EP3935210B1

EP3935210B1 - Knit component with apertures

Info

Publication number: EP3935210B1
Application number: EP20716244.7A
Authority: EP
Inventors: Hannah R. AMIS; David Malul
Original assignee: Nike Innovate CV USA
Current assignee: Nike Innovate CV USA
Priority date: 2019-03-04
Filing date: 2020-02-28
Publication date: 2024-03-06
Anticipated expiration: 2040-02-28
Also published as: WO2020180701A2; WO2020180701A4; US20200283936A1; IL285904A; EP3935210A2; CN113544321B; CN113544321A; WO2020180701A3

Description

FIELD OF THE INVENTION

Aspects herein relate to a knit component having apertures that are formed by an activatable yarn.

BACKGROUND OF THE INVENTION

Apertures formed in knit components are typically formed through post processing alterations (e.g., cutting) or by modifying the knitting process to create the apertures.
WO 2016/105539 A1 describes an easy settable stretch fabric comprising three types of yarns: a rigid fiber, an elastic fiber, and a low-melt fiber.
JP H07 305204 A describes the knitted fabric consisting of a cylindrical form having a portion corresponding to a panty, a second portion corresponding to leg and a third portion corresponding to toe.
CN 106 521 788 A relates to a medical splint material in flat-knitting structure. The material is woven from low melting synthetic fibers solely, or woven from the low melting synthetic fibers matched with general chemical fibers.
CA 1 247 392 A describes the method of production of a double knit fabric for sports garment, namely sweater and hockey includes repeating a pattern of predetermined courses containing wales of consecutive selected groups of tuck and welt stitches to form holes in and throughout the knitted fabric.
AT 508 899 A4 describes that in a method for producing a knitted fabric with holes using a single-cylinder circular knitting machine, loops consisting of at least one melt thread are knitted at points to be formed.
DE 102 26 313 A1 describes that the knitted material features a water-soluble yarn, which has been worked into a section at a predetermined place for the openings instead of the base yarn.

BRIEF DESCRIPTION OF THE DRAWING

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

FIG. 1 illustrates an example knit component in a first state in accordance with aspects herein;
FIG. 2 illustrates the knit component of FIG. 1 in a second state in accordance with aspects herein;
FIG. 3 illustrates an example knit schematic representation of a first area of a knit component in accordance with aspects herein;
FIG. 4 illustrates a first state of an example knit structure in a first area of the knit component of FIG. 1 in accordance with aspects herein;
FIG. 5 illustrates a second state of the knit structure of FIG. 4 in accordance with aspects herein;
FIG. 6 illustrates a first state of an alternative example of a knit structure in a first area of the knit component of FIG. 1 in accordance with aspects herein;
FIG. 7 illustrates a second state of the alternative knit structure of FIG. 6 in accordance with aspects herein;
FIG. 8 illustrates an example representation of one or more apertures in a first area of the knit structure of FIG. 5 in accordance with aspects herein;
FIG. 9 illustrates an example representation of one or more apertures having varying heights in a first area of a knit structure in accordance with aspects herein;
FIG. 10 illustrates an example representation of one or more apertures having varying widths in a first area of a knit structure in accordance with aspects herein;
FIG. 11 illustrates an example representation of a knit sock having one or more apertures formed from an activatable yarn in accordance with aspects herein;
FIG. 12 illustrates an example representation of a knit shirt having one or more apertures formed from an activatable yarn in accordance with aspects herein;
FIG. 13 illustrates an example representation of a knit upper of a shoe having one or more apertures formed from an activatable yarn in accordance with aspects herein; and
FIG. 14 is a flow diagram of an example method of knitting a knit component in accordance with aspects herein.

DETAILED DESCRIPTION OF THE INVENTION

The subject matter is defined in claim 1 and described with specificity herein to meet statutory requirements. Although the terms "step" and/or "block" might 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.
At a high level, aspects herein are directed to knit components having one or more apertures formed by an activatable yarn. Generally, the activatable yarn responds to a stimulus (such as thermal energy or an aqueous solution) such that the activatable yarn dissipates, dissolves, or melts thereby forming an aperture in the knit component. The aperture is positioned between a first knit course and a second knit course that each comprises a stable yarn type. The yarn type is stable as it does not generally respond to the stimulus by dissipating, dissolving, or melting. Generally, the stable yarn type may maintain its structural integrity upon being exposed to the stimulus. That is, if the stable yarn type comprises one or more filaments that are assembled together, this assembly is maintained even after being exposed to the stimulus. Accordingly, the first and second knit courses will remain and form a knit structure surrounding the aperture. By utilizing an activatable yarn type and a stable yarn type to form the aperture, it allows for quick and efficient manufacturing of apertures in knit components. For example, it may remove any post-processing alterations to the knit component (cutting, seaming, and the like) used to form apertures. As a further example, forming an aperture using an activatable yarn type removes the increased manufacturing time that is associated with modifying the knitting rotations on, for example, a circular knit machine used to knit the knit component.
Continuing, an aperture is formed in a knit component based on knitting one or more intermediate knit courses with an activatable yarn type where the one or more intermediate knit courses are positioned between the first yarn course and the second yarn course and are interlooped with the first yarn course and the second yarn course. For example, the activatable yarn type may be a fusible yarn type or a dissolvable yarn type. The activatable yarn may extend throughout the intermediate knit course(s) in a course-wise direction. Additionally, the one or more intermediate knit courses may comprise consecutively knit courses in a wale-wise direction. At any point during the knitting of the one or more intermediate knit courses, the stable yarn types of the first knit course (positioned on a first side the aperture-e.g., below the aperture) and the second knit course (positioned on an opposite side of the aperture-e.g., above the aperture) may be interlooped using, for instance, a tuck stitch or a held stitch.
At some point, after the knit component is knit with the activatable yarn type ) and the stable yarn type, the knit component may be exposed to the stimulus. For example, the knit component may be removed from a knit machine and exposed to steam or water. The activatable yarn will then dissipate, leaving behind the aperture. As described in greater detail below, while the activatable yarn type is described as "dissipating," it is contemplated that, in some aspects, portions of the activatable yarn type may still be present in the knit component. For instance, the activatable yarn type may have washed away or may have fused to the surrounding stable yarn types. Additionally, portions of the activatable yarn type may not have fully dissipated as the knit component may not have been exposed to enough stimulus or not exposed to the stimulus for an adequate amount of time, which would leave portions of the activatable yarn type still present in the knit component.
) After the knit component has been exposed to the stimulus, one or more apertures may be formed in the knit component. Specifically, the one or more apertures may be formed in areas once occupied or containing the one or more intermediate knit courses that were knit with the activatable yarn type. As such, the one or more apertures may extend throughout the previously knit intermediate courses in the course-wise direction. Additionally, the one or more apertures may extend in the wale-wise direction, such as in instances where the intermediate knit courses were consecutively knit.
As mentioned, the stable yarn type of the first knit course (positioned on the first side of the aperture, e.g., below the aperture) and the second knit course (positioned on the opposite side of the aperture, e.g., above the aperture) may be interlooped using, for instance, a tuck stitch or a held stitch, to form at least in part, for example, a perimeter edge of the aperture. Accordingly, the width of the aperture in the course-wise direction may be defined in part by the interlooping of the stable yarn type of the first knit course and the second knit course.
The perimeter edge that defines the aperture may extend through a first, a second, a third, and a fourth area. The first area and the third area of the perimeter edge may be defined by the interlooping (e.g., the tuck or held stitch) of the stable yarn type of the first knit course with the stable yarn type of the second knit course as described above. The second area may be defined in part by one or more knit courses on the first side of the aperture (e.g., below the aperture) being interlooped, while the fourth area may be defined in part by one or more knit courses on the second side (e.g., above the aperture) being interlooped.
The present disclosure relies on several terms, so definitions are provided here for the sake of clarity. Throughout this disclosure, an activatable yarn type may be described as "dissipating," "dissipate," or "dissipated." These terms generally refer to a change in a physical state of the activatable yarn type such that the yarn strand disintegrates. To describe this differently, the fibers, filament, and/or filaments of the activatable yarn type may have disintegrated or lost their structural integrity either because they melted or were dissolved. In some aspects, all the fibers, filament, or filaments of the activatable yarn type disintegrate based on being exposed to the stimulus.
Examples of an activatable yarn type include a fusible yarn type or a dissolvable yarn type. The term dissipation may be interpreted differently based on whether the activatable yarn type is a fusible yarn type or a dissolvable yarn type. For example, the term "dissipation" with respect to a fusible yarn may refer to fusible yarn melting and/or fusing to the surrounding knit structure. Referring to a dissolvable yarn, the term dissipating may refer to the activatable yarn type dissolving and being washed away. In some aspects, an activatable yarn type has a lower melting point than a stable yarn type. In some aspects, the activatable yarn type may have a melting point from about 40 degrees Celsius to about 160 degrees Celsius. In some aspects, the melting point of the activatable yarn is from about 60 degrees Celsius to about 110 degrees Celsius. Example activatable yarn types include a polyester yarn such as a 33 decitex polyester yarn and/or a 55 decitex polyester yarn, each having a melting point of about 60 degrees Celsius. Further example activatable yarn types include a polyamide yarn such as a 23 decitex polyamide yarn having a melting point of about 110 degrees Celsius. The term "about" used when, for instance, describing numbers or numerical ranges means within ± 10% of a designated value unless indicated otherwise.
Continuing, the term "dissipation" is not necessarily intended to mean that the activatable yarn type is not present in the knit component. In actuality, portions of the activatable yarn type may remain in the knit component. This may occur, for example, in aspects where the activatable yarn is a fusible yarn and portions of the fusible yarn fuse to the surrounding knit structure. As such, the activatable yarn type may still be present in the knit component even though it has dissipated. Additionally, portions of the activatable yarn type may still be present if the activatable yarn type was exposed to too little of stimulus or was exposed to the stimulus for too little of time.
It should be appreciated that while some of the figures depict the activatable yarn type as being absent, this is not intended to communicate that the activatable yarn is entirely absent from the knit component. For example, in some aspects, the activatable yarn may be a fusible yarn such that it fuses to the surrounding knit structure, which is not illustrated herein. As such, in some example aspects, the activatable yarn type is technically present because the fusible yarn may have bonded or fused to surrounding stable yarn types.
The term "stimulus" as used herein generally refers to an environmental condition that triggers the activatable yarn type to dissipate. To describe this differently, the physical structure of the fibers, filament, or filaments in the activatable yarn may break down or lose their structural integrity based on being exposed to the stimulus. The stimulus may be any condition, such as an aqueous solution or thermal energy. Example stimuli include water, steam, heat, and the like.
The term "stable yarn" type as used herein refers to yarn types that are dimensionally stable when exposed to the stimulus. For example, yarn types are dimensionally stable if they do not dissipate when exposed to the stimulus. In other words, stable yarn types are dimensionally stable because they generally maintain the same filament or fiber count after being exposed to the stimulus. To describe this differently, the stable yarn type maintains its structure despite being exposed to the stimulus. It is contemplated that while the stable yarn type may undergo slight changes, such as shrinking or expanding, the overall structural integrity of the stable yarn type is maintained. As such, the stable yarn type does not respond to the stimulus in the same way that the activatable yarn type responds to the stimulus. Example stable yarn types include a polyester yarn, nylon yarn, cotton yarn, or cotton blend yarn having a higher melting point than an activatable yarn type. In some aspects, the stable yarn type may have a melting point from about 180 degrees Celsius to about 300 degrees Celsius. In some aspects, the stable yarn type may have a melting point from about 220 degrees Celsius to about 300 degrees Celsius. In some aspects, the stable yarn type may have a melting point from about 250 degrees Celsius to about 300 degrees Celsius.
The term "first state" as used herein refers to a state of a knit component before it is exposed to a stimulus. The term "second state" as used herein refers the state of the knit component after it has been exposed to a stimulus.
The term "course" as used herein refers to a predominantly horizontal row of knit loops (in an upright fabric as knit) that are produced by adjacent needles during the same knitting cycle. The knit course may comprise one or more stitch types such as a loop stitch, a held stitch, a float stitch, a tuck stitch, a transfer stitch, and the like as these terms are known in the art of knitting. The term "wale" as used herein is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles. The terms "horizontal" and "vertical" as used herein are relative to an upright fabric as knit in which the heads of knit loops face toward the top of the fabric and the course knit first is oriented toward the bottom of the fabric.
The term "held loop" as used herein may include a loop having legs (or a base) that interloop in a first course and a head that interloops in a second course, wherein one or more intermediary courses are arranged between the first course and the second course. Based on this definition, a held loop is generally created by holding a loop in a needle for one or more intermediary courses in a manner that avoids interlooping with the intermediary courses, before eventually interlooping with a stitch in the second course. The term "tuck stitch" as used herein generally refers to a held loop and a tuck loop. The tuck stitch may be created when a needle holding the held loop receives a new yarn segment that passes. The new yarn segment becomes a tuck loop that is included with the needle having the held loop. The term "held stitch" as used herein generally refers to a held loop and a float loop. The float loop may be created when a needle holding a held loop fails to receive a new yarn segment that passes. The term "plating" as used herein means a knit construction where a yarn and one or more plating yarns are knit in the same knit stitch using, for instance, a body yarn feeder and one or more plating yarn feeders. When a particular knit course is described as comprising one or more yarn types, it is contemplated herein that the one or more yarn types are in a plated relationship.
The term "integrally knit" as used herein may mean a textile or fabric having a yarn from one or more knit courses being interlooped with one or more knit courses of another area. For instance, a knit course from a first area of a knit component may be integrally knit with a knit course from a second area of the knit component if a yarn from the first area is interlooped with a knit course in the second area.
Unless otherwise noted, all measurements provided herein are measured at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar) with the knit component in a resting or non-tensioned state.
FIGs. 1 and 2 depict a first state and a second state of a knit component 100 depicted in schematic form. FIG. 1 includes a magnified photographic view 136 of a portion of a first area 102 when the knit component 100 is in the first state. FIG. 2 includes a magnified photographic view 138 of the first area 102 when the knit component 100 is in the second state. Additionally, the knit component 100 further comprises a second area 104. In some aspects, the second area 104 is located between two or more first areas (e.g., 102).
The knit component 100 may be any type of knit structure that is knit by a circular or flat-knit machine. For example, the knit component 100 may be any garment, article of footwear, article of headwear, gloves, bag, or the like, that has a knit structure. In some aspects, as described in reference to FIGs. 11-13, the knit component 100 can be a knit sock, a knit shirt, or a knit upper. In some aspects, the knit component 100 is integrally knit and forms an entirety of an article. It is also contemplated herein that the knit component 100 may be joined to one or more additional components (knit, woven, nonwoven) to form an article.
Referring initially to FIG. 1, an example not according to the invention and present for illustration purposes only, the first area 102 may comprise a plurality of knit courses. The first area 102 may comprise one or more first knit courses 106, one or more intermediate knit courses 122, and one or more second knit courses 108. The one or more intermediate knit courses 122 may be positioned between the one or more first knit courses 106 and the one or more second knit courses 108.
Each of the plurality knit of courses in the first area 102 may comprise different yarn types, such as a stable yarn type and an activatable yarn type. In some aspects, the one or more first knit courses 106 and the one or more second knit courses 108 are knit with the stable yarn type, such as stable yarn 118. The one or more intermediate knit courses may be knit with an activatable yarn type, such as activatable yarn 120. It is contemplated that the one or more first knit courses 106 and the one or more second knit courses 108 may further comprise an activatable yarn type that is plated with the stable yarn type. Additionally, it is contemplated that the one or more first knit courses 106 and the one or more second knit courses 108 may further comprise two stable yarn types, where a first stable yarn type is plated with a second stable yarn type. Thus, in example aspects, the one or more first knit courses 106 and the one or more second knit courses 108 may comprise a first stable yarn type plated with a second stable yarn type and further plated with an activatable yarn type.
Continuing, the one or more first knit courses 106 and the one or more second knit courses 108 may be interlooped with the one or more intermediate knit courses 122. As shown, the stable yarn 118 of the one or more first knit courses 106 may be interlooped with the activatable yarn 120 of the one or more intermediate knit courses 122, as depicted by reference numeral 124. The activatable yarn 120 of the one or more intermediate knit courses 122 may further be interlooped with the stable yarn 118 of the one or more second knit courses 108, as depicted by reference numeral 126.
In some aspects, the stable yarn 118 of the one or more first knit courses 106 may be interlooped with the stable yarn 118 of the one or more second knit courses 108 at one or more intervals, such as at one or more intervals 116a-e using, for instance, a tuck stitch or a held stitch. In some aspects, the one or more intervals 116a-e may be described as being present at predefined intervals. For instance, a knit machine may be programmed to interloop the one or more first knit courses 106 with the one or more second knit courses 108 at predefined intervals.
Based on being exposed to a stimulus, the activatable yarn 120 in the one or more intermediate knit courses 122 may dissipate. As such, the one or more intermediate knit courses 122 in the first area 102 may dissipate as well. For example, as shown in FIG. 1, the one or more intermediate knit courses 122 are present along with the one or more first knit courses 106 and the one or more second knit courses 108. Yet, as shown in FIG. 2, the one or more intermediate knit courses 122 are depicted as being absent to form an aperture such as aperture 110b.
Because the one or more intermediate knit courses 122 in the first area 102 dissipate, one or more apertures, such as one or more apertures 1 10a-e, are formed in the knit component 100. In particular, as shown in FIG. 2, which is an embodiment not according to the invention, the one or more apertures 110a-e are formed between the one or more first knit courses 106 and the one or more second knit courses 108. Additionally, the one or more apertures 110a-e may be formed between the one or more intervals 116a-e, where the one or more first knit courses 106 are interlooped with the one or more second knit courses 108 using a tuck stitch or a held stitch. In this way, the one or more apertures 110a-e are formed in the first area 102 of the knit component 100.
The first area 102 may include any number of apertures. In some aspects, the one or more apertures 110a-e may appear as a mesh or lattice-like structure. Additionally, the one or more apertures 110a-e may be physically oriented (height, width, shape, spacing between apertures, patterns, and the like) in any configuration. For example, in FIG. 2, the first area 102 depicts the one or more apertures 110a-e in a diamond-like pattern. Additionally, it is contemplated that in tubular knit components (e.g., a sock) the first area 102 may extend circumferentially around the tubular portion of the sock.
As mentioned, the knit component 100 further comprises the second area 104. In some aspects, each knit course in the second area 104 comprises a stable yarn type, such as stable yarn 118. And in some aspects, it is contemplated that the second area 104 may not comprise any activatable yarns. Accordingly, in example aspects, the second area 104 may not include apertures formed by the activatable yarn type. It is contemplated that the knit component 100 may include any number of first areas (e.g., 102) or any number of second areas (e.g., 104).
FIG. 3 illustrates a schematic depiction 300 of a first area 302 of an example knit component, such as the knit component 100. Some features of the schematic depiction 300 may be similar to that shown on a knit programming file (e.g., a bitmap) that is used in knitting the knit component, such as the knit component 100. The bitmap may be used to instruct a knit machine, such as a circular knit machine or a flat knit machine, to knit the example knit component.
FIG. 3 depicts a plurality of knit courses schematically. For example, each horizontal line depicts a knit course. For illustrative purposes, a space is shown between each course, but in reality, the courses would be interlooped. The schematic depiction 300 illustrates one or more first knit courses 306 spaced apart from one or more second knit courses 308 by one or more intermediate knit courses 322. In actuality, in some aspects, portions of the one or more first knit courses 306 and the one or more second knit courses 308 may be brought together in physical proximity based on the interlooping of their respective yarns at intervals 316a-e using tuck stitches or held stitches as indicated by reference numerals 325, 326, 328, 329, and 330 (shown schematically as vertical lines). For example, as shown in FIG. 1, the one or more first knit courses 106 are brought together in physical proximity with the one or more second knit courses 108 at the one or more intervals 116a-e.
While discussed in greater detail below, the schematic depiction 300 includes a first magnified view 342 of an example transition prior to the one or more first knit courses 306, the one or more second knit courses 308, and the one or more intermediate knit courses 322. Similarly, the schematic depiction 300 includes a second magnified view 343 of an example transition after the one or more first knit courses 306, the one or more second knit courses 308, and the one or more intermediate knit courses 322.
As discussed below, the example transitions illustrate the dropping in or introduction of various yarn types. It should be appreciated that the dropping in or introduction of the various yarn types may be at any point during the knitting of a particular course. The example transitions also illustrate the dropping out or removal of the various yarn types. It should be appreciated that the dropping out or removal of the various yarn types may be at any point during the knitting of the particular course. It is contemplated that the various yarn types may be cut and secured (e.g., tied) once dropped out. It is further contemplated that the dropping out of the various yarn types may including floating the various yarn types until they are re-introduced.
The schematic depiction 300 and the first and second magnified views 342 and 343 illustrate the one or more first knit courses 306. According to the invention, the one or more first knit courses 306 comprise a first knit course 340. The first knit course 340 is depicted as a solid horizontal line to indicate that it comprises three yarn types, such as a first yarn type, a second yarn type, and a third yarn type. In some aspects, the first yarn type and the second yarn type may be one or more stable yarn types, such that the first yarn type may comprise a body yarn and the second yarn type may comprise a plating yarn. According to the invention, the third yarn type is an activatable yarn type that is plated with the first yarn type and the second yarn type. As illustrated in the first magnified view 342, reference numeral 344 indicates an example transition of dropping in or introducing the third yarn type.
According to the invention, the one or more first knit courses 306 comprise a second knit course 350. A segment of the second knit course 350 is depicted as a semi-dashed (long-short) horizontal line to indicate that it may comprise two yarn types, such as the second yarn type and the third yarn type in a plated relationship. The segment of the second knit course 350 depicted as the semi-dashed horizontal line does not comprise the first yarn type. It should be appreciated that, in some aspects, the third yarn type may be introduced or dropped in. As shown in the first magnified view 342, reference numeral 352 depicts an example transition of where the third yarn type may be dropped in or introduced into the second knit course 350.
According to the invention, the first yarn type is dropped out or removed from the second knit course 350. Reference numeral 353 illustrates an example transition of where the first yarn type is dropped out or removed. Thus, the segment of the second knit course 350 indicated by the reference numeral 353 may comprise just the first yarn type and the second yarn type without the third yarn type before the third yarn type is introduced at reference numeral 352 and the first yarn type is dropped out.
As mentioned, the schematic depiction 300 illustrates the one or more intermediate knit courses 322. The courses of the one or more intermediate knit courses 322 are depicted with a dashed (even length) horizontal line to illustrate that they comprise just the third yarn type. In some aspects, the third yarn type may be dropped in or introduced prior to knitting the one or more intermediate knit courses 322. As shown in the first magnified view 342, reference numeral 362 depicts an example transition where the third yarn type may be dropped in or introduced prior to the one or more intermediate knit courses 322.
Continuing, reference numeral 364 indicates an example transition of dropping out both the first yarn type and the second yarn type. While FIG. 3 depicts the example transition (e.g., 364) as a single point, it is contemplated that the first yarn type and the second yarn type may be dropped out or removed sequentially or simultaneously. According to the invention, the example transition includes dropping out or removing the first yarn type before the second yarn type. Based on the dropping out or removing the first yarn type and the second yarn type, the one or more intermediate knit courses 322 comprise the third yarn type and not the first yarn type nor the second yarn type. To describe this differently, the one or more intermediate knit courses 322 are knitted with the third yarn type and not the first yarn type nor the second yarn type.
As mentioned, the schematic depiction 300 illustrates the one or more second kmit courses 308. According to the invention, the one or more second knit courses 308 may comprise a third knit course 370. A segment of the third knit course 370 is depicted as a semi-dashed (long-short) horizontal line to indicate that it may comprise two yarn types, such as the second yarn type and the third yarn type. The segment of the third knit course 370 depicted as the semi-dashed horizontal line may not comprise the first yarn type. It should be appreciated that, in some aspects, the third yarn type may be introduced or dropped in. As shown in the first magnified view 342, reference numeral 374 depicts an example transition of where the third yarn type may be dropped in or introduced into the third knit course 370.
In some aspects, the first yarn type may be dropped out or removed from the third knit course 370. Reference numeral 372 illustrates an example transition of where the first yarn type is dropped out or removed. Thus, the segment of the third knit course 370 indicated by the reference numeral 372 may comprise just the first yarn type and the second yarn type without the third yarn type before the third yarn type is introduced at reference numeral 374 and the first yarn type is dropped out.
According to the invention, the one or more second knit courses 308 may comprise a fourth knit course 380. The fourth knit course 380 is depicted as a solid horizontal line to indicate that it comprises three yarn types, such as the first yarn type, the second yarn type, and the third yarn type. In some aspects, the third yarn type may be dropped in or introduced into the fourth knit course 380.
With continued reference to FIG. 3, the schematic depiction 300 shows the one or more intermediate knit courses 322 as being interrupted by the tuck stitches or held stitches 325, 326, 328, 329 and 330 at the one or more intervals 316a-e. The tuck stitches or held stitches 325, 326, 328, 329 and 330 comprise an interlooping of the one or more first knit courses 306 with the one or more second knit courses 308. It should be appreciated that the tuck stitches or held stitches 325, 326, 328, 329 and 330 may define in part a perimeter edge of an aperture that is formed after the one or more intermediate knit courses 322 dissipate.
The interlooping of yarns at the one or more intervals 316a-e may form one or more knit segments 390a-d in each of the one or more intermediate knit courses 322. The length of the one or more knit segments 390a-d may include any number of wales in the course-wise direction. By way of example, each of the one or more knit segments 390a-d may comprise between 1 wale and 50 wales. It should be appreciated that the length of the one or more knit segments 390a-d may correspond to the length of the one or more apertures (e.g., the one or more apertures 110a-e) to be formed in the knit component after it has been exposed to a stimulus. It should be appreciated that while FIG. 3 illustrates four knit segments (e.g., 390a-d) located between the one or more intervals 316a-e, any number of knit segments may be formed in the one or more intermediate knit courses 322.
As mentioned, the second magnified view 343 illustrates an example transition after the one or more first knit courses 306, the one or more second knit courses 308, and the one or more intermediate knit courses 322. Reference numeral 346 indicates an example transition of dropping out or removing the third yarn type from the first knit course 340. With respect to the second knit course 350, reference numeral 354 indicates an example transition of dropping in or re-introducing the first yarn type while reference numeral 356 indicates an example transition of dropping out or removing the third yarn type.
With respect to the one or more intermediate knit courses 322, reference numeral 365 indicates an example transition of dropping in or re-introducing the first and second yarn types, while reference numeral 366 indicates the dropping out or removal of the third yarn type. It is contemplated that dropping in or re-introduction of the first and second yarn types may be sequentially or simultaneously.
With respect to the one or more second knit courses 308, reference numeral 376 indicates an example transition of dropping in or re-introducing the first yarn type in the third knit course 370. Reference numeral 378 indicates an example transition of dropping out or removing the third yarn type from the third knit course 370.
As mentioned, according to the invention, the one or more first knit courses 306 and the one or more second knit courses 308 are described as comprising the third yarn type. It should be appreciated that, in some aspects, the activatable yarn type may fuse to the surrounding knit structure after it has been activated. This may be advantageous as it may strengthen a perimeter edge of an aperture that will be formed in a knit component (e.g., the knit component 100) after it has been exposed to the stimulus. It is contemplated that in some locations in a course of the one or more first knit courses 306 and the one or more second knit courses 308 may not comprise the third yarn type.
FIGs. 4-5 illustrate an example of a knit structure 400 in a first area of the knit component 100, such as the first area 102 of FIG. 1. FIGs. 4-5 are provided to illustrate the first and second state of the knit structure 400, respectively. The knit structure 400 illustrates a plurality of knit courses 412 comprising consecutively arranged knit courses and consecutively arranged wales, with knit stitches forming, for instance, a single-jersey knit.
The plurality of knit courses may comprise one or more first knit courses 406, one or more second knit courses 408, and one or more intermediate knit courses 422 that are positioned between the one or more first knit courses 406 and the one or more second knit courses 408. These knit courses may be similar the one or more first knit courses 306, the one or more second knit courses 308, and one or more intermediate knit courses 322 of FIG. 3. For example, in some aspects, the one or more first knit courses 406 may comprise a first knit course 420 and a second knit course 421. In some aspects, the one or more second knit courses 408 may comprise a third knit course 424, a fourth knit course 426, and a fifth knit course 427.
It should be appreciated that the yarn segments of the courses are depicted in a particular manner to more easily distinguish the type of yarns in each of the plurality of knit courses. For instance, the first knit course 420, the fourth knit course 426, and the fifth knit course 427 are depicted with a positive slope hatching to illustrate that they may comprise a first yarn type, a second yarn type, and a third yarn type (similar to the yarn types described in FIG. 3). The second knit course 421 and the third knit course 424 are depicted in a stipple to illustrate that they may comprise the second yarn type, and the third yarn type. Additionally, the one or more intermediate knit courses 422 are depicted in a cross-hatching to indicate that they may comprise the third yarn type.
The one or more intermediate knit courses 422 are depicted with break lines to convey that the one or more intermediate knit courses 422 may include additional intermediate knit courses arranged between the one or more first knit courses 406 and the one or more second knit courses 408. Any number of intermediate knit courses may be included in the one or more intermediate knit courses 422. For example, the one or more intermediate knit courses 422 may include as many courses as a needle will tolerate before the tension of a tuck stitch is too high. By way of example, the one or more intermediate knit courses 422 may comprise from about one knit course to about thirty knit courses, from about one knit course to about 10 knit courses, from about one knit course to about 7 knit courses, or from about one knit course to about 5 knit courses. It should be appreciated that varying the number of knit courses within the one or more intermediate knit courses 422 may be advantageous as it varies a height of an aperture that will be formed in the knit component 100. To describe this differently, varying the number of consecutively knit intermediate courses determines how far the aperture extends in the wale-wise direction after a stimulus has been introduced.
According to the invention, the first knit course 420 is interlooped with the second knit course 421. For example, the yarns of the first knit course 42C are interlooped with the yarns of the second kmit course 421. The third knit course 424 is interlooped with the fourth knit course 426. The yarns of the third knit course 424 are interlooped with the yarns of the fourth knit course 426. And the fourth knit course 426 is interlooped with the fifth knit course 427.
According to the invention, the one or more first knit courses 406 and the one or more second knit courses 408 are interlooped with the one or more intermediate knit courses 422. According to the invention, with respect to FIG. 4, the second knit course 421 is interlooped with the one or more intermediate knit courses 422. The third kmit course 424 is interlooped with the one or more intermediate knit courses 422. According to the invention, the first knit course 420 is knit with the fourth knit course 426 using a tuck stitch or a held stitch at two or more intervals comprising one or more wales during a knitting sequence.
In some aspects, the one or more first knit courses 406, the one or more second knit courses 408 and the one or more intermediate knit courses 422 may be interlooped using a tuck stitch (e.g., 428, 430, and 432) at one or more intervals 416a-c. Each tuck stitch 428, 430, and 432 may comprise a held loop 442 and one or more tuck loops 444. Both the held loop 442 and the one or more tuck loops 444 may be interlooped with the yarn(s) in the one or more second knit courses 408.
The one or more tuck loops 444 may comprise any of the yarn type(s) from the one or more first knit courses 406, the one or more second knit courses 408, and the one or more intermediate knit courses 422. For example, as shown in FIG. 4, the one or more tuck loops 444 may comprise the yarn types of the second knit course 421, the one or more intermediate knit courses 422, the third knit course 424, and the fourth knit course 426. The tuck stitches 428, 430, and 432 may be advantageous as it may reinforce a perimeter edge of an aperture that will be formed in the knit component 100 after it has been exposed to a stimulus.
As mentioned, each of the tuck stitches 428, 430, and 432 may comprise the held loop 442. The held loop 442 may include held loop legs 436, 438 that extend from a held loop base 440 through the plurality of knit courses 412. In some aspects, the held loop base 440 may be located in the one or more first knit courses 406. The held loop legs 436, 438 may then extend across the one or more intermediate knit courses 422. The held loop legs 436, 438 may be interlooped with a course in the one or more second knit courses 408. In an example aspect, as shown in FIG. 4, the held loop base 440 may be located in the first knit course 420. The held loop legs 436, 438 may then extend through the first knit course 420, the second knit course 421, the one or more intermediate knit courses 422, the third knit course 424, and the fourth knit courses 426. A head of the held loop 442 may then be positioned in the fifth knit course 427.
It is contemplated that, in some aspects, the head of the held loop 442 may be positioned in the fourth knit course 426 or the third knit course 424. For example, if the head of the held loop is positioned in the fourth knit course 426, the held loop legs 436, 438 may extend through the first knit course 420, the second knit course 421, the one or more intermediate knit courses 422, and the third knit course 424. As a further example, if the head of the held loop is positioned in the third knit course 424, the held loop legs 436, 438 may extend through the first knit course 420, the second knit course 421, the one or more intermediate knit courses 422, and the third knit course 424.
It should be appreciated that, in some aspects, the one or more intermediate knit courses 422 may have dissipated after exposure to a stimulus, as illustrated in FIG. 5. Accordingly, when the knit structure 400 is in the second state, the tuck stitches 428, 430, and 432 may appear to extend across four knit courses (e.g., the first knit course 420, the second knit course 421, the third knit course 424, and the fourth knit course 426). Accordingly, in some aspects, at least when the knit component 100 is initially knit, the tuck stitches 428, 430, and 432 are held for at least five knit courses as it includes the one or more intermediate knit courses 422.
In some aspects, the one or more intervals 416a-c may comprise any number of wales. As shown, FIG. 4 depicts the example tuck stitch 430 in a single wale 418. Accordingly, in some aspects, the one or more intervals 416a-c may each comprise a tuck stitch in a single wale. However, it is contemplated that the one or more intervals 416a-c may extend across any number of consecutive wales, where each consecutive wale includes a tuck stitch. For example, the number of wales may range from two consecutive wales to thirty consecutive wales. It should be appreciated that knitting consecutive tuck stitches in a plurality of wales may determine the spacing between one or more apertures (e.g., 410a-b) that will be formed in the example knit component 100.
In some aspects, the one or more tuck stitches 428, 430, and 432 may form one or more knit segments 450a-b. The one or more knit segments 450a-b may comprise one or more intermediary wales (e.g., 411, 413, 414, and 416). More particularly, the knit segment 450a comprises the intermediary wales 411 and 413, and the knit segment 450b comprises the intermediary wales 414 and 416. It is contemplated that each of the one or more knit segments 450a-b may extend across any number of wales. For example, the number of intermediary wales may range from one to forty wales. It should be appreciated that the number of intermediary wales will determine the length of the aperture (e.g., one or more apertures 410a-b) in the course-wise direction.
With respect to FIG. 5, the knit structure 400 has been exposed to the stimulus and the one or more apertures 410a-b are formed after the one or more intermediate knit courses 422 dissipate. As such, the one or more apertures 410a-b may be formed in the plurality of knit courses 412. According to the invention, the one or more apertures 410a-b are located between the one or more first knit courses 406 and the one or more second knit courses 408. As shown, in an example aspect, the one or more apertures 410a-b are positioned between the second knit course 421 and the third knit course 424.
In addition, according to the invention, the one or more apertures 410a-b are located between the interlooping of the first knit course 420 and the fourth knit course 426 at intervals 416a-c. In some aspects, the one or more apertures 410a-b may be located between the one or more tuck stitches 428, 430, and 432. In some aspects, a perimeter edge of the one or more apertures 410a-b may be defined in part by the one or more tuck stitches 428, 430, and 432.
In some aspects, each of the one or more apertures 410a-b may have a width of the one or more knit segments 450a-b. To describe this differently, the one or more apertures 410a-b may extend across the one or more intermediary wales (e.g., 411, 413, 414, and 416). For example, aperture 410a may extend across intermediary wales 411, 413, while aperture 410b may extend across intermediary wales 414, 416. The width of each of the one or more apertures 410a-b may be determined by the number of wales in each of the knit segments 450a-b.
Turning now to FIGs. 6-7, these figures illustrate an alternative example of a knit structure 600 in a first area of the knit component 100, such as the first area 102 of FIG. 1. In particular, FIG. 6 is provided to illustrate the first state of the knit structure 600, while FIG. 7 is provided to illustrate the second state of the knit structure 600. These examples are not covered by the scope of the claims in that the first knit course 606 is linked to a fifth knit course 627.
The knit structure 600 is generally the same as the knit structure 400 as described in FIGs. 4-5. For example, the knit structure 600 comprises a plurality of knit courses 612 that are similar to the plurality of knit courses 412. As such, the knit structure 600 may comprise one or more first knit courses 606, one or more intermediate knit courses 622, and one or more second knit courses 608. In some aspects, the one or more first knit courses 606 may comprise a first knit course 620 and a second knit course 621.The one or more second knit courses 608 may comprise a third knit course 624, a fourth knit course 626, and a fifth knit course 627.
In some aspects, the knit structure 600 may comprise one or more held stitches 628, 630, and 632 at one or more intervals 616a-c. For example, in some aspects, the one or more first knit courses 606 may be interlooped with the one or more second knit courses 608 using the held stitches 628, 630, and 632 at the intervals 616a-c. Each held stitch 628, 630, and 632 may comprise a held loop 642 and one or more float loops 660. The held loop 642 of the held stitch 630 may be similar to the held loop 442 of the tuck stitch 430 described in FIG. 4.
As mentioned, the held stitches 628, 630, and 632 may comprise the one or more float loops 660. In example aspects, the second knit course 621, the one or more intermediate knit courses 622, the third knit course 624, and the fourth knit course 626 may comprise a float loop 660 at the one or more intervals 616a-c.
In some aspects, the one or more intervals 616a-c may extend across any number of wales. As shown, FIG. 6 depicts the held stitch 630 in a single intermediary wale 618. Accordingly, in some aspects, the one or more intervals 616a-c may comprise a held stitch in a single wale. However, it is contemplated that the one or more intervals 616a-c may extend across any number of consecutive wales. For example, the number of wales may range from two consecutive wales to thirty consecutive wales. It should be appreciated that consecutively knitting held stitches in a plurality of wales may determine the spacing between one or more apertures (e.g., 610a-b).
In some aspects, the held stitches 628, 630, and 632 may define the boundaries of one or more knit segments 650a-b that extend across one or more intermediary wales (e.g., 611, 613, 614, and 616). It is contemplated that each of the one or more knit segments 650a-b may extend across any number of consecutive wales. For example, the number of intermediary wales may range from one to forty consecutive wales. It should be appreciated that varying the number of intermediary wales will determine the length of the aperture (e.g., 610a-b) in the course-wise direction.
It should be appreciated that while FIGs. 4-5 depict tuck stitches at the one or more intervals 416a-c, and while FIGs. 6-7 depict held stitches at the one or more intervals 616a-c, any and all variations of held stitches and tuck stitches at one or more intervals are contemplated as being within the scope of this disclosure.
Turning now to FIG. 7, the knit structure 600 has been exposed to the stimulus and the one or more apertures 610a-b are formed after the one or more intermediate knit courses 622 dissipate. As such, the one or more apertures 610a-b may be formed in the plurality of knit courses 612. In some aspects, the one or more apertures 610a-b may be located between the one or more first knit courses 606 and the one or more second knit courses 608. As shown, in an example aspect, the one or more apertures 610a-b may be located between the second knit course 621 and the third knit course 624. In addition, in some aspects, the one or more apertures 610a-b may be located between the one or more held stitches 628, 630, and 632. In some aspects, a perimeter edge of the one or more apertures 610a-b may be defined in part by the one or more held stitches 628, 630, and 632.
In some aspects, each of the one or more apertures 610a-b may have a width of the one or more knit segments 650a-b. To describe this differently, the one or more apertures 610a-b may extend across the one or more intermediary wales (e.g., 611, 613, 614, and 616). For example, the aperture 610a may extend across intermediary wales 611, 613, while the aperture 610b may extend across intermediary wales 614, 616.
Turning now to FIG. 8, a portion of a first area 802 of a knit component is illustrated in accordance with aspects described herein. The first area 802 of FIG. 8 references the knit structure 400 of FIGs. 5 and 6, although the first area may have a similar configuration to that shown in FIG. 7. The first area 802 of FIG. 8 is depicted in a second state after the knit component has been exposed to a stimulus.
In some aspects, the tension of the tuck stitches 428, 430 pulls the one or more first knit courses 406 toward the one or more second knit courses 408. This results in the first and second knit courses 406, 408 being brought closer in proximity. As shown in FIG. 8, the tuck stitches 428, 430 may cause the first knit course 420 and second knit course 421 to be brought closer in proximity to the third knit course 424 and the fourth knit course 426, such that the knit courses 420, 421, 424, and 426 are adjacent to each other, and the aperture 410a in FIG. 8 assumes a diamond shape. It is contemplated that when the tension of the one or more tuck stitches 428, 430 is not high, the one or more first knit courses 406 may not be pulled as close toward the one or more second knit courses 408. As such, the shape of the aperture 410a may appear to have a more rectangular appearance. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
The aperture 410a comprises a perimeter edge 850. The perimeter edge 850 may comprise one or more areas. In an example aspect, the perimeter edge 850 comprises a first area 810, a second area 820, a third area 830, and a fourth area 840. The aperture 410a may be defined by the perimeter edge 850 that extends from the first area 810 to the second area 820, from the second area 820 to the third area 830, from the third area 830 to the fourth area 840, and from the fourth area 840 back to the first area 810.
In some aspects, the interlooping of various knit courses in the plurality of knit courses 412 may form the one or more areas of the perimeter edge 850. For example, the first area 810 may be formed by the interlooping of the first knit course 420 and the fourth knit course 426 using the tuck stitch 428 at interval 416a. The second area 820 may be formed by the interlooping of the third knit course 424 and the fourth knit course 426. The third area 830 may be formed by the interlooping of the first knit course 420 and the fourth knit course 426 using the tuck stitch 430 at interval 416b. The fourth area 840 may formed by an interlooping of the first knit course 420 and the second knit course 421. In example aspects, the second knit course 421 may not be interlooped with the third knit course 424 at the second area 820 or the fourth area 840.
Turning now to FIG. 9, a portion of a first area 902 is depicted where apertures 910a-c have different heights in the wale-wise direction, in accordance with aspects described herein. As shown, the aperture 910b may have a larger height in the wale-wise direction than the aperture 910a or the aperture 910c. To describe this differently, the aperture 910b may extend through a greater number of knit courses than the aperture 910a or the aperture 910c.
To achieve various heights, the number of the one or more intermediate knit courses can be modified. For instance, a greater number of intermediate knit courses (e.g., the one or more intermediate knit courses 422) may increase the height of the one or more apertures 910a-c. While not shown, a first number of intermediate knit courses comprising the activatable yarn type may be knit in regions 920a and 920c corresponding to the aperture 910a and the aperture 910c respectively. A second number of intermediate knit courses comprising the activatable yarn type is knit in a region 920b corresponding to the aperture 910b. The aperture 910b has a larger height because the second number of intermediate knit courses in the region 920b is greater than the first number of intermediate knit courses in the region 920a and in the region 920c. This is because when the activatable yarn type is exposed to the stimulus, the activatable yarn in the one or more intermediate knit courses will dissipate, thereby forming the aperture 910b with a greater height than the apertures 910a and 910c.
Turning now to FIG. 10, a portion of a first area 1002 having one or more apertures 1010a-c of varied widths is depicted in accordance with aspects described herein. The first area 1002 may be similar to the first area 102 of knit component 100. As shown, the aperture 1010b may have a larger width in the course-wise direction than the aperture 1010a or the aperture 1010c. To describe this differently, the aperture 1010b may extend along a greater number of wales than the aperture 1010a or the aperture 1010c.
To achieve various widths in each of the one or more apertures 1010a-c, the spacing in regions 1020a-c may be increased by knitting the interval 1016a further apart from the interval 1016b. This may determine the course-wise length of the knit segments for any of the intermediate knit courses. Described differently, increasing the number intermediary wales in the knit segments between each of one or more intervals 1016a-b may increase the course-wise length of each of the one or more apertures 1010a-c.
For example, a first knit segment in the one or more intermediate knit courses may extend through a first number of intermediary wales in regions 1020a, 1020c. A second knit segment in the one or more intermediate knit courses may extend through a second number of intermediary wales in region 1020b. To achieve a larger width in the aperture 1010b compared to the aperture 1010a or the aperture 1010c, the second number of intermediary wales will generally be greater than the first number of intermediary wales. As such, based on introducing the stimulus, the activatable yarn in the first number of intermediary wales and second number of intermediary wales will dissipate, thereby forming the aperture 1010b with a greater width than the aperture 1010a or the aperture 1010c.
Additionally, as shown, the one or more apertures 1010a-c are spaced apart in the course-wise direction. To space the one or more apertures 1010a-c further apart, the number of consecutive wales in each of the intervals 1016a-b may be increased. To state it differently, the number of consecutive tuck stitches (or held stitches) in the intervals 1016a-b may be increased as shown by the presence of four vertical lines in each of the intervals 1016a-b. It should be appreciated that varying the length of intervals 1016a-b may create a unique aesthetic and different patterns in the first area 1002. In addition, it may increase or decrease the amount of ventilation. It should be appreciated that, while not shown, the length of each interval within the intervals 1016a-b may be varied. In other words, an interval may extend across a greater number of consecutive wales than a different interval.
In addition, it is contemplated that a first area within a knit component may have different configurations than another first area. For example, a knit component may have a first area having larger apertures and a different first area with smaller apertures. This may be advantageous as particular regions of the knit component may require greater ventilation than other regions. In addition, in some aspects, a density (e.g., the number of apertures or the spacing between the apertures) of the apertures between the first areas may increase or decrease. Controlling the density of the apertures for each of the first areas (e.g., 102) may increase or decrease the ventilation.
Turning now to FIG. 11, an example representation of a knit sock 1100 comprising a first area 1102 is illustrated in accordance with aspects herein. The knit sock 1100 is similar to the knit component of FIG. 1. The knit sock 1100 may comprise a sock body 1110 having a number of regions, such as a toe region 1120, a mid-foot region 1130, a heel region 1140, and a leg region 1150. In some aspects, the first area 1102 extends circumferentially around the sock body 1110 in the leg region 1150. A magnified view 1170 of the first area 1102 is provided. As shown in the magnified view 1170, the first area 1102 is similar to, for instance, the first area 102 described herein. It should be appreciated that the location of the first area 1102 is an example location. In some aspects, the first area 1102 may be positioned at any location of the sock body 1110, such as in the toe region 1120, the mid-foot region 1130, or the heel region 1140. Additionally, it is contemplated that the sock body 1110 comprises a plurality of first areas 1102. The sock body 1110 may further comprise a second area 1104, similar to the second area 104 of the knit component 100 described in FIG. 1. The second area 1104 may be positioned at any location of the sock body 1110, such as in the toe region 1120, the mid-foot region 1130, or the heel region 1140.
Turning now to FIG. 12, an example representation a knit shirt 1200 comprising a first area 1202 is illustrated in accordance with aspects herein. The knit shirt 1200 is similar to the knit component of FIG. 1. Although shown in the form of a short-sleeve shirt, it is contemplated herein that the garment may assume other forms such as a long-sleeved shirt, a pullover, a hoodie, a jacket, and the like. The knit shirt 1200 may comprise the first area 1202 in a shoulder region 1220 and sides 1250. A magnified view 1230 of the first area 1202 in the shoulder region 1220 is provided. As shown in the magnified view 1230, the first area 1202 is similar to the first area 102 of the knit component 100 described in FIG. 1. In addition, remaining regions 1240 of the knit shirt 1200 may comprise a second area 1204, similar to the second area 104 of the knit component 100 described in FIG. 1. It is contemplated that the first area 1202 and the second area 1204 may be located in any region of the knit shirt 1200. For example, the placement of the first area 1202 and the second area 1204 may be based on, for instance, heat or sweat maps of the human body.
Turning now to FIG. 13, an example representation a knit upper 1300 of a shoe comprising a first area 1302 is illustrated in accordance with aspects herein. The knit upper 1300 may be similar to the knit component 100 of FIG. 1. The knit upper 1300 may comprise a mid-foot region 1310, a heel region 1306, a throat region 1308, and a toe region 1312. A magnified view 1330 of the mid-foot region 1310 is provided. As shown in the magnified view 1330, the mid-foot region 1310 comprises the first area 1302 similar to the first area 102 of the knit component 100 of FIG. 1. In addition, the knit upper 1300 may comprise a second area 1304. It is contemplated that the first area 1302 and the second area 1304 may be positioned at any location of the knit upper 1300, including the heel region 1306, the throat region 1308, and the toe region 1312. It is contemplated that knit upper 1300 comprises a plurality of first areas (e.g., 1302).
Turning now to FIG. 14, a flow diagram of a method 1400 according to the invention of knitting a knit component, such as the knit component 100 of FIG. 1, is provided in accordance with aspects herein. In example aspects, it is contemplated herein that the knit component may be knit on a circular knit machine. It is also contemplated herein that the knit component may be knit on a two-bed flat knit machine. At block 1410, a first knit course is knit with a first yarn type, a second yarn type, and a third yarn type. In some aspects, both the first yarn type and the second yarn type are a stable yarn type. According to the invention, the third yarn type comprises an activatable yarn type. For instance, the stable yarn type may be dimensionally stable when exposed to a stimulus. In an example aspect, the first yarn type is plated with the second yarn type and the third yarn type in the first knit course. In some aspects, the third yarn type is dropped in or introduced prior to knitting to the first knit course.
At block 1420, a second knit course is knit with the second yarn type and the third yarn type. The second knit course is interlooped with the first knit course. In some aspects, the second yarn type is plated with the third yarn type in the second knit course.
At block 1430, one or more intermediate knit courses are knit with the third yarn type. The tin one or more intermediate knit courses are interlooped with the second knit course. In some aspects, the one or more intermediate knit courses comprises the third yarn type and no stable yarn type. According to the invention, the first yarn type and/or the second yarn type are dropped out (or removed) prior to knitting the one or more intermediate knit courses.
At block 1440, a third knit course is knit with the second yarn type and the third yarn type. The third knit course is interlooped with the one or more intermediate knit courses.
At block 1450 a fourth knit course is knit with the first yarn type, the second yarn type, and the third yarn type. The fourth knit course is interlooped with the third knit course. According to the invention, the first knit course is interlooped with the fourth knit course at two or more intervals during a knitting sequence. The first knit course is knit with the fourth knit course using one or more tuck stitches (such as tuck stitches 428, 430, and 432 of FIG. 4) or one or more held stitches (e.g., such as held stitches 628, 630, and 632 of FIG. 6).
While not shown, in some aspects, the method 1400 may further comprise activating the third yarn type to form an aperture, such as the apertures 110a-e, in the knit component. In an example aspect, activating the third yarn type may comprise exposing the knit component to a stimulus. In some aspects, the knit component may be removed from the knit machine and exposed to the stimulus.
Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not depart from the scope of the claims.
A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.
It will 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 carried out in the specific order described.

Claims

A method of manufacturing a knit component (100), the method comprising:
knitting a first knit course (340; 420; 620) with a first yarn type, a second yarn type, and a third yarn type, wherein the third yarn type comprises an activatable yarn type which responds to a stimulus such that the activatable yarn dissipates, dissolves, or melts;

after dropping out the first yarn type, knitting a second knit course (350; 421; 621) with the second yarn type and the third yarn type, wherein the second knit course (350; 421; 621) is interlooped with the first knit course (340; 420; 620);

after dropping out the second yarn type, knitting an intermediate knit course (322; 422; 622) with the third yarn type, wherein the intermediate knit course (322; 422; 622) is interlooped with the second knit course (350; 421; 621);

after dropping in the second yarn type, knitting a third knit course (370; 424; 624) with the second yarn type and the third yarn type, wherein the third knit course (370; 424; 624) is interlooped with the intermediate knit course (322; 422; 622); and

after dropping in the first yarn type, knitting a fourth knit course (380; 426; 626) with the first yarn type, the second yarn type, and the third yarn type,

wherein the fourth knit course (380; 426; 626) is interlooped with the third knit course (370; 424; 624), and

wherein the first knit course (340; 420; 620) is knit with the fourth knit course (380; 426; 626) using a tuck stitch (325, 326, 328, 329, 330; 428, 430, 432) or a held stitch (325, 326, 328, 329, 330; 628, 630, 632) at two or more intervals (316a, 316b, 316c, 316d, 316e; 416a, 416b, 416c; 616a, 616b, 616c) comprising one or more wales during a knitting sequence.
The method of manufacturing the knit component (100) according to claim 1, further comprising: exposing the knit component (100) to the stimulus to form an aperture (110a-e; 410a-b; 610a-b; 910a-c; 1010a-c) in the knit component (100).
The method of manufacturing the knit component according to claim 1 or 2, wherein the first yarn type is plated with the second yarn type and the third yarn type in the first knit course.
The method of manufacturing the knit component according to any of claims 1 through 3, wherein the second yarn type is plated with the third yarn type in the second knit course.
The method of manufacturing the knit component (100) according to any of the preceding claims, wherein the stimulus comprises thermal energy.
The method of manufacturing the knit component (100) according to any of the preceding claims, wherein the stimulus comprises an aqueous solution.
The method of manufacturing the knit component (100) according to any of the preceding claims, wherein the first yarn type and the second yarn type are dimensionally stable when exposed to the stimulus.