CN109415854B

CN109415854B - Article having multiple layers and method of making same

Info

Publication number: CN109415854B
Application number: CN201780041496.9A
Authority: CN
Inventors: 托马斯·G·贝尔; 克里斯托弗·J·查尔顿; 斯图尔特·W·迪利; 斯特凡·E·格斯特; 尼古拉·A·琼斯; 安娜-路易丝·莫里纽克斯; 赵阳
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2016-07-06
Filing date: 2017-06-29
Publication date: 2022-03-25
Anticipated expiration: 2037-06-29
Also published as: CN109415854A; WO2018009414A1; CN207152045U; EP3481982B1; US20180177260A1; TW202103597A; TW201804924A; TWM563172U; EP3481982A1

Abstract

One general aspect of the disclosure includes an article (300,400,500,600,900) having a first zone (1052,952) including a first region (152,552,942) of a knitted base layer (140,340,440,540,640,940) and a knitted second layer (150,350,450,550,650,950), wherein the second layer (150,350,450,550,650,950) is disposed primarily on one side of the base layer (140,340,440,540,640,940). The article (300,400,500,600,900) may further include a second zone (1054,954), the second zone (1054,954) may include a second region (154,554,944) of the base layer (140,340,440,540,640,940), wherein the second region (154,554,944) of the base layer (140,340,440,540,640,940) and the first region (152,552,942) of the base layer (140,340,440,540,640,940) may have a common yarn, and wherein the second region (154,554,944) of the base layer (140,340,440,540,640,940) and the second layer (150,350,450,550,650,950) may have a common yarn. The first zone (1052,952) may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone (1054,954) may have a second degree of elasticity such that it has a second elongation when subjected to a tensile load.

Description

Article having multiple layers and method of making same

Cross Reference to Related Applications

This application claims the benefit of U.S. provisional application No. 62/359,108 filed on 6/7/2016, which is hereby incorporated by reference in its entirety. This application also claims the benefit of U.S. provisional application No. 62/503,704 filed on 2017, 5, 9, which is hereby incorporated by reference in its entirety.

Background

Various articles are formed from textiles. For example, articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, underpants and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, vehicle seats) are typically formed at least in part from textiles. These textiles are often formed by weaving or interlooping (e.g., knitting) a yarn or yarns, often by machining involving a loom (loom) or knitting machine. One particular object that may be formed from textiles is an upper for an article of footwear.

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 within the article of footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. For example, in some articles of athletic footwear, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to relieve stresses placed on the foot and leg during walking, running, and other ambulatory activities. An outsole may be secured to a lower surface of the midsole and form a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material.

The upper of an article of footwear generally extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot. Access to the void on the interior of the upper is typically provided by an ankle opening in the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, allowing the foot to enter and be removed from the void within the upper. 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.

SUMMARY

One general aspect of the present disclosure includes an article having a first zone (zone) comprising a first region of a knitted base layer and a knitted second layer, wherein the second layer is disposed primarily on one side of the base layer. The article may further comprise a second zone, which may comprise a second region of the base layer, wherein the second region of the base layer and the first region of the base layer have a common yarn, and wherein the second region of the base layer and the second layer have a common yarn. The first zone may have a first degree of elasticity such that it has a first elongation (elongation) when subjected to a tensile load, and the second zone may have a second degree of elasticity such that it has a second elongation when subjected to a tensile load. The first elongation may be at least 5% greater than the second elongation.

Another general aspect of the present disclosure includes an article having a first zone comprising a knitted base layer and a first region of a knitted second layer, the first region being disposed primarily on one side of the base layer. The article may further comprise a second zone comprising the base layer and a second region of the second layer, the second region being located primarily on one side of the base layer, wherein the first zone has a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and wherein the second zone has a second degree of elasticity such that it has a second elongation when subjected to a tensile load. The first elongation may be at least 5% greater than the second elongation.

Another general aspect of the disclosure includes a method, where the method may include knitting a base layer in one pass (of) with a first yarn on a knitting machine having a first needle bed and a second needle bed, where the base layer is formed at least partially on the second needle bed. The method may further comprise: knitting a second layer of at least one pass with a second yarn at least partially on a first needle bed of the knitting machine, and transferring the second yarn from the first needle bed to a second needle bed.

Brief Description of Drawings

Fig. 1 illustrates an article of footwear according to certain aspects of the present disclosure.

Fig. 2 illustrates an upper for the article of footwear of fig. 1.

Fig. 3 shows an embodiment of an article having a base layer and a second layer.

Fig. 4 shows an embodiment of an article having a base layer and a second layer with a plurality of structures.

Fig. 5 shows an embodiment of an article having a base layer and a second layer with a plurality of zones.

Figure 6 shows an article having a base layer and a second layer with tie-down yarns.

Fig. 7 shows a schematic diagram illustrating a method of manufacturing an article having a base layer and a second layer.

Fig. 8 shows a schematic diagram illustrating a method of manufacturing an article having a base layer and a second layer with a plurality of structures.

Fig. 9 illustrates an article having a plurality of zones with a base layer having a plurality of regions having different elasticities in accordance with the present disclosure.

Fig. 10 illustrates an upper of an article of footwear incorporating certain aspects associated with the article described with reference to fig. 9.

Detailed description of the invention

Various aspects are described below with reference to the drawings, wherein like elements are generally referred to by like numerals. The relationship and function of the various elements of the aspects may be better understood by reference to the following detailed description. However, the aspects are not limited to those illustrated in the drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale and that, in some instances, details that are not necessary for an understanding of the aspects disclosed herein, such as conventional fabrication and assembly, may have been omitted.

Certain aspects of the present disclosure relate to articles formed at least in part from textiles. One example of an article is an article of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, underpants and other undergarments, hats and other headwear, etc.). The article may be an upper configured for use in an article of footwear. The upper may be used in conjunction with any style of footwear. Illustrative, non-limiting examples of articles of footwear include basketball shoes, cycling shoes, cross-training shoes, international football (soccer) shoes, football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. The upper may also be incorporated into non-athletic footwear (e.g., dress shoes, loafers, and sandals).

Referring to fig. 1, article of footwear 100 is generally depicted as including a sole 110 and an upper 120. Upper 120 includes a lateral side 104 and a medial side 105. The area where the sole 110 of the shoe joins the upper 120 may be referred to as the bite line 116. Upper 120 may be fixedly attached to sole 110 using any suitable technique (e.g., by using an adhesive, by stitching, etc.). It is contemplated that upper 120 may extend partially or completely around the foot of the wearer and/or may be integral with the sole, and that a sockliner may or may not be used.

In some embodiments, sole 110 includes a midsole (not shown) and an outsole. Article of footwear 100 may additionally include a throat 126 and an ankle opening 128, where ankle opening 128 may be surrounded by a cuff 130 and may open into a cavity 132. Void 132 of article of footwear 100 may be configured to receive a human foot. Throat 126 is generally disposed in midfoot region 102 of upper 120. Midfoot region 102 is generally the area of upper 120 located between heel region 101 and toe region 103.

In some embodiments, the tongue may be disposed in the throat 126 of the shoe, but the tongue is an optional feature. The tongue may be any type of tongue, such as a lined tongue (padded tongue) or a purse-roll tongue (burrito tongue). If no tongue is included, lateral and medial sides of throat 126 may be joined together. Although not shown, in some embodiments, article of footwear 100 may include optional fastening elements, such as, for example, laces (which may be associated with lace apertures 136). Any suitable type of fastening element may be used.

As shown in fig. 1, upper 120 may include a base layer 140, base layer 140 being described herein as a textile layer, although the base layer need not be limited to textile materials. The base layer 140 may be formed of a knitted material, a woven material, one or more layers of mesh, a solid material, and/or any other suitable material. The base layer 140 may include one or more strands (strand), threads (thread), yarns (yarn), mesh components (mesh component), or the like (referred to herein simply as "yarns"). Base layer 140 may have a first side that forms an interior surface of upper 120 (e.g., facing cavity 132 of article of footwear 100) and a second side that forms an exterior surface of upper 120. In some embodiments, another object or layer, for example, a cushioning layer, may be included between the cavity and the base layer 140. The base layer 140 may be formed as a unitary, one-piece element. For example, the base layer 140 can be formed during a single-sided weft knitting process (e.g., using a flat knitting machine or a circular knitting machine), a warp knitting process, or any other suitable knitting process, such that the knitting process substantially forms the knit structure of the base layer 140 without requiring significant post-knitting processing or steps. Although not shown, in some embodiments, base layer 140 of upper 120 may be configured to substantially surround the foot of a wearer such that it extends under the plantar surface (also referred to as the sole or bottom of the foot).

In some embodiments, upper 120 may include second layer 150. Although not limited to the inclusion of a mesh, the second layer 150 is depicted as a mesh layer. Here, the "mesh layer" may include, but is not limited to, an open-cell fabric or layer of yarns looped around, twisted, knotted, or woven together at intervals, and may have a relatively low stitch density (i.e., number of loops per measured area) relative to a typical knitted fabric and/or the base layer 140. In some exemplary embodiments, second layer 150 is formed on a knitting machine. As shown, the second layer 150 may have one or more regions (e.g., the first region 152, the second region 154, the third region 156, and the fourth region 158 shown in fig. 2) that exhibit different functional and/or visual characteristics. Each "zone" of second layer 150 may be associated with a "zone" of upper 120 (i.e., herein, "zone" refers only to a layer, while "zone" refers to an upper or other article). Second layer 150 may be formed as a unitary, one-piece element. In some embodiments, the second layer 150 and the base layer 140 are formed together as a unitary, one-piece element (which may be referred to as a "knitted component") and may be formed on a knitting machine by a single knitting process. For example, the base layer 140 and the second layer 150 can be formed simultaneously and/or integrally on a multi-bed flat knitting machine.

Second layer 150 is depicted as being located on an exterior surface of upper 120, but it is contemplated that second layer 150 may be located at least partially on another surface (e.g., an interior surface). Further, the second layer 150 may have substantially the same boundary dimensions as the base layer 140 such that a substantial portion of at least one surface of the base layer 140 is covered by the second layer 150. Alternatively, as shown in fig. 1, the second layer 150 may not exist in the isolation region (fifth region 142) of the base layer 140. Although not shown, it is also contemplated that article of footwear 100 may have one or more locations where second layer 150 is present, but base layer 140 is not.

Fig. 2 shows upper 120 of article of footwear 100 (of fig. 1) separately, and possibly as if upper 120 were after it was formed (e.g., on a knitting machine) and before it was combined with other elements of article of footwear 100 (e.g., sole 110). Upper 120 may generally be formed as a unitary, one-piece element during a single manufacturing process (e.g., a single knitting process).

Upper 120 is shown having four zones including second layer 150, where each zone is associated with one of four

regions

152, 154, 156, and 158 of second layer 150. The first region 152 of the second layer 150 may include a relatively large structure (e.g., a relatively large cell 160 as described in more detail below). For example, this structure may provide a desired level of support and flexibility to upper 120. The second region 154 of the second layer 150 may have a relatively dense structure (e.g., relatively small cells 160). The structure may be relatively rigid and/or inelastic (at least with respect to first zone 152), which may be advantageous in some areas of upper 120 where support, strength, durability, and/or other particular characteristics associated with a dense structure are desired. In some embodiments, the first regions 152 may have a first elasticity and the second regions 154 may have a second elasticity such that when the same tensile load is applied to both regions, the zone having the first regions 152 is at least 5%, at least 10%, at least 20%, at least 50%, or even at least 100% more elongated (or more elongated) than the zone having the second regions 154. As shown, it may be advantageous for second region 154 of second layer 150 to extend from bite line 116 to throat 126 and/or throat area 127 adjacent throat 126, which may provide durability and structural integrity to areas that typically experience high degrees and frequencies of stress during typical use of the article of footwear. In addition, second region 154 may interact with fastening elements, such as laces, to ensure a snug and comfortable fit of upper 120. For example, tightening of the lace may tighten second region 154 (and its associated zones) around the foot. Similarly, the third zone 156, depicted as including a region of the second layer 150 having two structures (described in more detail below), may exhibit increased strength and durability, as well as a reduced amount of elasticity relative to other regions, and/or may provide a desired visual effect. Fourth region 158 may have another structure (or substantially the same structure as the structure of the other region) to achieve the desired features in this region of upper 120. Although four zones of the second layer 150 have been shown for illustrative purposes, the second layer 150 may have more or less than four zones.

The fifth region 142 of the base layer 140 may comprise a portion of the base layer 140 that is isolated from the second layer 150 and not covered by the second layer 150. In this embodiment, the second layer 150 terminates at the edge of the fifth region 142, but it is contemplated that the structure of the second layer 150 may fade away (fade), or otherwise slowly transition from the fourth region 158 into the fifth region 142 in a transition zone. The fifth region 142 may be at least 20%, at least 50%, at least 100%, at least 200%, or even at least 300% more elongated (or more elongated) than at least one region of the region comprising the second layer 150. It may be advantageous to include the fifth region 142 and/or other uncovered isolation regions of the base layer 140, where flexibility, elasticity, and certain other characteristics that may be primarily associated with the isolated base layer 140 are desired.

Fig. 3 shows an article 300 having an embodiment of a second layer 350 and an underlying base layer 340. The second layer 350 may have a first yarn section 352, a second yarn section 354, and a third yarn section 356, each depicted as extending in a serpentine pattern in a generally side-by-side direction. These yarn portions may be formed of different materials or the same material, and it is contemplated that they may be formed of the same continuous yarn or separate yarns. As shown in fig. 3, the first yarn portion 352 of the second layer 350 may be twisted with at least one other yarn portion (e.g., second yarn portion 354). In this embodiment, the second yarn section 354 is twisted with two other yarn sections: a first yarn section 352 and a third yarn section 356. It is contemplated that one yarn may be partially wound with more than two yarns of the second layer 350. As shown, the structure of the second layer 350 defines a mesh 360, and the mesh 360 may have corners defined at points where yarn portions of the second layer 350 wrap and/or overlap.

The structure of the second layer 350 may form any suitable number of cells 360. The cells 360 are shown in fig. 3 as being generally quadrilateral (i.e., a four-sided polygon, such as a square or rectangle), but it is contemplated that the second layer 350 may include differently shaped cells having a different number of sides. For example, the second layer 350 may be formed to have triangular meshes, pentagonal meshes, hexagonal meshes, and the like. Further, the second layer 350 can have different zones having different characteristics (e.g., different mesh sizes or shapes), and it is contemplated that the second layer 350 can have a pattern of different shaped meshes that form adjacent to each other. The shape of the cells 360 may be selected for certain characteristics. For example, a mesh having a triangular shape may have an elasticity different from that of a quadrangular mesh in at least one direction. The size of the cells 360 may also be selected for certain characteristics. For example, a smaller mesh may result in a tighter, stiffer, and less elastic structure relative to a structure formed by a larger mesh. Mesh 360 may change size in response to movement and/or stretching of article 300 when article 300 is in use.

The base layer 340 and the second layer 350 can have different functional and/or visual characteristics. For example, the base layer 340 may be more elastic than the second layer 350. The difference in elasticity may be achieved by using yarns formed of different materials and/or having different dimensions, by varying the manner in which the yarns interact (e.g., by selecting a particular knit structure exhibiting a particular degree of elasticity), or a combination thereof. In some embodiments, the base layer 340 and the second layer 350 can additionally or alternatively have varying degrees of strength, durability, heat resistance, fluid (e.g., water or air) permeability, weight, flexibility, or other properties. Further, the second layer 350 can have a different visual characteristic (e.g., a different color) than the base layer 340, such that the combination of the second layer 350 and the base layer 340 is aesthetically pleasing. It is contemplated that when article 300 is in use (e.g., as an upper for an article of footwear), its movement may cause second layer 350 to visibly move relative to underlying base layer 340, which may produce a desired visual effect.

The yarns of the second layer 350 and the base layer 340 may be formed of any suitable material. For example, in some embodiments, the yarns forming the second layer 350 may be formed from a material that is relatively inelastic when compared to the yarns forming the underlying base layer 340. To illustrate, the yarns forming the base layer 340 may be at least 5%, at least 50%, at least 100%, or even at least 500% (and possibly more than 500%) more elongated than the yarns forming the second layer 350 when subjected to the same tensile load. The combination of the base layer 340 and the second layer 350 may be advantageous to achieve a desired combination of features for the article 300. For example, the base layer 340 may be relatively soft and abrasion resistant, which may be a desirable feature of an interior surface of an upper or other article that is configured to contact a wearer. Base layer 340 may also be relatively elastic, which may facilitate a snug and comfortable fit around a wearer's foot, for example, when used in an upper. The second layer 350, which may be located on the outer surface of the base layer 340, may be relatively inelastic to provide structural integrity and durability to the upper throughout the entire upper or at selected locations.

Fig. 4 shows an embodiment of article 400 in which second layer 450 includes two structures depicted as first structure 452 and second structure 454. As shown, the first structure 452 and the second structure 454 each form their own mesh. It is contemplated that more than two structures may be included. The first structure 452 and the second structure 454 are depicted as being substantially identical, but this is not required. In some embodiments, the first structure 452 may have different characteristics (visually or functionally) than the second structure 454. The yarns forming the first structure 452 may or may not be interlooped with the yarns forming the second structure 454. Both structures may be attached to the base layer 440, but alternatively, one or both of the structures may have a portion that is free with respect to the base layer 440 (e.g., unconstrained with respect to the base layer 440). The first structure 452 may interlock with the second structure 454. In other words, when the first and

second structures

452, 454 are viewed from the point of view shown in fig. 4, in some locations the first structure 452 may be in front of the second structure 454 (e.g., closer to the viewer), and in other locations the first structure 452 may be behind the second structure 454 (e.g., closer to the base layer 440). As shown, the mesh of the first structure 452 may be offset (from) from the mesh of the second structure 454.

Fig. 5 shows an article 500 having a second layer 550, the second layer 550 having three distinct regions: a first region 552, a second region 554, and a third region 556. The base layer 540 may include a fourth region 542, wherein the fourth region 542 of the base layer 540 may be isolated relative to the second layer 550. Two or more regions of the second layer 550 may have at least one different characteristic. For example, in the first region 552, the second layer 550 has two structures (similar to that shown in fig. 4). In the second region 554, the second layer 550 has a single structure with relatively large cells. In the third region 556, the second layer 550 has relatively small cells compared to the cells of the second region 554. The second layer 550 terminates adjacent to the fourth region 542 of the base layer 540 such that the fourth region 542 comprises uncovered and isolated portions of the base layer 540. The fourth region 542 may exhibit characteristics associated only with the base layer 540. Fig. 5 shows that in different zones, the article 500 may have different structures, and thus different functional and/or visual characteristics. Although all of the regions of the second layer 550 are depicted as being located on the same side of the base layer 540, it is contemplated that at least one region of the second layer 550 may be on the opposite side of the base layer 540. Further, it is contemplated that two or more regions of the second layer 550 can be spaced apart on the base layer such that the isolation region of the base layer 540 is disposed therebetween.

As shown in fig. 6, the article 600 may have a second layer 650, the second layer 650 being attached to the base layer 640, the second layer 650 having a series of binding yarns 642 at the corners of the mesh and/or a series of binding yarns 644 between the corners of the mesh. In some embodiments (not shown), a binding yarn 642 may be included at substantially each corner 660 of each mesh, but this is not required. The tying yarn 642 may be selectively placed to achieve a degree of securement between the second layer 650 and the base layer 640. In some instances, it may be advantageous to provide attachment at each corner when it is desired that the second layer 650 remain substantially in the same position relative to the base layer 640. In other cases, it may be advantageous to allow some of the cells of second layer 650 to remain free relative to base layer 640, which may allow for changing features depending on the motion of article 600, and/or may allow for corresponding movement between layers that produce a desired visual and/or functional effect. It is further contemplated that some or all of the binding yarns may be located at another location, for example, between corners of the mesh of the second layer 650, as shown by the binding yarns 644 of fig. 6.

The binding yarns 642 and/or 644 may be yarns that form the base layer 640. For example, as described in more detail below with reference to fig. 7-8, the yarns 652 (of fig. 6) forming the second layer 650 can be integral with (e.g., wound with) the yarns forming the base layer 640 during the knitting process. However, it is contemplated that the tying yarns 642 and/or 644 may be separate from the second layer 650 and the base layer 640, and/or may be embroidered or otherwise installed after the second layer 650 and the base layer 640 are formed. Other forms of attachment may additionally or alternatively be used. For example, the second layer 650 can be attached to the base layer 640 by means of an adhesive, by brazing (tack) or mechanical clamps, by sewing, or the like.

Fig. 7 shows a schematic view of one method of forming an article having a base layer and a second layer on a knitting machine having a first needle bed 762 and a second needle bed 764. The first needle bed 762 may be a component commonly referred to as the "front bed" on a flat knitting machine, and the second needle bed 764 may be a component commonly referred to as the "back bed" (or vice versa). The schematic diagram of fig. 7 is not intended to represent the entirety of the article, but is shown only to illustrate one particular sequence, which may be substantially repeated. Each repetition of the depicted sequence need not be identical. In addition, fig. 7 shows only a series of six (6) consecutive needles per needle bed, and it should be recognized that the steps may be repeated on additional needles per needle bed (with some possible changes between each repetition).

Referring to fig. 7, the first yarns 742 may be primarily associated with the base layer and the second yarns 752 may be primarily associated with the second layer. Step a (which need not be the first step of the sequence) shows that the second yarn 752 is being knitted on one needle of the first needle bed 762 and then on a needle of the second needle bed 764 spaced apart by about two needle pitches. The spacing is not limited to two (2) needles and may be related to the size of the mesh of the second layer. Steps B-E depict repeatedly knitting a first yarn 742 on each needle of second needle bed 764. This can form a base layer having a single-face plain-knit structure. In the depicted embodiment, the first yarn 742 completes four (4) passes before knitting the second yarn 752 again. The number of consecutive passes of the base layer may also be correlated to the mesh size of the second layer. After knitting a portion of the base layer, loops of the second yarn 752 that are located on needles of the first needle bed 762 may be transferred to needles of the second needle bed 764 at step F. This can provide an attachment point (e.g., a point where the binding yarn is located) between the second layer and the base layer once the knitting process is continued. The four depicted loops of the second yarn 752 in fig. 7 may each be associated with a corner of a mesh of the second layer.

This sequence may generally be repeated in steps G-K of fig. 7, but as shown, the sequence of the second yarn 752 in step G may be offset with respect to step a. Here, the deviation is shown to be equal to the distance between the six (6) needles of the first needle bed 762. This deviation may correspond to one dimension (dimension) of the mesh when the knitting process is complete. For example, the sequence depicted in fig. 7 may form an article having a structure similar to that of article 300 of fig. 3.

Figure 8 shows a schematic diagram illustrating one method of forming an article having a base layer and a second layer with multiple structures (e.g., as shown in figure 4) on a knitting machine having a first needle bed 862 and a second needle bed 864. The first yarns 842 may be primarily associated with the base layer and the second yarns 852 and the third yarns 854 may be primarily associated with the second layer. The second yarns 852 can be primarily associated with the first structure of the second layer and the third yarns 854 can be associated with the second structure of the second layer. In some embodiments, the second yarn 852 and the third yarn 854 can be substantially the same yarn, and it is contemplated that they can be the same continuous yarn. In step a as shown, a second yarn 852 is knitted on one needle of a first needle bed 862 and then on a needle of a second needle bed 864 that are spaced apart by approximately two needle pitches. Similarly, in step B, the third yarn 854 is depicted as undergoing the same sequence as the second yarn 852, but offset by one needle. This offset can result in two structures having cells that are offset from each other (as best illustrated in fig. 4). The deviation is not limited to one needle and does not have to remain constant throughout the article.

In fig. 8, steps C-F depict repeatedly knitting a first yarn 842 on each needle of the second needle bed 864. This can form the described base layer with a single-face plain-knit structure. After knitting a portion of the base layer, loops of the second yarn 852 located on the needles of the first needle bed 862 may be transferred to the needles of the second needle bed 864 in step G. This may form an attachment point between the base layer and the second layer. Similarly, in step H, the loops of the third yarn 854 located on the first needle bed 862 can be transferred to the second needle bed 864.

Referring to step I, the second yarn 852 can be knitted again on one needle of each of the first needle bed 862 and the second needle bed 864. However, the second yarn 852 may be offset from its previous pass. For example, it may be offset by six (6) needles relative to the previous pass, which may correspond to one dimension of the mesh of the second layer. The mesh size of the second layer may also be related to the number of separate base layer passes (e.g., passes of single jersey knit according to steps C-F and K-N) between knitting the second yarn 852 and/or the third yarn 854. Step J similarly involves knitting the third yarn 854 in a manner that is offset from the previous pass in step B. Steps K-N involve knitting the first yarn 842 of the base layer again to form a single face plain knit structure. The knitting process may be substantially repeated to form multiple regions of structure (e.g., two structures).

The inventors have found that varying the structure of the second layer as described herein may achieve certain advantageous features. For example, in one test, an article having five zones was formed according to the present disclosure. Here, each zone of the item may be associated with an area of the second layer. One zone (e.g., the control zone) includes only the knitted base layer and no second layer (i.e., is isolated from the second layer). Zone 1 includes a base layer and a second layer having a relatively large mesh. Zones 2, 3 and 4 include a base layer having a second layer with a reduced mesh size such that zone 4 includes the smallest mesh. Each land is formed as a strip of approximately 1 inch by 6 inches. The zones were then individually tested with a tester (i.e., an Instron 5965 test system) applying a specific load, and the elongation of each zone was then measured at a loading speed of 50 millimeters per minute (loading speed) and a gauge length of 75 millimeters (gauge length). Table 1 includes data obtained from these tests.

TABLE 1

As shown in table 1, elongation is related to mesh size, with smaller mesh sizes reducing elongation. Advantageously, the mesh size of the second layer as described herein may be selected to achieve particular elongation characteristics.

In a second test, the zones are tested to determine their recovery characteristics. In this test, the testing machine (i.e., the Instron 5965 test system) will pull each zone 100 cycles with a load of 100 newtons. The gauge length is set to 100 mm. Initially, a displacement measurement (P) was made at about 9.8 newtons₀) And then displacement measurement is performed again after 100 cycles (P)₁). Table 2 includes data obtained from this test. By measuring the length (P) initially₀) And the final measurement length (P)₁) The difference between the gauge length and the initial length is divided by the difference between the gauge length and the initial length to determine the stretch recovery index.

TABLE 2

As the data indicates, the mesh size of the second layer is associated with a lower tensile recovery index. Advantageously, the structure of the second layer as described herein may thus be configured to achieve specific recovery characteristics. For example, the second layer may provide certain zones with a desired locking-out effect in certain zones of the article of footwear, while other zones may be configured with a relatively high elasticity, for example, in which case a high degree of freedom of movement is desired.

In the above embodiments, zones having a second layer (e.g., a mesh layer) are generally described as having relatively low elasticity and high stretch resistance compared to zones not having a second layer. However, it is also contemplated that the zones having the mesh layer may be relatively elastic when compared to other zones.

For example, referring to fig. 9, an article 900 may include a first zone 952 and a second zone 954. The first zone 952 has a first region 942 of the base layer 940 and a second layer 950, which may be similar to the embodiments described above. The first regions of base layer 940 may include first yarns and second layer 950 may include second yarns. The second yarns of the second layer 950 may be relatively inelastic when compared to the first yarns forming the first regions 942 of the underlying base layer 940. Second layer 950 can be formed using the methods described above (e.g., by knitting the base layer on the first needle bed while holding the second yarn on the second needle bed and then transferring the second yarn to the first needle bed), and can include any of the features or other aspects described above with respect to the second layer.

A second region 954 of the article 900 may include a second region 944 of the base layer 940. The second layer 950 may terminate near the second region 944 of the base layer 940 such that it does not cover the surface of the second region 944. The second regions of the base layer 940 may share at least one common yarn (e.g., first yarn) and/or at least one common course with the first regions of the base layer 940, and it is contemplated that the knit structures forming the first regions 942 and the second regions 944 may be different. The second region 944 of the base layer 940 may also share at least one common yarn (e.g., a second yarn) and/or at least one common row with the second layer 950 located in the first region 942. In other words, the second region 944 of the base layer 940 may be at least partially formed from yarns forming the first region 942 of the base layer 940 and yarns forming the second layer 950. In some embodiments, this may result in the second region 944 of the base layer 940 having a higher stitch density (i.e., the total number of knitted loops in the measured area of the fabric) relative to the first region 942 of the base layer 940. Additionally or alternatively, the second region 944 of the base layer 940 may contain a second yarn (e.g., a yarn that at least partially forms the second layer 950), which may result in the second region 944 of the base layer 940 having a different elasticity than the first region 942 of the base layer 940.

Thus, in some embodiments, the first region 952 of the article 900 may comprise a relatively high elasticity when compared to the second region 954 of the article. In other words, the first zone 952 may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone 954 may have a second degree of elasticity such that it has a second elongation when subjected to a tensile load. For example, the first elongation may be at least 5%, at least 10%, at least 20%, at least 50%, or even at least 100% more (or greater) than the second elongation.

The yarns of the second region 944 of the base layer 940 may be distributed such that the first yarns forming the first region 942 of the base layer 940 are primarily associated with the outer surface of the second region 944 and/or such that the second yarns forming the second region 944 of the base layer 940 are primarily associated with the inner surface of the second region 944 of the base layer 940 (or vice versa). Advantageously, the second yarn may be hidden from an exterior visual perspective such that the first region 942 and the second region 944 of the base layer 940 may have a uniform appearance, which may be aesthetically desirable while still exhibiting the functional characteristics described above. Alternatively, the second yarn may be exposed (when associated with the outer surface) to create an apparent contrast between the first region 942 and the second region 944 of the base layer 940. Alternatively, both the first and second yarns may be associated with both surfaces.

Although not required, the article 900 can also include a third zone 956, the third zone 956 having a third region 946 of the base layer, the knit structure and/or yarn composition of the third region 946 being similar to the first region 942 of the base layer 940. The second layer 950 may terminate proximate to the third region 946 of the base layer 940 such that the third region 946 of the base layer 940 is isolated from other layers in the third zone 956. Thus, the third zone 956 may have a relatively high elasticity when compared to the first and

second zones

952, 954 and may thus be at least 5%, at least 10%, at least 20%, at least 50%, or even at least 100% more elongated (or more elongated) than the elongation of the first and

second zones

952, 954 when subjected to a certain tensile load. Also, although not shown, it is contemplated that second layer 950 may have multiple zones (similar to that described with reference to article 500 of fig. 5).

Referring to fig. 10, a knit upper 1020 for an article of footwear may have first zone 1052, second zone 1054, and third zone 1056, which may have corresponding features similar to those of first zone 952, second zone 954, and third zone 956 in fig. 9. The three zones may be located in any suitable portion of upper 1020. As shown, for example, the first zone 1052 may extend from the bite line 1016 to the throat area 1027 and may provide suitable rigidity, durability, and structural support in that particular area. As shown, second strap 1054 may be located in heel region 1001 to provide desired features for that region. Additionally or alternatively, the second strap 1054 may be located in the throat region 1027, which may be beneficial to provide sufficient rigidity, strength, and durability, wherein the upper 1020 is configured to be coupled to a fastening element (e.g., a lace). Third zone 1056 may be located in toe region 1003, where a relatively high elasticity is required in toe region 1003 to provide comfort and desired performance to the article of footwear. The various zones are shown in certain areas of upper 1020 for non-limiting illustrative purposes only, and it is contemplated that three zones (or more than three zones or less than three zones) may be arranged in any particular manner with respect to upper 1020.

In the present disclosure, ranges given in absolute terms or approximate terms are intended to encompass both, and any definitions used herein are intended to be illustrative and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the embodiments are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein (including all fractional and whole values).

Further, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims

1. An article having multiple layers, the article comprising:

a first zone comprising a first region of a knitted base layer and a knitted second layer, wherein the second layer is disposed primarily on one side of the base layer, and wherein the second layer is secured to the knitted base layer via a plurality of ties spaced apart from one another, the ties comprising knitted loops formed with yarns included in the knitted base layer; and

a second zone comprising a second region of the base layer, wherein the second region of the base layer and the first region of the base layer have a common yarn,

wherein the first zone has a first degree of elasticity such that it has a first elongation when subjected to a tensile load,

wherein the second zone has a second degree of elasticity such that it has a second elongation when subjected to the tensile load, the first elongation being at least 5% greater than the second elongation, and

wherein the second layer and the base layer are formed together as a unitary, one-piece element and are formed on a knitting machine by a single knitting process.

2. The article of claim 1, wherein the first elongation is at least 20% greater than the second elongation.

3. The article of claim 1 wherein the article is,

wherein the first zones of the base layer are formed at least in part from first yarns and the second layer is formed at least in part from second yarns, the first yarns having a characteristic different from a characteristic of the second yarns,

wherein the first yarn is a common yarn of the first and second zones of the base layer, and

wherein the second yarn is a common yarn of the second layer and the second region of the base layer.

4. The article of claim 3, wherein the first yarns are disposed primarily on a first side of the base layer in the second zone, and wherein the second yarns are disposed primarily on an opposite second side of the base layer in the second zone.

5. The article of claim 1, further comprising a third zone comprising a third region of the base layer, wherein the second layer terminates adjacent to the third region of the base layer, and wherein the third zone comprises a third elongation when subjected to the tensile load that is at least 5% greater than both the first elongation and the second elongation.

6. The article of claim 1, wherein the second layer comprises a first zone in a first portion of the first zone and a second zone in a second portion of the first zone, wherein the first zone of the second layer has at least one characteristic different from the second zone of the second layer.

7. The article of claim 6, wherein the first portion of the first zone has an elongation that is at least 5% greater than an elongation of the second portion of the first zone when subjected to a tensile load.

8. The article of claim 6, wherein the first and second zones of the second layer are each disposed primarily on the same side of the base layer.

9. The article of claim 6, wherein the first and second zones of the second layer are spaced apart on the base layer.

10. The article of claim 6, wherein the first zone of the second layer comprises first and second structures that each form their own respective cells, and wherein the cells of the first structures are offset relative to the cells of the second structures.

11. The article of claim 6, wherein the at least one characteristic of the first zone of the second layer comprises a first mesh size, and wherein the at least one characteristic of the second zone of the second layer comprises a second mesh size, and wherein the first mesh size in at least one dimension is larger than the second mesh size in the same at least one dimension.

12. The article according to claim 1, wherein the article is an upper of an article of footwear, and wherein the second layer extends from a bite line of the upper to a throat area of the upper.

13. An article having multiple layers, comprising:

a first zone comprising a knitted base layer and a first region of a knitted second layer disposed primarily on one side of the base layer; and

a second zone comprising the base layer and a second zone of the second layer disposed primarily on one side of the base layer,

wherein the second layer is secured to the base layer via a plurality of ties spaced apart from one another, the ties comprising knitted loops formed with yarns included in the base layer,

wherein the first zone has a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and

14. The article of claim 13, wherein the first zone and the second zone of the second layer are each disposed primarily on the same side of the base layer.

15. The article of claim 13, further comprising a third zone, wherein the base layer is isolated relative to the second layer in the third zone.

16. The article of claim 15, wherein the third zone has a third degree of elasticity such that it has a third elongation when subjected to a tensile load, the third elongation being at least 20% greater than the second elongation.

17. The article of claim 16, wherein the at least one characteristic of the first zone comprises a first mesh size, and wherein the at least one characteristic of the second zone of the second layer comprises a second mesh size, and wherein the first mesh size in at least one dimension is larger than the second mesh size in the same at least one dimension.

18. A method of manufacturing an article having multiple layers, comprising:

knitting a base layer of a run with a first yarn on a knitting machine having a first needle bed and a second needle bed, wherein the base layer is formed at least partially on the second needle bed;

knitting a second layer with a second yarn at least partially on the first needle bed of the knitting machine for at least one pass; and

transferring the second yarn from the first needle bed to the second needle bed,

the article formed by the method comprises a first zone comprising a first area of the base layer and the second layer and a second zone comprising a second area of the base layer,

wherein the second zone has a second degree of elasticity such that it has a second elongation when subjected to the tensile load, the first elongation being at least 5% greater than the second elongation.

19. The method of claim 18, wherein the first and second portions are selected from the group consisting of,

wherein during the step of knitting the base layer of a certain pass, the first yarn is knitted on at least two consecutive needles of the second bed and

wherein the second yarn is knitted on the needles of the first needle bed and on the needles of the second needle bed during the step of knitting the second layer of a certain pass.

20. The method of claim 19, further comprising knitting the second layer in at least two passes on the second needle bed after the step of knitting the second layer in the certain pass and before the step of transferring the second yarn from the first needle bed to the second needle bed.