. For example, in some embodiments, a
cross tuck may be utilized. A cross tuck is a tuck loop that
extends from one knit layer to a second knit layer. The knit layers
are connected by alternating tuck loops.
[0125] In some embodiments, multiple strands may be cross tucked
between different layers. In other embodiments, a single strand may
be cross tucked between different layers. As shown in FIG. 17,
tensile strand 1170 and tensile strand 1172 may be utilized to
cross tuck between interior layer 1160 and exterior layer 1162.
Although tensile strand 1170 and tensile strand 1172 are shown as
two separate strands, it should be recognized that in some
embodiments, tensile strand 1170 and tensile strand 1172 may be
formed from a single strand.
[0126] In some embodiments, each of tensile strand 1170 and tensile
strand 1172 may form loops between interior layer 1160 and exterior
layer 1162. In some embodiments, tensile strand 1170 and tensile
strand 1172 may cross one another, depicted as an "X" shape in FIG.
17. In other embodiments, a single tensile strand may be utilized
to connect interior layer 1160 and exterior layer 1162.
[0127] In some embodiments, cross stitching may affect the
thickness of knitted component 1130. In some embodiments, thicker
areas of knitted component 1130 may be located in areas of article
1100 where additional padding or cushioning may be desired. For
example, in some embodiments, knitted component 1130 may be thicker
in an area of upper 1104 that may rub against the ankle or top
portion of a wearer. Thinner areas of upper 1104 may be located in
areas where padding may not be necessary. For example, in some
embodiments, thinner areas may be located adjacent to sole
structure 1102. In some embodiments, a thinner area may assist in
securing upper 1104 to sole structure 1102. In other embodiments,
thicker and thinner areas may be arranged throughout article 1100
to allow for increased comfort in cushioning or for various design
purposes.
[0128] In some embodiments, the number of loops in a cross
stitching area may affect the thickness of knitted component 1130.
Referring to enlarged portion 1150, cross tuck area 1154
incorporates multiple tuck loops as compared to cross tuck area
1156 of enlarged portion 1156. Therefore, thickness 1180 depicted
in enlarged portion 1150 may be larger than thickness 1182 of
enlarged portion 1152. By varying the number of loops in a cross
tuck area, the thickness of the knitted component may be
varied.
[0129] In some embodiments, the elasticity of an article may be
varied by incorporating a different number of loops within the
cross stitching area. By varying the number of loops between
interior layer 1160 and exterior layer 1162 the stretchabilty or
elasticity of upper 1104 may be altered. An area of article 1100
that incorporates fewer loops within the cross stitching area may
be more stretch resistant than an area of article 1100 that
incorporates more loops. For example, referring to enlarged portion
1150, cross tuck area 1154 includes multiple tuck loops. By
contrast, cross tuck area 1156 includes fewer tuck loops. As shown
in FIGS. 7-10 and discussed in the Detailed Description,
incorporating fewer loops reduces the distance in which a strand
may extend. Further, by incorporating tuck loops rather than jersey
loops, the distance that a strand may extend may be further limited
compared to a cross stitch area incorporating a jersey loop.
[0130] Various configurations of cross-stitching may be utilized.
For example, in some embodiments, a tuck loop may be utilized. In
other embodiments, a jersey loop may be utilized. As depicted,
various tuck loops are used to connect an interior layer 1160 to an
exterior layer 1162 of upper 1104.
[0131] In some embodiments, the spacing of cross tucks may be
varied within a cross tuck area. In some embodiments, the number of
cross tucks may increase or decrease along knitted component 1130.
Referring to enlarged portion 1150, cross tuck area 1154 includes
first portion 1176 and second portion 1178. As depicted, first
portion 1176 includes a greater number of cross tucks than does
second portion 1178. In this configuration, the thickness of first
portion 1176 may be greater than the thickness of second portion
1178. Further, the cross tucks of second portion 1178 are more
spaced than the cross tucks of first portion 1176. The spacing of
the cross tucks of second portion 1178 may assist in reducing the
thickness of second portion 1178. Additionally, second portion 1178
may be more stretch resistant than first portion 1176. Further,
enlarged portion 1152 incorporates even fewer cross tucks than does
first portion 1176 or first portion 1178. Therefore the thickness
of enlarged portion 1151 may be less than second portion 1178.
Further, enlarged portion 1152 may be more stretch resistant than
first portion 1176 and second portion 1178. As such, the thickness
and stretch resistance of an area of knitted component 1130 may be
varied along a length or distance of upper 1104.
[0132] In some embodiments, the level of stretch resistance in an
article may be varied to accommodate different levels of force that
an article may experience during use. In some embodiments, the
stretch resistant of an article may be varied such that the
transition from stretch resistant to relatively elastic may be a
seamless or unnoticeable transition to a wearer. In some
embodiments, continuously varying the stretch resistance throughout
an article may increase comfort to a user.
[0133] Referring to FIGS. 18-22 an article is depicted under normal
use. Referring to FIG. 18, the top view of an article of footwear
incorporating large floated portions is depicted from a top view.
In this depiction, article 1200 includes a knitted component having
technical tensile course 1201 and technical tensile course 1202. As
depicted, the floated portions of technical tensile course 1201 and
technical tensile course 1202 extend from medial side 18 to lateral
side 16 of the upper. As such, technical tensile course 1201 and
technical tensile course 1202 are configured to resist stretch
laterally along article 1100.
[0134] Referring to FIGS. 18-23, representative views of an article
of footwear including an upper and a sole structure in use are
depicted. FIG. 19 depicts an athlete wearing an article 1200. As
shown in FIGS. 19-21, a cutaway of the forefoot portion of the
article of footwear includes the forefoot portion of the foot of an
athlete. Referring to FIG. 19, the foot of an athlete may
comfortable be located within article 1200. FIG. 19 illustrates the
athlete in a relaxed or non-moving state. While article 1200 may
experience force on the sole structure 1304 in this state, minimal
force may be exerted to portions of upper 1302 of article 1200.
[0135] Referring to FIGS. 20 and 21, the athlete is shown
performing a sport or athletic activity. In this embodiment, an
athlete is shown performing a typical motion for soccer, in
particular, making a cutting motion. During such a cutting motion,
lateral force may be exerted along portions of the upper of an
article of footwear. As depicted in FIG. 20, article of footwear
1400 includes an upper 1404 that does not include provisions for
distributing or reducing forces from a sport or athletic activity.
In this embodiment, upper 1404 of article of footwear 1400 may
incorporate a knitted component that does not include large floated
portions selectively located to correspond with areas of an article
that may be subjected to typical forces with the athletic
activities of the athlete wearing article of footwear 1200.
[0136] FIG. 20 shows a cutaway view of article of footwear 1400
when subjected to a cutting motion by an athlete. As an athlete
cuts laterally, forces exerted by the foot of an athlete press
against interior surface 1402 of upper 1404. As depicted, upper
1404 may deform by a distance 1406 due to the force exerted on
upper 1404 by the foot of an athlete. In some cases, this
configuration may cause less stability and traction between article
1400 and the ground. Further, an athlete may have less control due
to the deformation of article 1400.
[0137] FIG. 21 shows an exemplary embodiment of article of footwear
1200. As previously discussed, article 1200 includes a knitted
component with large floated portions which may distribute forces
through upper 1302. Additionally, the large floated portions may
direct or distribute forces such that the stretch of upper 1302 may
be limited in areas incorporating this structure. As depicted,
article of footwear 1200 may form a less elastic structure than
article 1400. The foot, in this case, may press against interior
surface 1506. In this case, however, upper 1302 may better hold its
shape than upper 1404 when subjected to a similar force. The
floated portions may limit the stretch of upper 1302 and create
channels or paths for the force to run along. The floated portions
therefore may accept or direct the forces, thereby reducing the
amount of force that may act upon other courses of the knitted
component of upper 1302. The use of large floated portions may
allow for better stability and control in areas of upper 1302 of
article 1200 than in article 1400.
[0138] FIGS. 22 and 23 illustrate a representative view of how
forces may act upon courses within a knitted component. Article
1200 as depicted in FIG. 22 includes an upper incorporating a
knitted component having multiple tensile courses that incorporate
large floated portions. A force 1600 may be exerted laterally along
the courses in the knitted component in areas of upper 1302 of
article 1200. As force 1600 acts upon the knitted component in
areas of upper 1302 article 1200, upper 1302 of article 1200 may
deform a small amount. Force 1600 may cause the tuck stitches of
technical tensile course 1201 and technical tensile course 1202 in
the knitted component incorporated into upper 1302 to flatten and
lengthen technical tensile course 1201 and technical tensile course
1202 as depicted in FIGS. 13 and 14. This action may lead to a
slight deformation of the knitted component of upper 1302 of
article 1200. As shown, the steady state formation of article 1200
depicted as a dotted line 1602, may be altered to the solid line of
article 1200.
[0139] FIG. 22 depicts article 1400 including an upper 1404
incorporating a knitted component that does not utilize tensile
courses or large floated portions. Rather, the knitted component of
article 1400 utilizes only courses formed of jersey loops. As
depicted, a force 1700 is shown acting on the knitted component
incorporated into upper 1404 in a lateral direction. Because the
knitted component incorporated into upper 1404 does not incorporate
tensile courses including large floated portions, the knitted
component of upper 1404 may deform or stretch laterally. In
comparison to article 1200 depicted in FIG. 22, article 1400 may
stretch to a greater degree. As depicted, upper 1404 of article
1400 may extend from a steady state as depicted by dotted line 1702
to the solid line of article 1400. The loops of each course in the
knitted component incorporated into upper 1404 may extend or
flatten as depicted in FIGS. 15 and 16 and therefore the size and
shape of the knitted component incorporated into upper 1404 may
deform accordingly.
[0140] The configuration of upper 1302 may result in reduced
distortion or alteration of shape as compared to upper 1404. The
knitted component in areas of upper 1302 of article 1200 includes
large floated portions particularly located to distribute forces
that may act upon upper 1302. The use of large floated portions in
the knitted component in areas of upper 1302 of article 1200 may
increase performance and durability, as well as increase a user's
comfort and feel as compared to upper 1404.
[0141] Referring to FIG. 24, a looping diagram of a portion of a
knitted component is depicted. Looping diagram 1800 depicts three
courses that may be used in the formation of a knitted component.
As depicted, looping diagram 1800 includes technical course 1802,
technical tensile course 1804 and technical course 1806. Arrow 1808
indicates the knitting direction. That is, as shown, first
technical course 1802 is formed. Technical tensile course 1804 is
formed second and interacts with technical course 1802. Technical
course 1806 is the final course formed. Technical course 1802
includes a plurality of jersey loops 1810. Each of jersey loops
1810 interacts with needles 1820, depicted in loop diagram 1800 as
dots. As shown, every needle along technical course 1802 interacts
with technical course 1802. In other embodiments, some of needles
1820 may not interact with technical course 1802. Many different
configurations of needles and loops may be used to form technical
course 1802.
[0142] As shown in looping diagram 1800, jersey loops 1810 are
formed on the front needle bed of a knitting machine. The
orientation of jersey loops 1810 indicates that they are formed on
the front needle bed. Locating the floated portion 1812 toward the
top of the diagram and the head portion 1814 toward the bottom of
the page indicates that technical course 1802 is formed on the
front bed of a knitting machine. Additionally, technical tensile
course 1804 and technical course 1806 are formed on the front
needle bed.
[0143] Referring to technical tensile course 1804, the looping
diagram notation for technical tensile course 1804 includes a tuck
stitch 1824. The symbol used to depict a tuck stitch is generally a
partial triangle. A large floated portion 1826 extends between tuck
stitch 1824 and tuck stitch 1834. As depicted, technical tensile
course 1804 does not interact with most of needles 1820. Rather,
floated portion 1826 passes along twelve of needles 1820 without
interlooping with needles 1820.
[0144] Looping diagrams similar to looping diagram 1800 may be
utilized in forming a knitted component. Looping diagrams may serve
as a consistent representation of how a knitted component may be
formed. Additionally, different variations of looping diagrams may
be utilized throughout this Detailed Description.
[0145] Knitting Machine Configuration
[0146] Although knitting may be performed by hand, commercial
manufacturing of knitted components is generally performed by
knitting machines. An example of a knitting machine capable of
producing a knitted component, including any of the embodiments of
knitted components described herein, is depicted in FIG. 25.
Knitting machine 1900 is configured as a v-bed flat knitting
machine; however, other types of knitting machines may be suitable
for construction of the knitted component. For example, a flatbed
flat knitting machine may also be utilized in some instances.
[0147] In some embodiments, knitting machine 1900 may include two
needle beds 1902. In some cases, needle beds 1902 may be angled
thereby forming a v-bed. Each needle bed 1902 contains a plurality
of individual needles 1904 that lay on a common plane. That is,
needles 1904 of one needle bed 1902 lie in one plane while needles
1904 of the other needle bed 1802 lie in a different plane. The
first plane and second plane are angled such that the intersection
of the planes extends along a majority of the width of the knitting
machine 1900. As described in further detail below, needles 1904
may have a first position where they are retracted, a second
position where they are extended, and a third position where they
are partially extended. In the first position the needles are
spaced from the intersection point. In the second position the
needles may pass through the intersection point. In the third
position the needles are located between the first position and the
second position.
[0148] A rail 1906 extends above and parallel to the intersection
of needle beds 1902. The rail may provide attachment points for
feeder 1908. The feeder 1908 may supply yarn 1910 to needles 1904
in order for the needles 1904 to manipulate yarn 1910. In addition,
another feeder 1920 may supply a second yarn 1922 to needles 1904
in order for needles 1904 to manipulate yarn 1922. Due to the
action of a carriage, feeder 1908 may move along the rail 1906 and
needle bed 1902, thereby supplying yarn 1910 to needles 1904.
Additionally, feeder 1920 may move along rail 1906 and needle bed
1902, thereby supplying yarn 1922 to needles 1904. In FIG. 25, a
yarn 1910 is provided to feeder 1908 by a spool 1912. More
particularly, yarn 1910 extends from spool 1912 to various yarn
guides 1914, a yarn take-back spring 1916 and a yarn tensioner
1918. The feeder 1908 has the ability to supply a yarn that needles
1904 may manipulate to knit, tuck and float. Some machines may have
multiple spools take back springs, and tensioners such that feeder
1920 may receive yarn 1922 and feeder 1908 may receive yarn 1910.
The multiple yarns may be utilized in the knit structure.
[0149] The manner in which knitting machine 1900 operates to
manufacture a knitted component will now be discussed in detail.
Moreover, the following discussion will demonstrate certain knit
combinations as well as gore creation.
[0150] FIGS. 26 through 31 depict a knit element in the process of
being manufactured. FIG. 26 depicts a portion of knit element 2000.
Feeder 1908 passes yarn 1910 to accepting needles 1904 which may
retract and extend to form knit element 2000. Additionally, feeder
1920 may pass yarn 1922 to needles 1904 which may retract and
extend to form knit element 2000. Needles 1904 are shown in the
retracted position. In this position needles 1904 accepted yarn
1910 and formed loops. For purposes of clarity, needles 1904 may
include fewer needles than on a typical knitting machine 1900.
Needles 1904 may include: needle 2002, needle 2004, needle 2006,
and needle 2008.
[0151] Each of the individual needles within needles 1904 may
include a hook portion 2010, arm 2012, and stem 2014. Yarn 1910 and
yarn 1922 may pass into hook portion 2010 when arm 2012 is in an
open position. Arm 2012 may be considered in an open position when
arm 2012 is pivoted away from hook portion 2010. After a loop is
formed using needles 1904, the loop may be passed out of hook
portion 2010 and onto stem 2014. Needles 1904 may move into an
extended position. As needles 1904 move, yarn 1910 and yarn 1922
may press against arm 2012, moving arm 2012 from a closed position
to an open position. The open position of arm 2012 allows the loop
of yarn 1910 to travel out of hook portion 2010, over arm 2012 and
onto stem 2014.
[0152] Additionally, in this configuration, knit element 2000
includes three technical courses. Knit element 2000 includes
technical course 2050, technical tensile course 2052, and technical
course 2054. In this configuration, technical course 2050 and
technical course 2054 may be formed using yarn 1910. Technical
tensile course 2052, by contrast, may be formed by using yarn 1922.
As shown in FIG. 26, technical tensile course 2052 and technical
course 2050 may be layered or plaited or otherwise combined such
that technical tensile course 2052 and technical course 2050 form a
single visual course. Looping diagram 2100 of FIG. 27 depicts the
looping diagram in order to show the structure of knit element 2000
as depicted in FIG. 26 in an alternate display.
[0153] Referring to FIG. 27, the knit element of FIG. 26 is
depicted in a looping diagram. Arrow 2102 indicates the knitting
direction. For example, technical course 2050 may be knit first.
Technical tensile course 2052 may be knit second and interact with
technical course 2050. Technical course 2054 may be knit last in
this configuration.
[0154] In FIG. 28, needle 2002 and needle 2008 partially extend
while needle 2004 and needle 2006 remain in the retracted position.
In the partially extended positions of needle 2008 and needle 2002,
yarn 1908 is not passed off of needle 2008 and needle 2002. In this
position, the loops on needle 2002 and needle 2002 move toward arm
2012; however the loops formed by yarn 1908 are not passed off onto
stem 2014.
[0155] In FIG. 29, feeder 1920 passes over partially extend needle
2002 and partially extended needle 2008. Feeder 1920 deposits yarn
1922 into the hook portion of needle 2002 and needle 2008. In this
configuration, needle 2002 and needle 2008 have not passed off
loops formed by yarn 1910.
[0156] FIG. 30 shows all needles 1904 in a retracted position. From
FIG. 28, needle 2002 and needle 2008 retract. In this depiction, a
fourth technical course, technical tensile course 2402 has been
formed.
[0157] FIG. 31 depicts knit element 2000 of FIG. 30 in looping
diagram 2500. As depicted, technical tensile course 2402 has been
formed after technical course 2054. Although knit element 2000
includes four technical courses in this configuration, knit element
2000 may include two visual courses. Technical course 2050 and
technical tensile course 2052 may interact as shown in FIG. 30 to
appear as a single course. Likewise, technical course 2054 and
technical tensile course 2402 make interact and interloop to appear
as a single visual course. In this configuration therefore, knit
element 2000 may appear to include two visual courses. By varying
the loops of each course, different visual effects may be
utilized.
[0158] FIG. 32 depicts needles 2004 in an extended position in
order to accept yarn 1910 from feeder 1908. Needle 2002 and needle
2008 pass of loops formed from yarn 1910 as well as loops formed
from yarn 1922. Needle 2004 and needle 2006 pass of yarn 1910.
Needle 2004 and needle 2006, however, had not previously extended
to accept yarn 1922, and therefore do not pass off yarn 1922.
[0159] Referring to FIG. 33, needles 1904 retract and interact with
yarn 1910 and form an additional course 2702. In this
configuration, knit element 2000 now includes five technical
courses, however, knit element 2000 may appear to include three
visual courses. Technical course 2050 and technical tensile course
2052 may appear as a single visual course. Technical course 2054
and technical tensile course 2402 may appear as a single visual
course. Additionally, technical course 2702 may appear as a single
visual course.
[0160] FIG. 34 includes looping diagram 2800 that depicts knit
element 2000 of FIG. 33 in a looping diagram format. As depicted,
technical course 2702 is formed after technical tensile course
2402. Technical course 2702 includes a loop at each needle
location, in contrast to technical tensile course 2402 and
technical tensile course 2052. Although the placement and layout of
each of the courses in knit element 2000 are displayed as a pattern
of tensile courses and other courses in similar configurations, it
should be recognized that various configurations of courses and
tensile courses may be utilized.
[0161] While various embodiments 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 embodiments. Accordingly, the embodiments are 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. As used in the claims, any
of when referencing the previous claims is intended to mean (i) any
one claim, or (ii) any combination of two or more claims
referenced.
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