CN108433234B

CN108433234B - Footwear upper with knitted tongue element

Info

Publication number: CN108433234B
Application number: CN201810315751.0A
Authority: CN
Inventors: 帕米拉·S·格林
Original assignee: Nike Inc
Current assignee: Nike Inc
Priority date: 2012-02-20
Filing date: 2013-02-19
Publication date: 2021-06-25
Anticipated expiration: 2033-02-19
Also published as: WO2013126314A2; EP2816924B1; WO2013126314A3; JP5950479B2; JP2015506813A; BR112014020411A2; CN108433234A; KR101668935B1; TW201350038A; EP2816924A2; CN104254260A; TWI581729B; KR20140122279A; HK1255601A1; BR112014020411B1; HK1201031A1

Abstract

The present application is directed to a footwear upper having a knitted tongue element. An article of footwear may incorporate various elements that are formed at least in part by a knitting process, such as a circular knitting process or a flat knitting process. Examples of elements include a tongue element, a collar element, and a collar-throat element. In some configurations, the element includes a compressible region and a flange region. The compressible regions may include free yarn segments that impart compressibility, and the flange regions may be used to join the component to the article of footwear.

Description

Footwear upper with knitted tongue element

This application is a divisional application of the application entitled "footwear upper with a knitted tongue element" filed as 2013, 2, 19, application No. 201380010127.5.

Cross Reference to Related Applications

This non-provisional U.S. patent application, serial No. 12/574,876, filed in the united states patent and trademark office on 10/7 Of 2009 and entitled Article Of Footwear Having An Upper With a knit element, is a continuation Of and claims priority to the non-provisional U.S. patent application serial No. 12/574,876.

Technical Field

The present application is directed to a footwear upper having a knitted tongue element.

Background

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void on the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower area of the upper and, as a result, is positioned between the upper and the ground. In athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole often includes a polymer foam material that attenuates ground reaction forces to reduce stresses on the foot and leg during walking, running, and other ambulatory activities. In addition, the midsole may include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. The outsole is secured to a lower surface of the midsole and provides the ground-engaging portion of the sole structure that is formed of a durable and wear-resistant material, typically rubber. The sole structure may further include a sockliner positioned within the void and adjacent to a lower surface of the foot to enhance footwear comfort.

The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the void on the interior of the upper is generally provided by an ankle opening in the heel region of the footwear. Lacing systems are often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet having different dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.

A variety of material elements (e.g., textiles, polymer foams, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing the upper. In athletic footwear, for example, the upper may have multiple layers that each include multiple joined material elements. As examples, the material elements may be selected to impart stretch resistance, abrasion resistance, flexibility, air-permeability, compressibility, comfort, and moisture wicking to different areas of the upper. To impart different properties to different areas of the upper, the material elements are often cut to the desired shape and then joined together, typically using stitching or adhesive bonding. Furthermore, material elements are often joined in a stacked configuration to impart multiple properties to the same area. As the number and type of material elements incorporated into the upper increases, the time and costs associated with transporting, stocking, cutting, and joining the material elements may also increase. As the number and type of material elements incorporated into the upper increases, waste material from the cutting and stitching process also accumulates to a greater extent. In addition, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from fewer types and numbers of material elements. By reducing the number of material elements utilized in the upper, waste may therefore be reduced while increasing the manufacturing efficiency and recyclability of the upper.

SUMMARY

An article of footwear is hereinafter disclosed as having an upper and a sole structure secured to the upper. The upper includes a material layer that forms at least a portion of an exterior surface of the upper. The upper also includes a knitted component formed of unitary knit construction. The knitted component may include a compressible region and a flange region. The compressible region forms a portion of the exterior surface and a portion of an opposite interior surface of the upper, and the flange region extends outward from the compressible region. The flange region may be located inwardly from the layer of material, and the flange region may engage the layer of material.

In some configurations, the upper may include a tongue element having a knitted component formed of unitary knit construction and forming a majority of an exterior of the tongue element. The compressible material may be located within a cavity of the knitted component, and an end of the knitted component may be secured to a throat area of the upper.

In another configuration, the upper may include a collar element having a braided exterior forming at least a portion of an exterior surface and an interior surface of the upper adjacent to an ankle opening of the upper. A plurality of floats may be located within the cavities of the knit element. In addition, the collar element may be formed as a separate component from and may be secured to other portions of the upper.

Various methods may be used to form components for articles of footwear. For example, circular knitting and flat knitting processes may be used to form various components of a unitary knit construction. After knitting, the component may be incorporated into an article of footwear. In addition, a braiding process may be used to form both the compressible region and the flange region of certain components. For example, the floats may be inlaid in compressible regions to enhance compressibility.

The present application provides the following:

1) a tongue element of an article of footwear, comprising a knitted component having a compressible region, a flange region extending outward from an end of the compressible region, and at least one peripheral knit structure extending outward from a side of the compressible region;

the compressible region includes a first knit layer and a second knit layer formed of unitary knit construction, wherein (a) regions of the first knit layer and regions of the second knit layer are spaced apart from one another to define a cavity within the knitted component, (b) edges of the first knit layer and edges of the second knit layer are joined to one another about at least a portion of the cavity, and (c) the at least one peripheral knit structure has a different type of knit structure than the first knit layer and the second knit layer.

2) The tongue element of claim 1), wherein the compressible region includes a plurality of free yarn sections located within the cavity.

3) The tongue element of claim 2), wherein the plurality of free yarn sections is a plurality of loops of material.

4) The tongue element of claim 2), wherein the plurality of free yarn sections are a plurality of floats.

5) The tongue element of claim 2), wherein the plurality of free yarn sections are formed of unitary knit construction with at least one of the first knit layer and the second knit layer.

6) The tongue element of claim 1), wherein the at least one peripheral knit structure includes a first peripheral knit structure extending outwardly from a first side of the compressible region and a second peripheral knit structure extending outwardly from a second side of the compressible region, the second side being disposed opposite the first side.

7) A tongue element for an article of footwear, comprising a knitted component having a compressible region and a flange region extending outward from the compressible region, the compressible region including a first knit layer and a second knit layer formed of unitary knit construction, wherein (a) regions of the first knit layer and regions of the second knit layer are spaced apart from one another to define a cavity within the knitted component, (b) edges of the first knit layer and edges of the second knit layer are joined to one another around at least a portion of the cavity, and (c) a plurality of free yarn sections are located within the cavity.

8) The tongue element of claim 7), wherein the plurality of free yarn sections is a plurality of loops of material.

9) The tongue element of claim 7), wherein the plurality of free yarn sections are formed of unitary knit construction with the first knit layer.

10) The tongue element of claim 8), wherein an additional plurality of free yarn sections are located within the cavity and are formed of unitary knit construction with the second knit layer.

11) The tongue element of claim 7), wherein the knitted component defines a flange in the flange region extending outwardly from one of the first knit layer and the second knit layer.

12) The tongue element of claim 7), wherein the knitted component defines a flange in the flange region extending outwardly from each of the first knit layer and the second knit layer.

13) The tongue element of claim 7), wherein the knitted component forms a majority of an exterior of the tongue element.

14) An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a first knitted component defining at least a portion of a void within the upper for receiving a foot, and the first knitted component defining an ankle opening to provide access to the void for a foot; and

a tongue element engaged with the first knitted component, the tongue element including:

a second knitted component formed of unitary knit construction and defining an interior cavity,

a plurality of free yarn segments located within the internal cavity, an

A peripheral knit structure extending outwardly from at least one side of the second knit component, the peripheral knit structure being formed of unitary knit construction with the second knit component and being separated from the interior cavity.

15) The article of footwear recited in 14), wherein the plurality of free yarn sections are a plurality of floats.

16) The article of footwear recited in claim 14), wherein the plurality of free yarn sections are a plurality of material loops formed of unitary knit construction with the second knitted component.

17) The article of footwear recited in claim 14), wherein the second knitted component has a compressible region and a flange region extending outward from an end of the compressible region, the compressible region defining the interior cavity, the peripheral knitted structure extending outward from at least one side of a periphery of the compressible region, and the flange region being joined to the first knitted component.

18) The article of footwear recited in claim 14), wherein the peripheral knit structure extends outwardly from opposite sides of the second knitted component and forms an edge of the tongue element.

19) The article of footwear recited in claim 14), wherein a first knit structure is incorporated in a region of the second knitted component, a second knit structure is incorporated in a region of the peripheral knit structure, and the first knit structure is different than the second knit structure.

20) The article of footwear recited in 14), wherein a first type of yarn is incorporated in a region of the second knitted component, a second type of yarn is incorporated in a region of the peripheral knit structure, and the first type of yarn is different than the second type of yarn.

21) The article of footwear recited in claim 14), wherein the perimeter knit structure is absent at one end of the tongue element.

The advantages and features of novelty characterizing aspects of the invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various configurations and concepts related to the invention.

Drawings

The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings.

Fig. 1 is a perspective view of an article of footwear.

Fig. 2 is a lateral side view of the article of footwear.

Fig. 3 is a medial side view of the article of footwear.

Fig. 4 is a top plan view of the article of footwear.

Figures 5A-5C are cross-sectional views of the article of footwear, as defined by section lines 5A-5C, respectively, in figure 4.

FIG. 6 is a perspective view of a tongue element of the article of footwear.

FIG. 7 is an exploded perspective view of the tongue element.

FIG. 8 is a plan view of the tongue element.

FIGS. 9A and 9B are cross-sectional views of the tongue element, as defined by

section lines

9A and 9B, respectively, in FIG. 8.

FIGS. 10A-10J are plan views corresponding to FIG. 8 and depicting additional configurations of the tongue element.

FIGS. 11A-11K are cross-sectional views corresponding to FIG. 9A and depicting additional configurations of the tongue element.

Fig. 12A and 12B are plan views of various engaged tongue elements.

Fig. 13 is a perspective view of a collar element of an article of footwear.

Fig. 14 is a plan view of the collar element.

Fig. 15A and 15B are cross-sectional views of the collar element, as defined by

section lines

15A and 15B, respectively, in fig. 14.

Fig. 16A-16C are plan views corresponding to fig. 14 and depicting additional configurations of collar elements.

Fig. 17A and 17B are plan views of various engaged collar elements.

FIG. 18 is a lateral side view corresponding with FIG. 2 and depicting another configuration of the article of footwear.

Fig. 19 is a perspective view of a collar-throat element of the configuration of the article of footwear depicted in fig. 18.

Fig. 20 is a plan view of the collar-throat element.

Figures 21A and 21B are cross-sectional views of the collar-throat element, as defined by

section lines

21A and 21B, respectively, in figure 20.

Fig. 22A-22D are cross-sectional views corresponding to a portion of fig. 5C and depicting various methods of incorporating a collar element into an article of footwear.

Fig. 23 is a plan view of another element.

FIG. 24 is a plan view of a tongue-vamp element.

FIG. 25 is a cross-sectional view corresponding with FIG. 5A and depicting a tongue-vamp element in the article of footwear.

FIG. 26 is a cross-sectional view corresponding with FIG. 5C and depicting another configuration of the article of footwear.

Fig. 27A and 27B are plan views of another collar element.

FIGS. 28A and 28B are cross-sectional views corresponding to FIG. 9A and depicting additional configurations of the tongue element.

FIG. 29 is a perspective view of another tongue element.

FIG. 30 is a cross-sectional view of the tongue element depicted in FIG. 29, as defined by section line 30 in FIG. 29.

FIG. 31 is a cross-sectional view corresponding to FIG. 30 and depicting another configuration of the tongue element depicted in FIG. 29.

Fig. 32 is a lateral side view of another arrangement of an article of footwear.

Figure 33 is a cross-sectional view of the article of footwear depicted in figure 32, as defined by section line 33 in figure 32.

Fig. 34 is a top plan view of a knitted component forming a portion of an upper of the article of footwear depicted in fig. 32.

Fig. 35 is a lateral side view of another arrangement of an article of footwear.

Figure 36 is a cross-sectional view of the article of footwear depicted in figure 35, as defined by section line 36 in figure 35.

Figure 37 is a top plan view of a knitted component forming a portion of an upper of the article of footwear depicted in figure 35.

Detailed Description

The following discussion and accompanying figures disclose an article of footwear having an upper that includes various knit elements, such as a tongue and collar. An article of footwear is disclosed as having a general configuration suitable for walking or running. Concepts associated with the footwear, including the upper and various knitted elements, may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking shoes, for example. Concepts may also be applied to footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, slippers, sandals, and work boots. Accordingly, the concepts disclosed herein with respect to knit elements and methods of manufacturing knit elements are applicable to a variety of footwear types.

General footwear construction

Article of footwear 10 is depicted in figures 1-5C as including a sole structure 20 and an upper 30. For reference purposes, footwear 10 may be divided into three general regions: forefoot region 11, midfoot region 12, and heel region 13, as shown in fig. 2 and 3. Footwear 10 also includes a lateral side 14 and a medial side 15. Forefoot region 11 generally includes portions of footwear 10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 12 generally includes portions of footwear 10 corresponding with the arch area of the foot, and heel region 13 corresponds with the heel area of the foot, including the calcaneus bone. Lateral side 14 and medial side 15 extend through each of regions 11-13 and correspond with opposite sides of footwear 10. Regions 11-13 and sides 14-15 are not intended to demarcate precise areas of footwear 10. Rather, regions 11-13 and sides 14-15 are intended to represent general areas of footwear 10 to aid in the following discussion. In addition to footwear 10, regions 11-13 and sides 14-15 may also be applied to sole structure 20, upper 30, and individual elements thereof.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when footwear 10 is worn. The primary elements of sole structure 20 are a midsole 21, an outsole 22, and a sockliner 23. Midsole 21 is secured to a lower area of upper 30 and may be formed from a compressible polymer foam member (e.g., 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 further configurations, midsole 21 may incorporate a fluid-filled chamber, plate, moderator or other element that further attenuates forces, enhances stability, or affects the motion of the foot, or midsole 21 may be primarily formed from a fluid-filled chamber. Outsole 22 is secured to a lower surface of midsole 21 and may be formed of a wear-resistant rubber material that is textured to impart traction. Sockliner 23 is positioned within upper 30 and is positioned to extend under a lower surface of the foot. While this configuration for sole structure 20 provides an example of a sole structure that may be used in conjunction with upper 30, a variety of other conventional or non-conventional configurations for sole structure 20 may also be utilized. Accordingly, the configuration and features of sole structure 20, or any sole structure utilized with upper 30, may vary widely.

Upper 30 is formed from various elements that are combined to provide a structure for securely and comfortably receiving a foot. Although the configuration of upper 30 may vary significantly, the various elements generally define a void within footwear 10 for receiving and securing a foot relative to sole structure 20. The surface of the void within upper 30 is shaped to receive the foot and extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. A portion of upper 30 is formed from

various layers

31 and 32, as depicted in figures 5A-5C. Layer 31 forms a portion of an exterior surface of upper 30, and layer 32 forms a portion of an interior surface of upper 30 (i.e., the surface that defines the void within upper 30). Each of

layers

31 and 32 may be formed from one or more of a plurality of material elements (e.g., fabric, polymer foam, leather, synthetic leather) that are stitched or otherwise bonded together. As one example, layer 31 may be formed of a synthetic leather material, while layer 32 may be formed of a moisture-wicking textile material. As another example, each of

layers

31 and 32 may be formed from a different fabric material. In some configurations, a polymer foam layer may be positioned between

layers

31 and 32 to enhance comfort. In other configurations of upper 30, a single, triple, or other multi-layer structure formed from multiple materials may be utilized in place of

layers

31 and 32.

A lace 33 extends through various lace apertures 34 and through a throat area of upper 30 to allow the wearer to modify dimensions of upper 30 and accommodate proportions of the foot. That is, lace 33 operates in a generally conventional manner to tighten upper 30 around the foot (i.e., when lace 33 is tied) and loosen upper 30 (i.e., when lace 33 is untied). Tongue element 40 extends under lace 33 to enhance the comfort and adjustability of footwear 10. Upper 30 also includes a collar element 50 located in at least heel region 13. In addition to enhancing the comfort of footwear 10, collar element 50 forms an ankle opening that provides access to the void within upper 30 for the foot. That is, the ankle opening defined by collar element 50 facilitates entry and removal of the foot from the void, particularly when lace 33 is untied to impart a loose-fitting configuration to upper 30 around the foot.

Portions of upper 30, including tongue element 40 and collar element 50, may be a knitted component formed using a relatively small number of material elements. As discussed above in the background section, reducing the number of material elements utilized in the upper may reduce waste, while also increasing manufacturing efficiency and recyclability of the upper. The tongue and collar of conventional uppers are often formed from multiple joined material elements. However, as discussed in more detail below, the tongue element 40 and collar element 50 may be formed primarily by a knitting process (rather than a stitching and turning process) that reduces waste and increases manufacturing efficiency and recyclability. In addition, the tongue element 40 and collar element 50 configurations may incorporate a smaller number of seams or other discontinuities, thereby enhancing the overall comfort of footwear 10.

Tongue element arrangement

Tongue element 40 is centrally located in the throat area of upper 30 and extends from forefoot region 11 to heel region 13, and from lateral side 14 to medial side 15. Lateral regions of tongue element 40 are positioned adjacent to and in contact with regions of layer 32 that form lace apertures 34, and a central region of tongue element 40 is in contact with lace 33 and may be exposed between regions of lace 33 that cross each other. In forefoot region 11, tongue element 40 is joined to

layers

31 and 32, but the remainder of tongue element 40 is generally free or unsecured to other areas of upper 30. In heel region 13, tongue element 40 may protrude from an ankle opening formed by collar element 50.

The primary components of tongue element 40, as depicted in FIGS. 6-9B, are a braided sock 41 and a compressible core 42. Typically, the sheath 41 is formed as a braided element extending around the core 42. More specifically, the sock 41 forms a majority of the exterior of the tongue element 40 and also defines an interior cavity in which the core 42 is located. Core 42 is a compressible structure within tongue element 40 that enhances the overall comfort of footwear 10. While the core 42 may be formed from a polymer foam material (e.g., polyurethane or ethylvinylacetate foam), the core 42 may also be formed from, for example, yarns or fluid-filled chambers. In some configurations, tongue element 40 may include additional features such as (a) a logo or trademark that is screen printed, stitched, or otherwise bonded to sheath 41, (b) a lace loop that receives a portion of lace 34 to limit movement of tongue element 40, or (c) care instructions and material labels that are stitched or otherwise bonded to sheath 41.

The sheath 41 has a generally tubular structure forming a cavity in which the core 42 is located. Generally, the sheath 41 includes an upper region 43, a lower region 44, a first end 45, a second end 46, and a pair of flanges 47. Upper region 43 extends across one surface of core 42 and is exposed to the exterior of footwear 10 between the areas of lace 33 that intersect one another. Lower region 44, which is positioned relative to upper region 43, extends across another surface of core 42 and forms a portion of an interior surface of upper 30 (i.e., the surface that defines the void within upper 30). Referring to fig. 9A and 9B, for example,

regions

43 and 44 effectively form layers of woven material on opposite sides of core 42 and joined to one another, thereby effectively extending around core 42. The first end 45 has a closed configuration, while the second end 46 forms an opening through which the core 42 is inserted into the cavity within the sheath 41. A flange 47 is located at the second end 46 and on the opposite side of the opening. Flanges 47 extend outward from tongue element 40 and may be used to join tongue element 40 to upper 30. For example, referring to FIG. 5A, flange 47 extends between

layers

31 and 32 in the throat area of upper 30 and is secured to one or both of

layers

31 and 32. Although each of

regions

43 and 44 includes one of flanges 47, jacket 41 may form only a single flange 47, or may not have two flanges 47 in certain configurations.

While many conventional footwear tongues have a sock formed of multiple textile elements or other material elements joined by stitching or bonding, for example, the sock 41 is formed as a one-piece element by a knitting process, such as by circular knitting or flat knitting. More specifically, the sheath 41 is typically formed of unitary braided construction through a braiding process. As utilized herein, a knitted component, such as sheath 41, is defined as being formed of a "unitary knit construction" when constructed as a single piece knit element substantially free of additional stitching or bonding processes. That is, the braiding process essentially forms the various features and structures of the sheath 41 without the need for significant additional manufacturing steps or processes. In some configurations, jacket 41 remains formed of unitary knit construction when either first end 45 or second end 46 is closed by stitching or bonding to seal core 42 within jacket 41, or when the regions are trimmed after the knitting process. In addition, the sheath 41 remains formed of unitary knit construction when other small elements (e.g., logos, trademarks, lace loops, care instructions, and material tags) are added to the tongue element 40 after the knitting process.

The knitting process of the sheath 41 utilized to form the unitary knit construction typically involves mechanically manipulating one or more yarns to form a series of stitches (stich). A variety of different types of yarns may be incorporated into the jacket 41 during the knitting process. For example, polyester provides relatively high durability and recyclability, and may also impart non-stretch properties, depending on the weave pattern within the jacket 41. Cotton provides a soft hand, natural aesthetics, and biodegradability. The elastase and the stretched polyester each provide great stretch and recyclability, with the stretched polyester also providing relatively easy recyclability. Rayon provides high gloss and moisture absorption. Wool also provides high moisture absorption, as well as insulating properties. Nylon is a durable and abrasion resistant material with relatively high strength. In addition to the specific materials, other aspects about the yarn may affect the properties of the sock 41 and tongue 40. For example, the yarns may be monofilament or multifilament yarns. The yarn may also include separate filaments each formed of a different material. The yarn may also include filaments that are each formed of two or more different materials, such as a bicomponent yarn having filaments with a sheath-core configuration or two halves formed of different materials. Different degrees of twisting and crimping, as well as different deniers, may affect the properties of the sock 41 and tongue 40. The yarns may also retain a desired shape when formed from a material susceptible to heat setting. Accordingly, various types of yarns may be incorporated into sock 41, depending on the desired properties for sock 41 and tongue 40.

The tongue element 40 provides various advantages over conventional footwear tongues. For example, tongue element 40 may enhance footwear comfort by incorporating several seams or other discontinuities in the foot-contacting area. As another example, the tongue element 40 includes relatively few material elements. As discussed above in the background section, by reducing the number of material elements utilized in the upper, waste may be reduced while increasing manufacturing efficiency and recyclability of the upper. To further enhance efficiency, forming the sheath 41 by a braiding process limits the number of cutting operations or other processes that typically generate waste material, while allowing the creation of profiles that are relatively difficult with stitching and flipping methods.

Additional tongue element arrangement

The configuration of tongue element 40 discussed above provides examples of suitable configurations for footwear 10 and various other types of footwear. However, the tongue element 40 may incorporate a variety of other features. Whether the sock 41 is formed by circular knitting or flat knitting, the overall shape of the tongue element 40 may vary significantly. For example, fig. 10A depicts a configuration in which the tongue element 40 has a greater length and a lesser width than the configuration from fig. 6-8, while fig. 10B depicts a configuration in which the tongue element 40 has a lesser length and a greater width. Referring to FIG. 10C, the tongue element 40 has side areas with indentations. Another configuration is depicted in FIG. 10D, in which the tongue element 40 is tapered to impart a generally triangular shape. Further, the tongue element 40 may exhibit a generally diamond-shaped configuration, as depicted in FIG. 10E. Referring to fig. 10F, the sheath 41 may also be absent the flange 47.

A variety of methods may be used to impart the various shapes depicted in fig. 6-8 and 10A-10F. For example, a circular knitting process or a flat knitting process used to form the sheath 41 may impart any of a variety of shapes. That is, the knitting machine may be programmed to mechanically manipulate the yarns to form stitches that combine to impart any of the various shapes discussed above as well as numerous other shapes. As another example, a stretcher form (stretcher form) may be placed within a cavity in the sheath 41, and upon application of heat or steam, the stretcher form may modify the overall shape of the sheath 41. Further, the shape of the core 42 may be varied to impart different shapes to the sheath 41. One advantage of utilizing different shapes for the shank form or core 42 is that multiple sheaths 41 may be formed with substantially the same shape, and the shank form or differently shaped core 42 may be used to impart a shape to tongue 40 that is suitable for footwear having various sizes or for different types of footwear.

The configuration of the sheath 41 depicted in fig. 6-8 incorporates a single type of yarn and a single stitch type. That is, the sheath 41 has a substantially continuous configuration in which the properties imparted by the yarn and stitch type are substantially the same throughout various areas of the sheath 41. The properties of the various regions may be modified by varying one or both of the yarn and stitch types utilized in the various regions of the sheath 41. The yarn and stitch types may vary, and thus, to impart different properties to different areas of the tongue 40. Further, both circular knitting and flat knitting allow for selection of combinations of yarn and stitch types for various regions of the sheath 41, thereby allowing selection of properties of the regions based on comfort or performance characteristics.

As discussed above, the sheath 41 may incorporate various yarn and stitch types. As one example, the sheath 41 is depicted in fig. 10G as having two regions formed from different types of yarns. The area adjacent to the first end 45 is formed from one type of yarn and the area adjacent to the second end 46 is formed from another type of yarn. One region may incorporate elastase to enhance stretching, while another region may incorporate nylon to enhance abrasion resistance and durability. Similarly, one zone may incorporate yarns having one denier while another zone may incorporate yarns having a greater denier to enhance caliper or bulk. As another example, the stitch type may vary between zones, as depicted in fig. 10H. The area adjacent to first end 45 includes stitches that impart a relatively non-textured configuration, while the area adjacent to second end 46 has a textured configuration that may impart stretch or a different aesthetic quality. The type of yarn utilized in the different regions of fig. 10H may also be varied to further enhance or vary the properties of the tongue 40. As a matter of concern, the density of the weave within the sheath 41 may vary between zones to create, for example, a less permeable or stiffer portion. Accordingly, jacket 41 may exhibit various properties in separate zones depending on the particular yarns and weave types selected with respect to the zones.

The yarns and weave types may also be varied to enhance aspects related to assembling footwear 10. Referring to fig. 10I, the sheath 41 exhibits a ribbed configuration around the opening at the second end 46. This ribbed configuration may stretch to allow insertion of the core 42, and then the ribbed configuration may contract to ensure that the core 42 remains properly positioned within the sheath 41. The braid type may also form various holes in the sheath 41, as depicted in fig. 10J. In addition to imparting greater permeability that allows air to circulate within upper 30, the apertures may increase both flexibility and stretch of tongue 40. As further examples, other properties that may be varied by selecting the particular yarn and weave type used for the sheath 41 include permeability to liquids, the direction in which the sheath 41 stretches or resists stretching, and the stiffness of the sheath 41.

The overall configuration of the core 42 may also vary, depending on various factors, including the size and type of footwear into which the tongue 40 is being incorporated. For example, the thickness, length, and width of the core 42 may be modified. Referring to fig. 11A, the core 42 assumes a tapered configuration. The core 42 may also be contoured, as depicted in fig. 11B. In some configurations of the tongue 40, the core 42 may be formed from two separate elements (e.g., foam elements having different densities), as depicted in FIG. 11C. In a similar configuration, the core 42 may be formed from two overlapping elements (e.g., foam elements having different densities), as depicted in fig. 11D, which imparts greater thickness and profile. While foam elements may be utilized as the core 42, various other materials may also be utilized. Referring to FIG. 11E, the various floats are located within the cavity formed by the jacket 41. As described in more detail below with respect to collar element 50, the flat knitting process may position floats within cavities formed between the knit layers. Referring to fig. 11F, the ends are cut from the yarn in a circular knitting process, e.g., to provide material for the core 42. Similarly, loops of yarn similar to those in the fluff material may provide the material for the core 42. In some configurations, core 42 may also be formed from a fiber mat made from recycled fabric and yarn materials utilized in other areas of upper 30, or core 42 may be a fluid-filled bladder.

Although the sheath 41 may be formed of a unitary braided construction, the sheath 41 may also be formed of joined elements, each formed by a braiding process. Referring to fig. 11G, sheath 41 includes a first knit element adjacent first end 45 and a second knit element extending from the first knit element to second end 46, and the knit elements are joined by stitching. In some configurations, the stitches may extend completely through the tongue 40, as depicted in fig. 11H, to impart contours or other features to the tongue 40. While the second end 46 may have an open configuration for insertion of the core 42, a flap may be formed in the lower region 44, as depicted in fig. 11I, for insertion of the core 42. As set forth above, other elements including lace loops may be added to the sheath 41, as depicted in fig. 11J. As an alternative, the lace loops may be formed of unitary knit construction with the sock 41 during the flat knitting process, as depicted in fig. 11K.

Based on the discussion above, various features of the sock 41 and core 42 may be varied to impart different properties to the tongue 40. As discussed, the overall shape of sock 41 may vary depending on the type of footwear or size of footwear into which tongue 40 is incorporated. In some configurations, the yarn and/or stitch type may also vary between different regions of the sheath 41 to impart different properties. The core 42 may also have a variety of shapes or may be formed from various types of elements.

Knitting process

Various knitting processes including circular knitting and flat knitting may be used to manufacture the sheath 41. Circular knitting is a form of knitting that creates a seamless tube, which is effectively in the form of a sheath 41. Various knitting machines may be used to form the jacket 41 to have a circular knit structure. For example, specialized sock knitting machines use separate latch-hook needles to make each stitch in a circular frame. Depending on the type of circular knitting machine utilized, first end 45 may be closed as part of the knitting cycle, or an additional finishing step may be performed to close first end 45. Flat knitting is a method for producing a knitted material that is periodically turned over (i.e., the material is knitted from alternating sides). The two sides of the material (otherwise referred to as faces) are conventionally designated as the correct side (i.e., the side facing outwardly toward the viewer) and the wrong side (i.e., the side facing inwardly away from the viewer).

Advantageously, both circular knitting and flat knitting may be used to form the jacket 41 to have, for example, (a) various yarn types that impart different properties to separate regions of the jacket 41, and (b) various knitting types that impart different properties to separate regions of the jacket 41. While each of the circular knitting and the flat-bed knitting may be used to make many configurations of the sock 41, the flat-bed knitting may be used to add additional features to the tongue 40, including (a) positioning the floats within the sock 41 to form the core 42, as in FIG. 11D, and (b) overlapping knit layers that form the lace loops of the unitary knit construction, as in FIG. 11I.

While many of the edges of the textile elements incorporated into footwear tongues are cut to expose the ends of the yarns forming the textile elements, sock 41 may be formed to have a trimmed configuration when manufactured by circular knitting or flat knitting. That is, a circular knitting or a flat knitting may be used to form the sheath 41 such that the ends of the yarn within the sheath 41 are substantially absent at the edges of the sheath 41. One advantage of the trimmed configuration is that the yarns forming the edges of the jacket 41 are less likely to unravel and fewer trimming steps are necessary after the jacket 41 is manufactured. By forming the trimmed edges, the integrity of the jacket 41 is enhanced and fewer or no post-processing steps are required to prevent unraveling. In addition, loose yarn is less likely to inhibit the aesthetic appearance of the tongue 40. In other words, the tailored configuration of the sock 41 may enhance the durability and aesthetic qualities of the tongue 40, while increasing manufacturing efficiency.

A circular knitting machine and a flat knitting machine may be used to form the respective sheaths 41. To enhance manufacturing efficiency, a braiding machine may also be used to form a series of joined sheaths 41, as depicted in fig. 12A and 12B. That is, the braiding machine may form a single component comprising multiple sheaths 41. Referring to fig. 12A, each of the sheaths 41 may have substantially the same shape and size. Alternatively, each of the sheaths 41 may have a different shape and size, as depicted in fig. 12B. Further, the braided release regions may be braided into a series of sheaths 41 to allow various sheaths 41 to be separated without requiring a cutting operation.

Collar element arrangement

Collar element 50 extends around heel region 13 and extends from lateral side 14 to medial side 15 to form an ankle opening for providing the foot with access to the void within upper 30. The collar element 50 depicted in fig. 13-15B, respectively, is formed of two overlapping and at least partially coextensive layers of knit material enclosing a plurality of floating yarns 53, specifically an outer layer 51 and an opposing inner layer 52. While the edges of

layers

51 and 52 are secured to one another in a seamless manner (i.e., having a unitary knit construction) by the knitting process, the central region between

layers

51 and 52 is generally not secured to one another to form a cavity in which floats 53 are located. Accordingly, the layers of woven material effectively form a tube or tubular structure, and the floats 53 may be located or laid between the

layers

51 and 52 and oriented substantially parallel to the surfaces of the

layers

51 and 52. That is, the floats 53 extend between the

layers

51 and 52 and also pass through and fill the internal cavity between the

layers

51 and 52. Although the

layers

51 and 52 are formed from yarns that are mechanically manipulated (e.g., by a flat knitting machine knitting process), the floats 53 are generally free or otherwise laid within the cavity between the

layers

51 and 52 during the knitting process.

Exterior layer 51 forms a portion of the exterior surface of upper 30 in the area of the ankle opening, while interior layer 52 forms a portion of the interior surface of upper 30 (i.e., the surface that defines the void within upper 30). In the upper region of collar element 50, layers 51 and 52 are joined to one another seamlessly. Similarly, layers 51 and 52 are joined to one another seamlessly in the lower area of collar element 50. In addition, flanges 54 extend outwardly from

layers

51 and 52 and are utilized to join collar element 50 to the remainder of upper 30. More specifically, the flange 54 extends between the

layers

31 and 32 and is secured to one or both of the

layers

31 and 32, as depicted in fig. 5A and 5C.

The presence of floating yarns 53 imparts a compressible characteristic to collar element 50, thereby enhancing the comfort of footwear 10 in the area of the ankle opening. Many conventional articles of footwear incorporate polymer foam elements or other compressible materials into the collar area. In contrast to conventional articles of footwear, collar element 50 utilizes floating yarns 53 to provide a compressible structure. In some configurations, foam elements or other fiberizing elements (e.g., floats and cut ends of yarns) may be located within collar element 50 and may replace floats 53.

Any of the various types of yarns discussed above with respect to sheath 41 may also be used in collar element 50. In some configurations, the yarns utilized in

layers

51 and 52 may be the same as the yarns used for floats 53, or a different type of yarn may be used for floats 53. As with sheath element 41, collar element 50 may be formed with different yarns in various regions or different stitch types in various regions.

The collar element 50 may be formed by a flat knitting process to have an integral knit construction. Accordingly, collar element 50 is constructed as a single piece of knit element substantially free of additional stitching or bonding processes. That is, the knitting process essentially forms the various features and structures of collar element 50 without the need for significant additional processing. As discussed above, flat-bed knitting may be used to form collar element 50 to have, for example, (a) various yarn types that impart different properties to respective regions of collar element 50, and (b) various knit types that impart different properties to respective regions of collar element 50. Flat knitting may also be used to incorporate additional features into collar element 50, including (a) forming the tubular structures of

layers

51 and 52, (b) forming flange 54 to extend seamlessly outward from the tubular structures of

layers

51 and 52, and (c) positioning floating yarns 53 between

layers

51 and 52.

As another fact, when manufactured by flat knitting machine knitting, collar element 50 may be formed to have a trimmed configuration. That is, flat knitting may be used to form collar element 50 such that there are substantially no ends of yarn at the edges of collar element 50. As with the sheath 41, one advantage of the trimmed configuration is that the yarn is less likely to unravel and requires fewer trimming steps after manufacture. By forming the finished edge, the integrity of collar element 50 is enhanced and fewer or no post-processing steps are required to prevent unraveling. In addition, loose yarns are less likely to inhibit the aesthetic appearance of collar element 50.

The particular shape of collar element 50 in fig. 13 and 14 is intended to provide an example of a shape that is suitable for footwear 10. A variety of other shapes may be utilized. As one example, fig. 16A depicts a more contoured configuration. As a further example, fig. 16B and 16C depict a simpler collar profile that may be incorporated into a variety of footwear styles.

A flat knitting machine may be used to form the individual collar elements 50. To enhance manufacturing efficiency, the knitting machine may also be used to form a series of joined collar elements 50, as depicted in fig. 17A and 17B. That is, the knitting machine may form a single component that includes multiple collar elements 50. Referring to fig. 17A, each of collar elements 50 may have substantially the same shape, but be adapted to different sizes of footwear 10. Alternatively, each of collar elements 50 may have a different shape and size, as depicted in fig. 17B. The knit release region may be knit into a series of collar elements 50 to allow multiple collar elements 50 to be separated without requiring a cutting operation. More specifically, release lines 55 positioned in the release areas during the knitting process may extend between the plurality of collar elements 50. By pulling or otherwise removing release wire 55, collar element 50 may be separated without cutting or other manufacturing steps. Similar release wires may be used to separate the various sheaths depicted in fig. 12A and 12B.

Collar-throat element

Another configuration of footwear 10 is depicted in fig. 18 as including collar-throat element 60, collar-throat element 60 extending at least partially around the ankle opening and also extending into the throat area of footwear 10, which defines various lace apertures 34 on lateral side 14. A similar collar-throat element may also be located on medial side 15. Collar-throat element 60 is similar in construction to collar element 50 and includes an outer layer 61, an opposing inner layer 62, a plurality of floating yarns 63, and a flange 64. Although the edges of

layers

61 and 62 are secured to each other, the central area between

layers

61 and 62 is generally not secured to each other to form a cavity in which floats 63 are located. Accordingly, the layers of woven material effectively form a tube or tubular structure, and the floats 63 may be located or rest between the

layers

61 and 62.

Although exterior layer 61 forms a portion of the exterior surface of upper 30 in the area of the ankle opening, interior layer 62 forms a portion of the interior surface of upper 30 (i.e., the surface that defines the void within upper 30). In the upper area of collar element 50, layers 61 and 62 are joined to one another seamlessly. Similarly, layers 61 and 62 are joined to one another seamlessly in the lower area of collar-throat element 60. In addition, flange 64 extends outwardly from

layers

61 and 62 and serves to join collar-throat element 60 to the remainder of upper 30. As with collar element 50, flange 64 may extend between

layers

31 and 32 and be secured to one or both of

layers

31 and 32. Flange 64 extends into the throat area and defines various lace apertures 34. A portion of flange 64 adjacent lace apertures 34 may also extend between

layers

31 and 32 and be secured to one or both of

layers

31 and 32.

Collar-throat element 60 may be formed by a flat knitting process to have a unitary knit construction, and may also be formed to have a trimmed configuration. Further, any of the various yarn types or stitch types discussed above may also be utilized in collar-throat element 60. The particular shape of collar-throat element 60 in fig. 19 and 20 is intended to provide an example of a shape that is suitable for footwear 10. In the configuration depicted in fig. 19 and 20, collar-throat element 60 is constrained to lateral side 14, and another element may be utilized on medial side 15. However, in other configurations, a single collar-throat element 60 may extend around heel region 13 to form ankle openings on both

sides

14 and 15, and single collar-throat element 60 may extend through the throat area on both

sides

14 and 15 to form each of lace apertures 34. A variety of other shapes may also be utilized. Like sheath 41 and collar element 50, the braiding machine may form a single component including a plurality of engaged collar-throat elements 60 to increase manufacturing efficiency.

Another element 70 is depicted in FIG. 23 as a combination of the tongue element 40 and collar-throat element 60. While flat-bed knitting and circular knitting may be used to form discrete and relatively small areas of upper 30 (i.e., the areas formed by tongue element 40, collar element 50, and collar-throat element 60), the knitting process may also be used to form larger areas having a unitary knit construction. As another example, tongue-vamp element 80 is depicted in fig. 24. Tongue-vamp element 80 includes a tongue region 81 and a vamp region 82 formed of unitary knit construction. For example, tongue region 81 may have the general configuration of tongue element 40, while vamp region 82 may be a single layer of material. When incorporated into footwear 10, vamp region 82 may form an interior lining, as depicted in fig. 25. In addition, a portion of vamp region 82 may be exposed through apertures in

layers

31 and 32. Although vamp region 82 may be formed to exhibit a single type of knit construction or may have a variety of knit constructions. For example, the areas exposed by the apertures in

layers

31 and 32 may define various apertures to enhance breathability.

Footwear combination

Each of tongue element 40, collar element 50, and collar-throat element 60 includes a compressible region and a flange region. In general, the compressible regions form a comfortable structure that may be supported on the foot, while the flange regions are used to engage elements with footwear 10 (e.g., by engaging between layers 31 and 32). With respect to the tongue element 40, the compressible region includes the portion of the tongue element 40 where the core 42 is located, and the flange region includes two flanges 47. With respect to collar element 50, the compressible region includes

layers

51 and 52 and floating yarns 53, and the flange region includes flange 54. Similarly, and with respect to collar-throat element 60, the compressible region includes

layers

61 and 62 and floats 63, and the flange region includes flange 64. In each or these elements, the

various flanges

47, 54, and 64 extend outward from the compressible area and are positioned inward from one of the material layers forming upper 30 (i.e., layer 31), and the

various flanges

47, 54, and 64 are joined to that material layer or another portion of upper 30.

Referring to fig. 5A and 5C, flange 47 from tongue element 40 and flange 54 from collar element 50 are positioned between

layers

31 and 32 and joined to at least one of

layers

31 and 32. In other configurations,

flanges

47 and 54 may be joined to an upper formed from a single layer or may be joined to an upper formed from multiple layers. For example, fig. 22A depicts a configuration in which collar element 50 is joined to an area of upper 30 that includes only layer 31. Although flange 54 may be engaged inward from a material layer, such as layer 32, to upper 30, fig. 22B depicts a configuration in which collar element 50 is engaged with an exterior of layer 31. Fig. 22C depicts a configuration in which collar element 50 is joined to the area of upper 30 in which central layer 35 is present and flange 54 is positioned between

layers

32 and 35. In another configuration depicted in fig. 22D, collar element 50 includes two compressible regions at which floating yarns 53 are present, and one of the compressible regions is exposed through an aperture in layer 31. Similar concepts may be applied to the manner in which tongue element 40 and collar-throat element 60 engage other areas of upper 30. In another configuration depicted in fig. 26, flange 54 from collar element 50 extends along an interior surface of the void within upper 30 to form a continuous lining. Accordingly, the manner in which flanges 47, 54, and 64 are used to couple elements to an article of footwear may vary significantly.

When knitting collar-throat element 60, opposite sides of

layers

61 and 62 and flange 64 may be symmetrically knit and of the same quality. When formed in this manner, collar-throat element 60 may be used on either lateral side 14 or medial side 15. That is, collar-throat element 60 may have symmetrical features that allow it to be incorporated into either side of footwear 10, thereby reducing the types of elements manufactured for use in footwear 10.

One additional advantage of forming knit elements to have opposite sides of the same quality is that the respective elements may be incorporated into the style of footwear 10 for either the right foot or the left foot. With reference to fig. 27A and 27B, for example, the opposite side of another collar element 80 is depicted. Collar element 80 is similar to collar element 50 and has (a) a lateral portion 81 that is intended to extend into lateral side 14 of footwear 10, and (b) a medial portion 82 that is intended to extend into medial side 15 of footwear 10.

Portions

81 and 82 are shaped differently and give collar element 80 the asymmetrical character adapted to

sides

14 and 15. However, the opposite sides or faces of collar element 80 are symmetrical and of the same quality. When incorporated into footwear 10, the outwardly facing side depends on whether footwear 10 is shaped for a right foot or a left foot. That is, one side (i.e., the side depicted in fig. 27B) will face outward when incorporated into footwear 10 for the right foot, and the opposite side (i.e., the side depicted in fig. 27A) will face outward when incorporated into footwear 10 for the left foot. Thus, the same collar element 80 may be incorporated into footwear 10 for both the right and left feet, depending on which side faces outward. One advantage of this configuration is that the types of elements manufactured for use in different versions of footwear 10 are reduced.

To assist in incorporating a knit element into footwear 10, registration marks may be knit into the element. That is, yarns having different colors or different types of stitches may be woven into the element to form the registration mark. As one example, element 70 includes a centrally located registration flag 71, as depicted in FIG. 23. Registration marks 71 may be used when incorporating element 70 into footwear 10 to ensure that element 70 is centrally located and properly aligned with other elements. Similar registration marks may be used for tongue element 40 (i.e., on flange 47), collar element 50, and collar-throat element 60.

Tongue element for receiving loops of material

The tongue element may incorporate any of a variety of free yarn sections. One benefit of incorporating the free yarn sections into the tongue element is that a compressible or padded area of the tongue element is formed thereby. For purposes of this application, a "free yarn section" or variation thereof is defined as a segment or portion of a yarn that does not directly form interdigitated loops (e.g., loops defining courses and wales), such as floats, inlaid yarns, loops, ends of yarns, and cut segments of yarn.

In various configurations, and referring to fig. 11E and 11F, respectively, the free yarn segments may be various floats within the cavity formed by the jacket 41, or cut ends from the yarn in a circular knitting process. Further, in some configurations, the free yarn segments may be loops of yarn similar to those in the material of the pile providing the material for the core 42. Such loops may be part of the woven structure and may extend outwardly from the sections of yarn that define the course and striations of the woven structure.

For example, a plurality of loops 48 of material may be located within the interior cavity defined by the jacket 41 and may form part or all of the core 42. The plurality of material loops 48 may extend through substantially all of the tongue element 40 to form substantially all of the core 42, as depicted in fig. 28A. Alternatively, as depicted in fig. 28B, the plurality of material loops 48 may extend through a portion of the tongue element 40 to form a portion of the core 42, and another portion 49 of the core 42 may include any of a variety of elements formed from other materials, including polymer foam materials, yarns, fluid-filled chambers, and fiber mats.

The loop of material 48 may be formed of unitary, braided construction with the upper region 43 of the sheath 41, with the lower region 44 of the sheath 41, or both. That is, the loop of material 48 may be formed during the knitting process that forms the jacket 41. Furthermore, the loops of material 48 may also be formed from the same yarn as the rest of the sheath 41. Further, substantially all of the loop of material 48 may be located within an interior cavity defined by the sheath 41, although some loops of material 48 may be located on an exterior surface of the sheath 41 in some configurations.

Some tongue elements may include a knitted sock member as well as other knitted structures. For example, as depicted in fig. 29 and 30, tongue element 140 includes a braided sock 141 and a compressible core 142. The sheath 141 is formed as a braided element extending around the core 142. More specifically, the sock 141 forms a substantial portion of the exterior of the tongue element 140 and also defines an interior void in which the core 142 is located. Core 142 is a compressible structure within tongue element 140 that enhances the overall comfort of footwear 10. . The core 142 is depicted as being formed from a loop 148 of material. However, in certain configurations, the core 142 may be at least partially formed from other free yarn segments or other materials, including polymer foam materials, fluid-filled chambers, and fiber mats. Accordingly, the tongue element 140 may incorporate various structural features of the tongue element 40.

In contrast to tongue element 40, tongue element 140 includes two peripheral knit structures 150 extending outwardly from portions of the periphery of sock 141. More specifically, peripheral knit structure 150 may extend outwardly from opposite sides of sock 141 to form opposite edges of tongue element 140, and may include peripheral bond 151. In this configuration, the peripheral braided structure 150 is of a different type of braided structure than the sheath 141 and does not form part of the internal cavity in which the core 142 is located. That is, tongue element 140 may be formed to have regions with different types of knit structures. In other configurations, as depicted in fig. 31, peripheral knit structure 150 may not be present in different areas of tongue element 140. In addition, different areas of the tongue element 140 may also be formed from different types of yarns. Accordingly, tongue element 140 may be formed to have regions with different types of knit structures or yarns.

In some configurations of footwear 10, in addition to incorporating tongue element 40 or tongue element 140, a majority of upper 30 may be formed from knitted component 36 that is configured to extend around a wearer's foot and conform to the shape of the foot. In such a configuration, knitted component 36 may extend through each of regions 11-13 along both lateral side 14 and medial side 15, across forefoot region 11, and around heel region 13. Knitted component 36 may also define at least a portion of a void within upper 30 and an ankle opening to provide access to the void. For example, as depicted in fig. 32-34, tongue element 40 of upper 30 is secured to knitted component 36, which may be configured as set forth in U.S. patent application serial No. 12/338,726 to Dua filed on 12/18, 2008, which is incorporated herein by reference. Tongue element 40 may be secured to knitted component 36 by stitches 37. As one further example, as depicted in fig. 35-37, tongue element 140 of upper 30 is secured to knitted component 36 by stitches 37, which may be configured as set forth in U.S. patent application serial No. 13/048,514 to huffa et al, filed 3, 15, 2011, which is incorporated herein by reference. Accordingly,

tongue elements

40 and 140, including loops of material 48 or other free yarn sections, may be utilized with a knitted component to provide an upper formed substantially from the knitted element or component.

Knitted component 36 may incorporate different knit structures in different regions of knitted component 36 and different types of yarns in different regions of knitted component 36 to impart specific properties and advantages to the different regions, as discussed in the previously referenced U.S. patent application serial No. 13/048,514. Similarly, tongue element 40 and tongue element 140 may also incorporate different knit structures, different types of yarns, or both, as set forth above. Moreover, the knit structure incorporated into a region of knitted component 36 may be substantially the same as the knit structure incorporated into tongue element 40 or tongue element 140, and the type of yarn incorporated into a region of knitted component 36 may be substantially the same as the type of yarn incorporated into tongue element 40 or tongue element 140. Utilizing a common knit structure and type of yarn in either of

tongue elements

40 and 140 and knitted component 36 provides the advantage of imparting uniform aesthetic, tactile properties, or both, to various areas and major components of upper 30. Accordingly, one region of knitted component 36 and one region of tongue element 40 or tongue element 140 may share one or more properties, such as color, softness, biodegradability, durability, abrasion resistance, strength, denier, softness, aesthetic properties, stretch properties, recovery properties, insulative properties, hydrophobic properties, or thermal bonding properties, for example.

The present invention is disclosed above and in the accompanying drawings with reference to a variety of configurations. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. A person skilled in the relevant art will appreciate that numerous variations and modifications may be made to the arrangement described above without departing from the scope of the present invention, as defined by the appended claims.

Claims

1. A tongue element for an article of footwear, comprising a knitted component formed of unitary knit construction, the knitted component having a compressible region and a flange region extending outward from an end of the compressible region, the compressible region including a first knit layer and a second knit layer formed of unitary knit construction, wherein (a) a region of the first knit layer and a region of the second knit layer are spaced apart from one another to define a cavity within the knitted component, (b) an edge of the first knit layer and an edge of the second knit layer are joined to one another around at least a portion of the cavity,

wherein the knitted component further includes at least one peripheral knitted structure extending outwardly from a side of the compressible region, the at least one peripheral knitted structure having a different type of knitted structure than the first knitted layer and the second knitted layer, and wherein the at least one peripheral knitted structure does not form a portion of the cavity.

2. The tongue element of claim 1, wherein the compressible region includes a plurality of free yarn sections located within the cavity.

3. The tongue element of claim 2, wherein the plurality of free yarn sections is a plurality of loops of material.

4. The tongue element of claim 2, wherein the plurality of free yarn sections are a plurality of floats.

5. The tongue element of claim 2, wherein the plurality of free yarn sections are formed of unitary knit construction with at least one of the first knit layer and the second knit layer.

6. The tongue element of claim 1, wherein the at least one peripheral knit structure includes a first peripheral knit structure extending outwardly from a first side of the compressible region and a second peripheral knit structure extending outwardly from a second side of the compressible region, the second side being disposed opposite the first side.

7. A tongue element for an article of footwear, comprising a knitted component formed of unitary knit construction, the knitted component having a compressible region and a flange region extending outward from the compressible region, the compressible region including a first knit layer and a second knit layer formed of unitary knit construction, wherein (a) regions of the first knit layer and regions of the second knit layer are spaced apart from one another to define a cavity within the knitted component, (b) edges of the first knit layer and edges of the second knit layer are joined to one another around at least a portion of the cavity, (c) a plurality of free yarn segments are located within the cavity,

8. The tongue element of claim 7, wherein the plurality of free yarn sections are a plurality of loops of material.

9. The tongue element of claim 7, wherein the plurality of free yarn sections are formed of unitary knit construction with the first knit layer.

10. The tongue element of claim 8, wherein an additional plurality of free yarn sections are located within the cavity and are formed of unitary knit construction with the second knit layer.

11. The tongue element of claim 7, wherein the knitted component defines a flange in the flange region extending outwardly from one of the first knit layer and the second knit layer.

12. The tongue element of claim 7, wherein the knitted component defines a flange in the flange area extending outwardly from each of the first knit layer and the second knit layer.

13. The tongue element of claim 7, wherein the knitted component forms a majority of an exterior of the tongue element.

14. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a plurality of free yarn segments located within the internal cavity, an

A peripheral knit structure extending outwardly from at least one side of the second knit component, the peripheral knit structure being formed of unitary knit construction with the second knit component and being separated from the interior cavity,

wherein the second knitted component has a compressible region that defines the internal cavity and a flange region extending outwardly from an end of the compressible region, the peripheral knitted structure extending outwardly from at least one side of a periphery of the compressible region, wherein the second knitted component and the peripheral knitted structure are different types of knitted structures, and wherein the peripheral knitted structure does not form a portion of the internal cavity.

15. The article of footwear recited in claim 14, wherein the plurality of free yarn sections are a plurality of floats.

16. The article of footwear recited in claim 14, wherein the plurality of free yarn sections are a plurality of material loops formed of unitary knit construction with the second knitted component.

17. The article of footwear recited in claim 14, wherein the peripheral knit structure extends outwardly from opposite sides of the second knitted component and forms an edge of the tongue element.

18. The article of footwear recited in claim 14, wherein a first knit structure is incorporated in an area of the second knitted component, a second knit structure is incorporated in an area of the peripheral knit structure, and the first knit structure is different than the second knit structure.

19. The article of footwear recited in claim 14, wherein a first type of yarn is incorporated in a region of the second knitted component, a second type of yarn is incorporated in a region of the peripheral knit structure, and the first type of yarn is different than the second type of yarn.

20. The article of footwear recited in claim 14, wherein the peripheral knit structure is absent at one end of the tongue element.

21. The article of footwear recited in claim 14, wherein the flange region is joined to the first knitted component.

22. A tongue element for an article of footwear, comprising a knitted component having a compressible region and a flange region extending outward from the compressible region, the compressible region including a first knit layer and a second knit layer formed of unitary knit construction, wherein (a) regions of the first knit layer and regions of the second knit layer are spaced apart from one another to define a cavity within the knitted component, (b) edges of the first knit layer and edges of the second knit layer are joined to one another around at least a portion of the cavity, and (c) a plurality of free yarn segments are located within the cavity, wherein the plurality of free yarn segments are formed of unitary knit construction with the first knit layer.

23. The tongue element of claim 22, wherein the plurality of free yarn sections are a plurality of loops of material.

24. The tongue element of claim 23, wherein an additional plurality of free yarn sections are located within the cavity and are formed of unitary knit construction with the second knit layer.

25. The tongue element of claim 22, wherein the knitted component defines a flange in the flange area extending outwardly from one of the first knit layer and the second knit layer.

26. The tongue element of claim 22, wherein the knitted component defines a flange in the flange area extending outwardly from each of the first knit layer and the second knit layer.

27. The tongue element of claim 22, wherein the knitted component forms a majority of an exterior of the tongue element.

28. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a plurality of free yarn segments located within the internal cavity, an

A peripheral knit structure extending outwardly from at least one side of the second knit component, the peripheral knit structure being formed of unitary knit construction with the second knit component and being separated from the interior cavity, wherein the plurality of free yarn segments are a plurality of loops of material formed of unitary knit construction with the second knit component.

29. The article of footwear recited in claim 28, wherein the plurality of free yarn sections are a plurality of floats.

30. The article of footwear recited in claim 28, wherein the second knitted component has a compressible region and a flange region extending outward from an end of the compressible region, the compressible region defining the interior void, the peripheral knitted structure extending outward from at least one side of a periphery of the compressible region, and the flange region is joined to the first knitted component.

31. The article of footwear recited in claim 28, wherein the peripheral knit structure extends outwardly from opposite sides of the second knitted component and forms an edge of the tongue element.

32. The article of footwear recited in claim 28, wherein a first knit structure is incorporated in an area of the second knitted component, a second knit structure is incorporated in an area of the peripheral knit structure, and the first knit structure is different than the second knit structure.

33. The article of footwear recited in claim 28, wherein a first type of yarn is incorporated in a region of the second knitted component, a second type of yarn is incorporated in a region of the peripheral knit structure, and the first type of yarn is different than the second type of yarn.

34. The article of footwear recited in claim 28, wherein the peripheral knit structure is absent at one end of the tongue element.

35. A collar element for use in the article of footwear of claim 28, the upper comprising the collar element in at least a heel region, the collar element forming an ankle opening for providing access to a foot to a void within the upper, wherein the collar element is formed from two overlapping and at least partially coextensive layers of woven material enclosing a plurality of floating yarns.

36. The collar element of claim 35, wherein the layer comprises an outer layer and an opposing inner layer.

37. The collar element of claim 36, wherein the outer layer forms a portion of an exterior surface of the upper in the area of the ankle opening and the inner layer forms a portion of an interior surface of the upper.

38. The collar element of claim 37, wherein a flange extends outwardly from the outer layer and the inner layer and is used to join the collar element to the remainder of the upper.