CN116670347A - Knitted article with variable features - Google Patents

Abstract

Aspects herein relate to a knitted structure for forming a knitted article, wherein the knitted structure can be adjusted to provide zonal cushioning, zonal insulation, zonal conformability, zonal permeability/breathability characteristics, and/or zonal tactile feedback characteristics. The knit structure has a repeating pattern of a first number of courses and a second number of courses, the first number of courses having a first yarn knitted with a first base stitch, wherein within each course of the second number of courses the first yarn is knitted with a repeating pattern having a first number of stitches and a second number of floats, the first number of stitches being knitted with a second base stitch, the second number of floats being knitted with floats to form a float zone.

Description

Knitted article with variable features

Technical Field

Aspects herein relate to a knit structure for forming a knit article, wherein the knit structure can be modified to impart variable cushioning, insulation, fit, breathability, and tactile feedback features to the knit article.

Background

The conventional knitted structure used to form the knitted article may have a uniform construction or knitting pattern. As such, the resulting knitted article may lack, for example, zonal cushioning, zonal insulation, zonal fit, zonal tactile feedback, and/or zonal permeability/breathability characteristics. Further, if the knitted article includes zoned features at a particular location of the knitted article (such as the heel area of a sock), the knitted structure is substantially uniform at that location such that the features are substantially uniform (e.g., uniform cushioning) at that location.

Drawings

Examples of aspects herein are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 illustrates an example knit structure with break lines at various locations to illustrate different ways in which the knit structure may be modified, in accordance with aspects herein;

FIG. 2 illustrates a cross-sectional view of the example knit structure of FIG. 1 with loop loops formed on a technical back of the example knit structure in accordance with aspects hereof;

FIG. 3 illustrates a view of a first side of a sock having the example knit structure of FIG. 1, in accordance with aspects herein;

FIG. 4 illustrates a bottom view of a sock having the example knit structure of FIG. 1, in accordance with aspects herein;

FIG. 5 illustrates a cross-section taken at cut line 6-6 of FIG. 5 and depicts a slight bulge of a knitted article according to aspects herein;

fig. 6-7 illustrate front and rear views, respectively, of an example upper body knitted article having the knitted structure of fig. 1 in accordance with aspects hereof;

FIG. 8 illustrates a front view of an example lower body knitted article having the knitted structure of FIG. 1 in accordance with aspects hereof;

figures 9-11 illustrate, respectively, a lateral side view, a rear side view, and a medial side view of a sock having a heel strap incorporating the example knit structure of figure 1, in accordance with aspects hereof; and

fig. 12 illustrates a flow chart of an example method of manufacturing a knitted article in accordance with aspects herein.

Detailed Description

The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Furthermore, although the terms "step" and/or "block" may be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

The conventional knitted structure used to form the knitted article may have a uniform construction or knitting pattern. As such, the resulting knitted article may lack, for example, zonal cushioning, zonal insulation, zonal fit, zonal tactile feedback, and/or zonal permeability/breathability characteristics. Further, if the knitted article includes zoned features at a particular location of the knitted article (such as the heel area of a sock), the knitted structure is substantially uniform at that location such that the features are substantially uniform (e.g., uniform cushioning) at that location.

Aspects herein relate to a knitted structure for forming a knitted article, wherein the knitted structure can be adjusted or modified to provide zonal cushioning, zonal insulation, zonal conformability, zonal permeability/breathability characteristics, and/or zonal tactile feedback characteristics. At a high level, the knit structure has a repeating pattern of a first number of courses and a second number of courses, the first number of courses having a first yarn knitted with a first base stitch, wherein within each course of the second number of courses the first yarn is knitted with a repeating pattern having a first number of stitches and a second number of floats, the first number of stitches being knitted with a second base stitch, the second number of floats forming a float zone. In an example aspect, the first base stitch includes loop stitches and the second base stitch does not include loop stitches (i.e., no loop stitches when knitted).

Different parameters associated with the knit structure can be adjusted to provide more or less cushioning, more or less thermal insulation, more or less breathability/permeability, more or less fit, more or less tactile feedback, and the like. For example, greater cushioning and/or thermal insulation may be achieved in the knitted article by increasing the first number of courses including the first base stitch having loop stitches, while less cushioning and/or thermal insulation may be achieved by decreasing the first number of courses including the first base stitch.

Since the first yarn is not intertwined with another stitch in the float zone, the yarn density is less in the float zone. Thus, by increasing the second number of courses to increase the number of float areas and/or the size of the float areas in the wale direction, greater permeability/breathability may be achieved. Greater permeability/breathability may also be achieved by increasing the length of the floats within a given number of courses to increase the size of the floats within a given number of courses in the course direction. Conversely, by reducing the second number of courses and/or by reducing the length of the floats within a given number of courses, less permeability/breathability may be achieved.

For example, by using an elastic yarn as the first yarn, a greater tactile feedback may be achieved. In one example aspect, in a second number of courses, and particularly when elastic yarns are used in the float zone, the elastic yarns may cause "dishing" of the knitted article due to their recovery properties pulling or tensioning the edges of the float zone toward each other. The slightly convex regions may be positioned adjacent to skin surfaces where tactile feedback is desired when the knitted article is worn, such as toe ball and/or heel regions of a wearer's foot, as these regions typically experience a substantial amount of contact with the ground. For example, greater tactile feedback can be achieved by increasing the second number of courses in the knit structure and/or by increasing the length of the float stitch.

Since the first yarn is not intertwined with another stitch in the float zone, the yarn length is smaller in the float zone. This in turn reduces the amount of stretch in the float region and creates a tighter fit. Thus, by increasing the number or size of the float zone in the knitted article, a tighter fit (i.e., greater stretch resistance) can be achieved in the area of the knitted article. This is achieved by increasing the second number of knitting courses and/or by increasing the length of the float stitch within a given number of courses. By reducing the number of float areas in the knitted article, a more relaxed fit can be achieved in the areas of the knitted article. This may be achieved by reducing the second number of courses and/or by reducing the length of the float stitch within a given number of courses.

The parameters of the knitted structure may also be adjusted along a specific set of courses. For example, with respect to the second number of courses, the length of the float stitch may be adjusted to different lengths along a particular set of courses to adjust the permeability/breathability characteristics, fit characteristics, and/or tactile feedback characteristics along the length of the courses.

As used herein, the term "knitted structure" refers to a textile product produced during a single knitting event. Aspects herein contemplate that the knitted structure may be formed by a weft knitting process including, for example, circular knitting and flat knitting processes. The knitted structure may be used to form one or more knitted articles. As used herein, the term "knitted article" refers to any type of article that can be worn by a wearer, including, for example, upper body garments, lower body garments, limb sleeves (e.g., calf sleeves, arm sleeves), socks, shoe uppers, gloves, hats, and the like. As used herein, the positional terms used to describe the knitted article are relative to the intended wearing of the knitted article by an upstanding wearer. The term "inwardly facing surface" means the surface of the knitted article that is configured to face the skin surface of the wearer. In an example aspect, the inwardly facing surface can be an innermost facing surface of the knitted article. The term "outwardly facing surface" means the surface of the knitted article that faces away from the inwardly facing surface and toward the external environment. In an example aspect, the outwardly facing surface may be an outermost facing surface of the knitted article. In an example aspect, the inwardly facing surface may comprise a technical back of the knitted article and the outwardly facing surface may comprise a technical front of the knitted article.

As used herein, the term "course" refers to a predominantly horizontal row of stitches (in an upstanding textile article when knitted) produced by adjacent needles during the same knitting cycle. The courses may include one or more stitch types, such as knitting, holding, float, tuck, transfer, etc., as these terms are known in the knitting art. As used herein, the term "wale" is a predominantly vertical column of knitted loops that are mutually nested or intertwined, typically created by the same needle in successive (but not necessarily all) courses or knitting cycles. The terms "horizontal" and "vertical" are relative to an upstanding textile article when knitted, with the head of the knitted loop facing the top of the textile article and the course knit being oriented first toward the bottom of the textile article. The term "course direction" refers to a direction parallel to the knitting course direction. The term "wale direction" refers to a direction orthogonal to the knitting course direction and/or parallel to the wale direction.

As used herein, the term "first basic stitch" refers to a basic stitch type in which the loops of yarn are pulled from the technical back to the technical front of the knitted article by a previous stitch. Thus, the legs of the stitch appear on the technical face of the knitted article, and the top and bottom of the stitch appear on the technical back of the knitted article. As used herein, the first primary stitch includes a loop stitch. The term "terry loop" refers to loops formed from a knitted yarn that extends away from the technical face and/or technical back of the knitted article, and the term is given its ordinary meaning in the knitting arts. In an exemplary aspect, the loop coils extend away from the technical back of the knitted article such that they face the skin surface of the wearer. As used herein, the term "second base stitch" refers to a base stitch type in which the loops of yarn are pulled from the technical back to the technical front of the knitted article by a previous stitch, but the second base stitch does not include loops of yarn (i.e., no loops of yarn are knitted). As used herein, the term "float stitch" occurs when no new stitch is formed at the needle. Thus, the floats may extend across one or more adjacent wales. When describing that a first location of a knitted article may have a "greater number of stitches" than a second location, this may mean that the stitches extend a greater number of wales in the first location than in the second location. As used herein, the term "plating" means a knitting configuration in which one or more body yarns (i.e., first yarns) and one or more plating yarns (i.e., second yarns) are knitted in the same knitting stitch using, for example, a body yarn feeder and one or more plating yarn feeders.

Yarns used to form the knitted article may include yarns formed from natural fibers/filaments (e.g., cotton, wool, silk, etc.), yarns comprising synthetic fibers/filaments (e.g., polyester, nylon, etc.), or yarns comprising both natural fibers/filaments and synthetic fibers/filaments. Yarns used to form the knitted article may also include elastic yarns, where the term "elastic" refers to the ability of a yarn to stretch to about 100% to about 200% of its original length and return to about (e.g., within 5% to 10%) of its original length after removal of the stretching force. In an example aspect, the elastic yarns may be covered with other yarns, such as polyester or nylon yarns. As used herein, the term "integrally knit" may mean a knitted article in which yarn from one or more courses is intertwined with one or more courses of another area. The knitted article may be integrally knitted during a single knitting event, although cut-sewing configurations are also contemplated herein.

The term permeability is a measure of airflow through a given area of a knitted structure and can be measured using ASTM D737 test methods. As used herein, the term breathability is the ability of a knitted structure to allow moisture vapor to pass through a material and may be measured, for example, using ASTM E96 test methods.

Unless otherwise indicated, all measurements provided herein were made while the knitted article was at standard ambient temperature and pressure (298.15K and 100 kPa) and the knitted article was in a quiescent state (e.g., unstretched state).

Fig. 1 illustrates an example knitted structure 100 that can be used to form a knitted article, wherein the knitted structure 100 is knitted using at least a first yarn 112 (shown in cross-hatching) and an optional second yarn 114 (shown in cross-hatching), wherein the first yarn 112 and the second yarn 114 (when used) are in plated relation. The knitting structure 100 may include additional plating yarns. The knit structure 100 depicts a portion of a repeating pattern that includes a first number of courses 110 integrally knit with a second number of courses 118. Thus, the pattern includes a first number of courses 110, a second number of courses 118, and the like. Thus, there may be multiple sets of a first number of courses 110 and multiple sets of a second number of courses 118.

In an exemplary aspect, a first number of courses 110 are knitted with a first base stitch. As shown in fig. 2 discussed below, the first yarn 112 and optional second yarn 114 are knitted to form a loop stitch on the technical back of the knitted structure 100. The terry loop provides cushioning and thermal insulation due to air entrapment in the yarn loop. They may provide increased stretch properties due to the extra yarn length in the loop. In an example aspect, the first yarn 112 may include different deniers, depending on the desired functional benefit. For example, higher denier yarns may be used to achieve increased cushioning and/or insulation as compared to yarns having smaller denier. The first yarn 112 may be elastic or inelastic. In an example aspect, the second yarn 114 may include an elastic yarn or a non-elastic yarn. The elastic second yarn 114 may be used in a knitted article, such as a sock or limb sleeve, to provide stretch and recovery and to help hold the knitted article in a fixed position on the wearer.

A break line 116 is depicted to illustrate that the first number of courses 110 may include additional courses not shown. In an example aspect, the first number of courses 110 may include from about two courses to about ten courses. A greater number of courses 110 may be used when it is desired to increase cushioning, insulation, and/or stretch due to an increased number of loop stitches. Conversely, a fewer number of courses 110 may be used when reduced cushioning, insulation, and/or stretch is desired.

Knitting structure 100 also includes a second number of courses 118. The second number of courses 118 includes a repeating pattern of a first number of stitches (generally indicated by reference numeral 120) knitted with a second base stitch without terry loops and a second number of stitches (generally indicated by reference numeral 124) for forming the float zone 128. In an example aspect, when second yarn 114 is used, second yarn 114 may be continuously knitted with a second base stitch in a second number of courses 118 (including in float zone 128), as indicated by reference numeral 130. Continuously knitting second yarn 114 in second number of courses 118 may help to provide structure and stability to the knitted article. In further example aspects, when the second yarn 114 is used, the first yarn 112 can float on the technical back of the knit structure 100 in the float zone 128, as shown. Within the second number of knitting courses 118, the first number of knitting stitches 120 are aligned in the wale direction and the second number of float stitches 124 are aligned in the wale direction. Although fig. 1 depicts that the first number of knitting stitches 120 is the same number as the second number of stitches 124, it is contemplated herein that the first number of knitting stitches 120 may be a different number than the second number of stitches 124.

As depicted, the float region 128 has a lower yarn density due to the float stitch 124 than the region knitted with the first and second base stitch. In other words, since the first yarn 112 is not intertwined with other knit stitches in the float zone 128, there is less yarn in the float zone 128. This in turn increases the permeability and/or breathability of the knitted structure 100 in the float zone 128. Further, because the first yarn 112 is not intertwined with other knit stitches in the float zone 128, the length of the first yarn 112 is reduced in the float zone 128 as compared to the non-float zone of the knit structure 100. Because of the smaller yarn length in the float zone 128, stretch resistance (including mechanical stretch resistance) is greater, which may result in a tighter fit.

When first yarn 112 is an elastic yarn, the recovery properties of first yarn 112 can cause micro-embossing or three-dimensional (3-D) deformation of knitted structure 100 because the edges of float zone 128 are pulled toward each other, causing float zone 128 to extend in the z-direction relative to the surface plane of knitted structure 100. In an exemplary aspect, when the first yarn 112 floats on the technical back of the knit structure 100, the float zone 128 extends toward the skin surface of the wearer. The slight convexity or 3-D deformation of the knit structure 100 can provide tactile feedback features to the knit article. For example, the slightly convex region of the knitted article may be positioned adjacent to a region of the wearer where tactile feedback is desired (such as the wearer's foot, back, etc.).

A break line 132 is depicted to illustrate that the second number of courses 118 may include additional courses not shown. In an example aspect, the second number of courses 118 may include from about two courses to about fourteen courses depending on the knitting capability. A greater number of courses 118 within a given set of courses 118 may increase the size of the float zone 128 in the wale direction, which may increase the permeability and/or breathability characteristics of the knitted structure 100. Conversely, a smaller number of courses 118 within a given set of courses 118 may reduce the size of the float zone 128 in the wale direction, which may reduce the permeability and/or breathability characteristics of the knitted structure 100.

A break line 134 is depicted to illustrate that the first number of knitting stitches 120 may include additional knitting stitches not shown. In an example aspect, the first number of knitting stitches 120 can include from two knitting stitches to ten knitting stitches (or more), from two knitting stitches to eight knitting stitches, from two knitting stitches to six knitting stitches, or from two knitting stitches to four knitting stitches. Increasing the first number of knitting stitches 120 decreases the number of float areas 128 within the second number of courses 118 of the resulting knitted article. This in turn reduces the permeability and/or breathability of the resulting knitted article. Additionally, as the number of loops of yarn increases, it may create a greater degree of stretch in the resulting knitted article.

It is also contemplated herein that the first set 136 of the first number of knitting stitches 120 may include the same or a different number of knitting stitches than the second set 138 of the first number of knitting stitches 120. In other words, the first number of knitting stitches 120 may vary or remain the same along the second number of courses 118, depending on the desired attribute.

A break line 140 is depicted to illustrate that the second number of float stitches 124 may extend a greater number of wales. In an example aspect, the second number of floats 124 may extend from two wales to ten wales, from two wales to eight wales, from two wales to six wales, or from two wales to five wales. Extending the second number of stitches 124 a greater number of wales increases the size or surface area of the stitch-down region 128 in the course of the course. This in turn increases the permeability and/or breathability of the knitted structure 100. Additionally, it may create greater stretch resistance in the knit structure 100. In an example aspect, it may be desirable not to extend the second number of float stitches beyond, for example, 10 wales to reduce the incidence of snags.

It is additionally contemplated herein that the first set 142 of the second number of stitches 124 may include the same or a different number of stitches than the second set 144 of the second number of stitches 124. In other words, the second number of stitches 124 can vary or remain the same along a given set of second number of courses 118, depending on the desired attribute.

Changing the first number of knitting stitches 120 and the second number of floating stitches 124 allows the feature to be adjusted at different locations along the course direction of a given set of second number of knitting courses 118. For example, if it is desired to increase air permeability/permeability at a particular location along a given set of second number of courses 118, then the second number of stitches 124 may be increased relative to the first number of stitches 120 at that location such that the second number of stitches 124 extend a greater number of wales. If reduced breathability/permeability is desired at that location, the opposite is true. If greater stretch resistance is desired at a particular location along a given set of second number of courses 118, the second number of stitches 124 may be increased relative to the first number of stitches 120 at that location. If it is desired to reduce stretch resistance at that location, then the reverse is true. By increasing or decreasing the length of float stitch 124 at a desired location and/or by making first yarn 112 an elastic yarn, the tactile feedback can be adjusted at various locations along a given set of second number of courses 118.

Fig. 2 illustrates a cross-sectional view of an example knit structure 100. As shown, in a first number of courses 110, a first yarn 112 and optional second yarn 114 are knitted with a first basic stitch to form a terry loop 210 on a technical back of the knitted structure 100. The extra volume of yarn in the loop coil 210 helps to provide cushioning in use and may provide increased stretch properties. Additionally, loop coils 210 may help to trap air and provide thermal insulation. In a second number of courses 118, first yarn 112 and optional second yarn 114 are knitted with a second base stitch that does not form a loop. As further shown in fig. 2, a first number of courses 110 are integrally knit with a second number of courses 118.

Fig. 3 depicts an example knitted article in the form of a sock 300 utilizing the example knitted structure 100. Various portions of the knit structure 100 are schematically depicted at various locations on the sock 300 such that the float area 128 is indicated by boxes and the courses are represented by lines. Sock 300 includes a location 310 positioned at a leg portion of sock 300, a location 312 positioned at a heel portion of sock 300, and a location 314 positioned at a forefoot portion of sock 300.

At position 310, the second number of courses 118 is greater than the first number of courses 110. In addition, the second number of floating stitches 124 at location 310 is greater than, for example, locations 312 and 314. This results in the size of the float zone 128 being greater in both the course and wale directions of the coil than the float zones at locations 312 and 314. As such, the air permeability/permeability at location 310 may be greater than locations 312 and 314. Also, because the float area 128 is larger at location 310, there may be greater stretch resistance than locations 312 and 314. The greater stretch resistance may help to maintain the leg portions of sock 300 in a relatively fixed position on the legs of the wearer, and the increased size of the float region 128 may allow for increased air and/or moisture exchange and provide a cooling effect to the wearer.

At position 312, the first number of courses 110 is greater than the second number of courses 118. As such, the buffering at location 312 may be increased as compared to, for example, location 310. Increased cushioning may be a desirable attribute because the wearer's heel is a high contact area with the ground. The use of the float area 128 at location 312 may increase stretch resistance and provide a more secure fit of the heel portion of sock 300. Additionally, when elastic yarns are used in the float zone 128, the micro-embossments of the knit structure may provide tactile feedback features at location 312.

At location 314, which is positioned at the forefoot portion of sock 300, increased cushioning may also be a desirable feature, as this is typically the high contact area of sock 300. As such, at location 314, the first number of courses 110 is greater than the second number of courses 118. To provide enhanced tactile feedback at this high contact area, the second number of courses 118 and/or the second number of stitches 124, and thus the size of the stitch area 128 in both the course and wale directions, may be increased as compared to position 312. The positioning of locations 310, 312, and 314 is illustrative, and it is contemplated herein that the features of the knit structure 100 described herein can be modified to achieve one or more desired functional effects at desired locations on a knitted article such as sock 300.

Fig. 4 illustrates a bottom view of an example knitted article in the form of a sock 400 in which a location 410 of the knitted structure 100 is positioned in the heel area towards the rear of the sock 400. Fig. 4 is provided to illustrate how the size of the float region 128 varies along a given set of second number of courses 118. For example, along a second number of knitting courses 118a, float area 128b extends a greater number of wales than float area 128 a. The configuration thus described changes the breathability/permeability characteristics, fit characteristics, and tactile feedback characteristics in a given location, such as location 410 shown in fig. 4. The positioning of location 410 is illustrative and it is contemplated herein that the features of the knit structure 100 described herein can be modified to achieve a desired functional effect at a desired location on a knitted article such as sock 400.

Fig. 5 is a cross-section of sock 400 taken along cut line 5-5 of fig. 4 and is provided to illustrate how the use of elastic yarns for first yarn 112 in knitted structure 100 causes a slight convexity or 3-D deformation of sock 400. The surface plane of sock 400 is indicated by dashed line 510. The float zone 128 is shown extending away from the surface plane 510 in the z-direction. The float area 128 is positioned generally on the technical back 514 of the sock 400 and away from the technical front 512 of the sock 400. By positioning the embossed area 128 on the technical back 514, the embossed area 128 extends toward the skin surface of the wearer to provide a tactile feedback feature. In an example aspect, the slight convexity or 3-D deformation of sock 400 at this location may provide important sensory or tactile feedback for balance and muscle activity during exercise.

Fig. 6-7 illustrate front and rear views, respectively, of an example upper body knit article 600 formed in whole or in part from knit structure 100. With respect to fig. 6, a location 610 having a knit structure 100 is depicted as crossing the upper chest portion of the upper body knit article 600 such that the location 610 is configured to be positioned adjacent the upper front chest region of the wearer. With respect to fig. 7, locations 612 having a knitted structure 100 are shown on each of the sleeve portions 614 of the upper body knitted article 600 such that the locations 612 are configured to be positioned adjacent to the arm regions of the wearer. Comparing location 610 with location 612, the size of float zone 128 is greater in both the course and wale directions of the coil at location 610 than at location 612. This may reflect a desired increased level of breathability/permeability in the high heat generating region of the wearer. The first number of courses 110 is greater at location 612 than at location 610 such that the number of loop stitches at location 612 is increased as compared to location 610. This may reflect a desire to increase the level of thermal insulation, cushioning, and/or stretch in this region of the upper body knit article 600. The positioning of locations 610 and 612 is illustrative and it is contemplated herein that the features of the knitted structure 100 described herein may be modified to achieve a desired functional effect at a desired location on a knitted article, such as upper body knitted article 600.

Fig. 8 illustrates a front view of an example lower body knitted article 800 formed in whole or in part from knitted structure 100. Fig. 8 depicts a location 810, the location 810 being formed by the knitted structure 100 and positioned at a front upper torso part of the lower torso knitted article 800 such that the location 810 is configured to be positioned adjacent a front lower torso region of the wearer. Fig. 8 also depicts a location 812, the location 812 being formed by the knit structure 100 and positioned at a front upper portion of the leg portion 814 such that the location 812 is configured to be positioned adjacent to the front thigh area of the wearer. Comparing location 810 with location 812, the size of float region 128 is greater in both the course and wale directions of the coil at location 810 than at location 812. This may reflect a desired increased level of breathability/permeability in this region of the wearer. The first number of courses 110 is greater than at location 810 such that the number of loop stitches at location 812 is increased as compared to location 810. This may reflect a desire to increase the level of thermal insulation, cushioning, and/or stretch in this region of the lower body knit article 800. The positioning of locations 810 and 812 is illustrative, and it is contemplated herein that the features of the knitted structure 100 described herein may be modified to achieve a desired functional effect at a desired location on a knitted article, such as lower body knitted article 800.

Fig. 9-11 depict additional exemplary uses of aspects of the knit structure 100 in a knitted article such as a sock 900. Fig. 9-11 depict a lateral side view, a rear side view, and a medial side view, respectively, of sock 900. Sock 900 includes a collar 901, the collar 901 having a peripheral edge surrounding an opening 902, the opening 902 for receiving a foot of a wearer. Sock 900 additionally includes a leg portion 903 extending from collar 901 and a foot portion 904 extending from leg portion 903, wherein foot portion 904 terminates at toe end 905. Sock 900 also includes a heel portion 910 positioned between leg portion 903 and foot portion 904, wherein heel portion 910 is configured to be positioned adjacent to the heel area of the wearer when sock 900 is worn. In an example aspect, portions of the heel portion 910 (e.g., heel pocket) can be knitted using a reciprocating knitting process known in the art of sock knitting. To help secure heel portion 910 to the heel area of the wearer when sock 900 is worn, sock 900 may also include an integrally knit heel strap 912, heel strap 912 being knit to extend circumferentially around the lower end of leg portion 903. In other words, heel strap 912 is circular knit rather than reciprocating knit.

Heel strap 912 has a first portion, indicated by reference numeral 914, that includes a continuous knit stitch forming a plurality of courses that extend from a first location 916 (shown in fig. 9) positioned at a rear lateral side of heel portion 910, around a front aspect of sock 900 in the ankle/instep area of sock 900, to a second location 918 (shown in fig. 11) positioned at a rear medial side of heel portion 910. In an example aspect, the first portion 914 can include a higher denier elastic yarn that helps secure the heel strap 912 in place and prevents shifting during wear.

The heel strap 912 also includes a second portion, indicated by reference numeral 920. In an example aspect, the second portion 920 extends from the first location 916 around the apex of the heel portion 910 at the rear of the heel portion 910 and to the second location 918. Second portion 920 may be positioned generally at the area where the bottom of the wearer's heel transitions into the rear of the heel when sock 900 is worn. In an example aspect, the combination of the first portion 914 and the second portion 920 substantially divides the heel portion 910 into an upper half and a lower half.

The second portion 920 can be knitted using one or more yarns including a body yarn and one or more plating yarns (e.g., first yarn 112 and second yarn 114). In an example aspect, each of the body yarn and the one or more plating yarns can include an elastic yarn that imparts a high degree of recovery to the second portion 920. In an example aspect, the second portion 920 can be knitted using aspects of the knitted structure 100. For example, the second portion 920 may be formed using at least a second number of courses 118, the second number of courses 118 having a repeating pattern of a first number of stitches 120 and a second number of stitches 124, the second number of stitches 124 forming the stitch float region 128.

As described above, the yarn length is smaller in the float region 128 than in the first portion 914 of the heel strap 912, which results in greater stretch resistance in the course direction of the coil (i.e., in the medial-to-lateral direction when the sock 900 is worn). In other words, since the first portion 914 of the heel strap 912 does not include the float stitch, the stretch resistance in the medial-to-lateral direction is less than the second portion 920 of the heel strap 912. In the second portion 920, the stretch resistance in the medial-to-lateral direction is greater, which further helps secure the heel strap 912 in position around the rear heel of the wearer. In other words, the first portion 914 of the heel strap 912 may exhibit a first degree of stretch in the course of the coil, and the second portion 920 of the heel strap 912 may exhibit a second degree of stretch in the course of the coil, wherein the second degree of stretch is less than the first degree of stretch.

Aspects herein contemplate that additional areas of heel portion 910 and/or sock 900 may be formed by knitted structure 100, as described above with respect to sock 300 and/or sock 400, for example.

The knitted structure 100 described herein may be used for additional knitted articles not shown, such as limb sleeves, uppers, gloves, hats, and the like. As described herein, the knit structure 100 can be adjusted at different locations or regions of the knit article to achieve desired properties, such as breathability/permeability, fit, cushioning, thermal insulation, tactile feedback, and the like.

Fig. 12 depicts a flow chart of an example method 1200 of knitting a knitted article, such as sock 300, sock 400, upper body knitted article 600, lower body knitted article 800, and sock 900. Method 1200 may be performed on, for example, a circular weft knitting machine or a flat knitting machine. It is contemplated herein that method 1200 can be performed during a single knitting event such that an overall knitted article is formed with minimal post-production manufacturing steps.

At step 1210, a first knitted structure, such as knitted structure 100, is knitted at a first location of the knitted article, such as location 310 of sock 300. The first knitted structure includes a repeating pattern of a first number of courses, such as first number of courses 110, and a second number of courses, such as second number of courses 118, the first number of courses having a first yarn knitted with a first base stitch having terry loops. The second number of courses is knitted in a repeating pattern having a first number of stitches (such as first number of stitches 120) knitted with a second base stitch without terry loops and a second number of stitches (such as second number of stitches 124) used to form a float region, such as float region 128.

At step 1212, a second knitted structure is knitted at a second location of the knitted article (such as location 312 of sock 300). In an example aspect, the second knitted structure includes one or more modifications of the first knitted structure to achieve a different functional effect. In an example aspect, the second knit structure includes a repeating pattern of a third number of courses and a fourth number of courses, the third number of courses having a first yarn knitted with a first base stitch having terry loops. A fourth number of courses is knitted in a repeating pattern having a third number of stitches knitted with the second base stitch without terry loops and a fourth number of floats for forming a float zone. In an example aspect, there are one or more of the following: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches. In further example aspects, there are one or more of the following: the fourth number of courses is different from the second number of courses and the third number of stitches is different from the first number of stitches. Any and all aspects and any variations thereof are contemplated as being within the various aspects herein.

With respect to method 1200, in an example aspect, the first and second knitted structures can also include one or more additional yarns, such as second yarn 114 knitted in plating relation with the first yarn. Within a second number of courses, it is contemplated that the second yarn may be continuously knitted such that the float zone includes the second yarn knitted with a second base stitch that is devoid of loop stitches.

The following clauses represent example aspects of the concepts contemplated herein. Any of the following clauses may be combined in a multi-subordinate manner to rely on one or more other clauses. Furthermore, any combination of subordinate clauses (clauses explicitly dependent on previous clauses) may be combined while remaining within the scope of aspects contemplated herein. The following clauses are examples and not limiting.

Clause 1. A knitted article comprising: a first location having a first knit structure comprising a repeating pattern of a first number of courses having a first yarn knitted with a first base stitch and a second number of courses having the first yarn, wherein within each course of the second number of courses the first yarn is knitted in a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches being knitted with a second base stitch.

Clause 2. The knitted article of clause 1, wherein the first number of knitting stitches is the same as the second number of floating stitches.

Clause 3, the knitted article of clause 1, wherein the first number of knitting stitches is different than the second number of floating stitches.

Clause 4 the knitted article of any of clauses 1-3, wherein the first number of courses is the same as the second number of courses.

Clause 5 the knitted article of any of clauses 1-3, wherein the first number of courses is different than the second number of courses.

Clause 6 the knitted article of any of clauses 1-5, wherein the first knitted structure further comprises a second yarn in plated relation to the first yarn.

Clause 7. The knitted article of clause 6, wherein the second yarn is continuously knitted with the second base stitch in the second number of courses.

The knitted article of any one of clauses 6-7, wherein one or more of the first yarn and the second yarn is an elastic yarn.

Clause 9 the knitted article of any of clauses 1-8, further comprising a second location having a second knitted structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first base stitch and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted in a repeating pattern comprising a third number of stitches and a fourth number of floats, the third number of stitches being knitted with the second base stitch, wherein one or more of: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

Clause 10. The knitted article of clause 9, wherein the first knitted structure is integrally knit with the second knitted structure.

Clause 11. A knitted article comprising: a first location having a first knit structure comprising a repeating pattern of a first number of courses with a first yarn knitted with a first base stitch and a second number of courses with the first yarn, wherein within each course of the second number of courses the first yarn is knitted with a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches is knitted with a second base stitch; and a second location having a second knitting structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first base stitch and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted in a repeating pattern comprising a third number of stitches and a fourth number of float stitches, the third number of stitches being knitted with the second base stitch, wherein one or more of: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

Clause 12 the knitted article of clause 11, wherein one or more of the following are present: the fourth number of courses is different from the second number of courses and the third number of stitches is different from the first number of stitches.

Clause 13 the knitted article of any of clauses 11-12, wherein the first knitted structure is integrally knit with the second knitted structure.

The article of knitting of any of clauses 11-13, wherein each of the first knit structure and the second knit structure further comprises a second yarn in plated relation to the first yarn.

Clause 15, the article of knitting of clause 14, wherein the second yarn is continuously knitted with the second base stitch in each of the second number of courses and the fourth number of courses.

The article of knitting of any of clauses 14-15, wherein one or more of the first yarn and the second yarn comprise an elastic yarn.

Clause 17. A method of knitting a knitted article comprising: during a single knitting event: knitting a first knit structure at a first location of the knit article, the first knit structure comprising a repeating pattern of a first number of courses and a second number of courses, the first number of courses having a first yarn knitted with a first base stitch, the second number of courses having the first yarn, wherein within each course of the second number of courses, the first yarn is knitted in a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches being knitted with a second base stitch; and knitting a second knit structure at a second location of the knit article, the second knit structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first basic stitch and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted with a repeating pattern comprising a third number of stitches and a fourth number of floats, the third number of stitches being knitted with the second basic stitch, wherein one or more of the following are present: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

Clause 18 the method of knitting the article of claim 17, wherein the float stitch in the second number of courses and the fourth number of courses extends from two wales to five wales.

The method of knitting a knitted article of any of clauses 17-18, wherein each of the first knit structure and the second knit structure further includes a second yarn in plated relation to the first yarn.

Clause 20 the method of knitting the article of clause 19, wherein the second yarn is continuously knitted with the second base stitch in each of the second number of courses and the fourth number of courses.

Clause 21, a knitted sock, comprising: a collar having a peripheral edge surrounding an opening for receiving a foot of a wearer; a leg portion extending from the collar; a foot portion extending from the leg portion and terminating at a toe end; a heel portion positioned between the leg portion and the foot portion; and an integrally knit heel strap extending around a circumference of the sock and positioned at a lower end of the leg portion, the integrally knit heel strap including a first portion extending from a first location at a rear-outer side of the heel portion around a front side of the leg portion and extending to a second location at a rear-inner side of the heel portion, the first portion including a plurality of continuous knitting stitches forming a plurality of courses, the second portion extending from the first location around a rear aspect of the heel portion and extending to the second location, the second portion being formed from a course of knitting stitches including a repeating pattern of a first number of knitting stitches and a second number of stitches, the first number of knitting stitches being knitted with a second base knitting stitch, the second number of stitches forming a float zone.

Clause 22 the knitted sock of clause 21, wherein the heel strap divides the heel portion into an upper half and a lower half.

Clause 23 the knitted sock of any of clauses 21-22, wherein the first portion of the heel strap extends around the ankle/instep area of the knitted sock.

Item 24. The knitted sock of any of items 21 to 23, wherein at least the second portion of the heel strap is knitted with a first yarn, and wherein the first yarn is an elastic yarn.

Clause 25, knitting the sock of clause 24, wherein the second portion of the heel strap is knitted with one or more additional yarns, and wherein at least one of the one or more additional yarns comprises an elastic yarn.

Clause 26 the knitted sock of any of clauses 21-25, wherein the first portion of the heel strap exhibits a first degree of stretch in a course direction of the loops, and wherein the second portion of the heel strap exhibits a second degree of stretch in the course direction of the loops, the second degree of stretch being less than the first degree of stretch.

Aspects of the present disclosure have been described with an illustrative, but non-limiting, intent. Alternative aspects will become apparent to those skilled in the art without departing from the scope thereof. Alternative means of implementing the above-described improvements may be developed by the skilled person without departing from the scope of the present disclosure.

It should be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be performed in the particular order described.

Claim (modification according to treaty 19)

1. A knitted article comprising: a first location having a first knit structure comprising a repeating pattern of a first number of courses with a first yarn knitted with a first base stitch including terry loops and a second number of courses with the first yarn, wherein within each course of the second number of courses the first yarn is knitted with a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches being knitted with a second base stitch not including terry loops.

2. The knitted article of claim 1, wherein the first number of knitted stitches is the same as the second number of floating stitches.

3. The knitted article of any one of claims 1 to 2, wherein the first number of knitted stitches is different than the second number of float stitches.

4. A knitted article according to any one of claims 1 to 3, wherein the first number of courses is the same as the second number of courses.

5. A knitted article according to any one of claims 1 to 3, wherein the first number of courses is different from the second number of courses.

6. The knitted article of any one of claims 1 through 5, wherein the first knitted structure further comprises a second yarn in plated relation to the first yarn.

7. The knitted article of claim 6, wherein the second yarn is continuously knitted with the second base stitch in the second number of courses.

8. The knitted article of any one of claims 6 to 7, wherein one or more of the first yarn and the second yarn is an elastic yarn.

9. The knitted article of any one of claims 1 to 8, further comprising a second location having a second knitted structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first base stitch comprising loop stitches and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted with a repeating pattern comprising a third number of stitches and a fourth number of float stitches, the third number of stitches being knitted with the second base stitch not comprising loop stitches, wherein one or more of the following is present: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

10. The knitted article of claim 9, wherein the first knitted structure is integrally knit with the second knitted structure.

11. A knitted article comprising: a first location having a first knit structure comprising a repeating pattern of a first number of courses with a first yarn knitted with a first base stitch including loop stitches and a second number of courses with the first yarn, wherein within each course of the second number of courses the first yarn is knitted with a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches is knitted with a second base stitch not including loop stitches; and a second location having a second knitting structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first base stitch including loop stitches and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted with a repeating pattern comprising a third number of stitches and a fourth number of float stitches, the third number of stitches is knitted with the second base stitch not including loop stitches, wherein one or more of the following is present: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

12. The knitted article of claim 11, wherein one or more of the following are present: the fourth number of courses is different from the second number of courses and the third number of stitches is different from the first number of stitches.

13. The knitted article according to any one of claims 11 to 12, wherein the first knitted structure is integrally knitted with the second knitted structure.

14. The knitted article of any one of claims 11-13, wherein each of the first knitted structure and the second knitted structure further comprises a second yarn in plated relation to the first yarn.

15. The knitted article of claim 14, wherein the second yarn is continuously knitted in the second base stitch in each of the second number of courses and the fourth number of courses.

16. The knitted article of any one of claims 14 to 15, wherein one or more of the first yarn and the second yarn comprises an elastic yarn.

17. A method of knitting a knitted article, comprising: during a single knitting event: knitting a first knit structure at a first location of the knit article, the first knit structure comprising a repeating pattern of a first number of courses and a second number of courses, the first number of courses having a first yarn knitted with a first base stitch comprising terry loops, the second number of courses having the first yarn, wherein within each course of the second number of courses the first yarn is knitted with a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches being knitted with a second base stitch not comprising terry loops; and knitting a second knit structure at a second location of the knit article, the second knit structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first base stitch excluding loops and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted with a repeating pattern comprising a third number of stitches and a fourth number of floats, the third number of stitches being knitted with the second base stitch excluding loops, wherein one or more of the following is present: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

18. The method of knitting the article of claim 17, wherein the float stitch in the second number of courses and the fourth number of courses extends from two wales to five wales.

19. The method of knitting the article of any of claims 17-18, wherein each of the first knit structure and the second knit structure further comprises a second yarn in plated relation to the first yarn.

20. The method of knitting the article of claim 19 wherein the second yarn is continuously knitted in the second basic stitch in each of the second number of courses and the fourth number of courses.

Claims (20)

1. A knitted article comprising: a first location having a first knit structure comprising a repeating pattern of a first number of courses having a first yarn knitted with a first base stitch and a second number of courses having the first yarn, wherein within each course of the second number of courses the first yarn is knitted in a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches being knitted with a second base stitch.

2. The knitted article of claim 1, wherein the first number of knitted stitches is the same as the second number of floating stitches.

3. The knitted article of any one of claims 1 to 2, wherein the first number of knitted stitches is different than the second number of float stitches.

4. A knitted article according to any one of claims 1 to 3, wherein the first number of courses is the same as the second number of courses.

5. A knitted article according to any one of claims 1 to 3, wherein the first number of courses is different from the second number of courses.

6. The knitted article of any one of claims 1 through 5, wherein the first knitted structure further comprises a second yarn in plated relation to the first yarn.

7. The knitted article of claim 6, wherein the second yarn is continuously knitted with the second base stitch in the second number of courses.

8. The knitted article of any one of claims 6 to 7, wherein one or more of the first yarn and the second yarn is an elastic yarn.

9. The knitted article of any one of claims 1 to 8, further comprising a second location having a second knitted structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first base stitch and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted in a repeating pattern comprising a third number of stitches and a fourth number of floats, the third number of stitches being knitted with the second base stitch, wherein one or more of: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

10. The knitted article of claim 9, wherein the first knitted structure is integrally knit with the second knitted structure.

11. A knitted article comprising: a first location having a first knit structure comprising a repeating pattern of a first number of courses with a first yarn knitted with a first base stitch and a second number of courses with the first yarn, wherein within each course of the second number of courses the first yarn is knitted with a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches is knitted with a second base stitch; and a second location having a second knitting structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first base stitch and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted in a repeating pattern comprising a third number of stitches and a fourth number of float stitches, the third number of stitches being knitted with the second base stitch, wherein one or more of: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

12. The knitted article of claim 11, wherein one or more of the following are present: the fourth number of courses is different from the second number of courses and the third number of stitches is different from the first number of stitches.

13. The knitted article according to any one of claims 11 to 12, wherein the first knitted structure is integrally knitted with the second knitted structure.

14. The knitted article of any one of claims 11-13, wherein each of the first knitted structure and the second knitted structure further comprises a second yarn in plated relation to the first yarn.

15. The knitted article of claim 14, wherein the second yarn is continuously knitted in the second base stitch in each of the second number of courses and the fourth number of courses.

16. The knitted article of any one of claims 14 to 15, wherein one or more of the first yarn and the second yarn comprises an elastic yarn.

17. A method of knitting a knitted article, comprising: during a single knitting event: knitting a first knit structure at a first location of the knit article, the first knit structure comprising a repeating pattern of a first number of courses and a second number of courses, the first number of courses having a first yarn knitted with a first base stitch, the second number of courses having the first yarn, wherein within each course of the second number of courses, the first yarn is knitted in a repeating pattern comprising a first number of stitches and a second number of float stitches, the first number of stitches being knitted with a second base stitch; and knitting a second knit structure at a second location of the knit article, the second knit structure comprising a repeating pattern of a third number of courses with the first yarn knitted with the first basic stitch and a fourth number of courses with the first yarn, wherein within each course of the fourth number of courses the first yarn is knitted with a repeating pattern comprising a third number of stitches and a fourth number of floats, the third number of stitches being knitted with the second basic stitch, wherein one or more of the following are present: the third number of courses is different from the first number of courses and the fourth number of stitches is different from the second number of stitches.

18. The method of knitting the article of claim 17, wherein the float stitch in the second number of courses and the fourth number of courses extends from two wales to five wales.

19. The method of knitting the article of any of claims 17-18, wherein each of the first knit structure and the second knit structure further comprises a second yarn in plated relation to the first yarn.

20. The method of knitting the article of claim 19 wherein the second yarn is continuously knitted in the second basic stitch in each of the second number of courses and the fourth number of courses.