JP6288743B2 - Footwear products incorporating knit components with integrated knit contours - Google Patents

Description

  The present disclosure relates to footwear products, and more particularly to footwear products incorporating a knit component with an integral knit contour.

  This section provides background information related to the present disclosure, which is not necessarily prior art.

  Conventional footwear products generally include two main elements: an upper and a sole structure. The upper is fixed to the sole structure and forms a cavity inside the footwear to receive the foot comfortably and stably. The sole structure is secured to the lower area of the upper so that it lies between the upper and the ground. For example, in athletic footwear, the sole structure may include a midsole and an outsole. The midsole often includes a polymeric foam material that reduces ground reaction forces and reduces stress on the feet and legs when walking, running, and during other walking activities. In addition, the midsole may include fluid-filled chambers, plates, moderators, or other elements that further reduce forces, increase stability, or affect foot movement. The outsole is fixed to the lower surface of the midsole and forms a ground engaging portion of a sole structure formed of a durable wear-resistant material such as rubber. The sole structure may also include an insole disposed within the cavity and proximate to the lower surface of the foot to enhance the comfort of the footwear.

  The upper extends generally around the heel area of the foot, along the medial and lateral sides of the foot, over the instep and toe areas. In some footwear products, such as basketball footwear and boots, the upper may extend above and around the ankle to provide support or protection to the ankle. Access to the cavity inside the upper is generally provided by an ankle opening in the heel area of the footwear. To adjust the comfort of the upper, a lace system is often incorporated into the upper, which allows the foot to enter and withdraw from the cavity in the upper. The lacing system also allows the wearer to accommodate specific dimensions of the upper, particularly the circumference, to accommodate feet of various dimensions. In addition, the upper may include a tongue that extends under the lace system to increase the adjustability of the footwear, and the upper may incorporate a heel counter to limit heel movement. .

  Various material elements (eg, woven fabrics, polymer foams, polymer sheets, leather, synthetic leather) are conventionally used in manufacturing uppers. For example, in athletic footwear, the upper may have multiple layers, each containing various joining material elements. By way of example, these material elements may be selected to impart stretch resistance, abrasion resistance, flexibility, breathability, compressibility, comfort and quick drying to different areas of the upper. In order to impart different properties to different areas of the upper, the material elements are often cut into the desired shape and then joined together, usually with sewing or adhesive. Also, the material elements are often joined in a layered configuration to impart multiple properties to the same area.

US Patent Application Publication No. 2010/0154256 US Patent Application Publication No. 2012/0233882 US Patent Application Publication No. 2014/0245634

 As the number and type of material elements incorporated into the upper increases, the time and costs associated with transporting, storing, cutting and joining the material elements can also increase. More waste material from the cutting and sewing process accumulates as the number and type of material elements incorporated into the upper increases. In addition, the greater the number of material elements in the upper, the more difficult it may be to recycle than an upper formed from fewer and fewer material elements. Therefore, by reducing the number of material elements used for the upper, waste can be reduced while improving the manufacturing efficiency and recyclability of the upper.

  This section provides an overview of the disclosure, but is not a comprehensive disclosure of its full scope or all of its features.

  This specification discloses an article of footwear that includes a sole structure and an upper connected to the sole structure. The upper includes an inner side and an outer side, and the upper includes a knit component that is formed of a unitary knit structure. The knit component includes a first edge and a second edge. The knit component also includes a base portion that is disposed adjacent to the sole structure and configured to be disposed under the foot. The knit component further includes a heel portion, a foot tip portion, an inner portion, and an outer portion that are each formed in an integral knit structure with the base portion. In addition, the knit component includes a collar with a rim, which extends from the inner and / or outer portions. The second edge is joined to the first edge at the seam of the knitted component to form a cooperating cavity for receiving the foot in the base, heel, toe, medial and lateral parts doing. The seam has a first end and a second end, and the first end is positioned generally on the collar rim on one of the inner side and the outer side of the upper.

  In addition, a knit component is disclosed that is configured to form an upper for an article of footwear. The upper is configured to be attached to the sole structure. The knitted component includes a base portion having a first side that is at least partially defined by a first edge of the knitted component. The base portion is configured to be disposed adjacent to the sole structure. The knit component also includes a heel portion and a foot portion that are formed in an integral knit structure with the base portion. The knit component also includes an inner portion and an outer portion that extend from the second side of the base portion. The second side is opposite the first side, and one of the inner and outer portions is at least partially defined by the second edge of the knit component. The second edge is joined to the first edge at the seam to position one of the inner side and the outer side adjacent to the first side of the base, and of the inner side and the outer side The other is configured to be positioned adjacent to the second side of the base portion. The second edge also includes a first edge such that the base, heel, toe, inner and outer portions cooperate to define a cavity configured to receive the foot. It is comprised so that it may join.

  Further disclosed is a method of manufacturing a footwear product. The method includes a base portion having a first side at least partially defined by a first edge of a knitted component, a heel portion and a toe formed from an integral knit structure with the base portion. Knitting a knit component formed in a unitary knit structure to have a portion and an inner portion and an outer portion extending from the second side of the base portion. The second side is opposed to the first side. One of the inner and outer portions is at least partially defined by the second edge of the knit component.

  The method positions one of the inner and outer portions adjacent to the first side of the base portion, and the other of the inner and outer portions adjacent to the second side of the base portion. Moving the second edge toward the first edge so as to be positioned.

  The method is configured to join the second edge to the first edge at the seam of the knit component to receive the foot on the base, heel, toe, inner and outer portions. It further includes cooperating to define the cavity.

  Further, the method includes forming an upper of the footwear product from the knit component. The upper includes an inner side defined at least in part by an inner portion of the knitted component. The upper also includes an outer side defined at least in part by the outer portion of the knit component.

  Further scope of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

  The drawings described herein are merely illustrative of selected embodiments and embodiments that may not be all, and are not intended to limit the scope of the disclosure.

1 is a perspective view of a footwear product according to an embodiment of the present disclosure. FIG. FIG. 2 is a perspective view of the footwear product of FIG. 1 with the closure member removed. FIG. 3 is an enlarged perspective view of the footwear product of FIG. 2. FIG. 2 is a perspective view of a knit component with an inlay strand of the footwear product of FIG. 1. FIG. 5 is a plan view of the knit component of FIG. 4. FIG. 5 is a bottom view of the knit component of FIG. 4 with footprints illustrated in phantom lines. FIG. 7 is a cross-sectional view of the knit component taken along line 7-7 of FIG. FIG. 8 is a schematic view of the heel portion of the knit component taken from the perspective view of line 8-8 of FIG. FIG. 7 is a detailed view of a portion of the knit component taken from FIG. 6. FIG. 6 is a bottom view of the knit component, showing the closure member in an unfixed position. FIG. 4 is a bottom view of the knit component, showing the closure member in a fixed position. FIG. 6 is a bottom view of a knit component with an inlay strand according to an additional embodiment of the present disclosure. It is a schematic diagram of the integral knit structure provided with the inlay strand. It is a schematic diagram of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. It is a typical perspective view of the member of the flat knitting machine which shows the formation of the integral knit structure provided with the inlay strand. FIG. 6 is a side view of an upper of an article of footwear including a knitted component according to an additional embodiment of the present disclosure. FIG. 25 is a bottom view of the upper of FIG. 24. It is a front view of the upper of FIG. FIG. 25 is a perspective view of the upper in FIG. 24. FIG. 25 is a plan view of the knit component of the upper of FIG. 24 showing the inside surface of the knit component. FIG. 25 is a plan view of the knit component of the upper of FIG. 24 showing the outer surface of the knit component. FIG. 25 is a perspective view of the knit component showing the stepwise assembly to the upper of FIG. 24. FIG. 25 is a perspective view of the knit component showing the stepwise assembly to the upper of FIG. 24. FIG. 25 is a perspective view of the knit component showing the stepwise assembly to the upper of FIG. 24. FIG. 25 is a perspective view of the upper of FIG. 24 being fitted with a sole structure to form a footwear product. FIG. 25 is a perspective view of the upper of FIG. 24 mounted on a sole structure to form an article of footwear according to an embodiment. FIG. 6 is a bottom view of an upper of an article of footwear including a knit component according to an additional embodiment of the present disclosure. FIG. 36 is a rear view of the upper of FIG. 35. FIG. 36 is a plan view of the knit component of the upper of FIG. 35. FIG. 36 is a bottom view of the upper of FIG. 35 to which a sole structure is attached.

  Corresponding reference characters indicate corresponding parts throughout the drawings.

  Embodiments will now be described more fully with reference to the accompanying drawings.

  The following description and the accompanying drawings disclose various concepts relating to the knit component and the manufacture of the knit component. While the knitted component can be utilized in a variety of products, an example footwear product incorporating one of the knitted components is disclosed.

<General considerations regarding footwear products>
Referring initially to FIGS. 1-3, an article of footwear 100 according to an embodiment is illustrated. The footwear 100 can generally include a sole structure 110 and an upper 120.

  The sole structure 110 is fixed to the upper 120 and extends between the foot and the ground when the footwear 100 is worn. The sole structure 110 can include a midsole 112 and an outsole 114 that overlap each other. The midsole 112 can include an elastically compressible material, a fluid filled bladder, and the like. Accordingly, the midsole 112 acts as a cushion for the wearer's foot, and can reduce impact and other forces when running, jumping, and the like. Outsole 114 can be secured to midsole 112 and can include an abrasion resistant material such as rubber. The outsole 114 can also include treads and other static friction enhancing features.

  Further, the upper 120 can define a cavity 122 that receives the wearer's foot. In other words, the upper 120 can define an inner surface 121 that defines a cavity 122, and the upper 120 defines an outer surface 123 that faces away from the inner surface 121. Can be made. Once the wearer's foot is received within the cavity 122, the upper 120 can at least partially surround and enclose the wearer's foot.

  Many conventional footwear uppers are formed from a plurality of material elements (eg, fabric, polymer foam, polymer sheet, leather, synthetic leather) that are joined together, for example, by sewing or gluing. In contrast, at least a portion of the upper 120 is formed from a knit component 116 having an integral knit structure. The outer boundary of the knitted component 116 can be defined by the peripheral edge 199 illustrated in FIGS. As will be described, the knitted component 116 can define at least a portion of a cavity in the upper 120. The knit component 116 can also define at least a portion of the outer side 123 and / or the inner side 121 of the upper 120.

  In some embodiments, the knitted component 116 can define a majority of the upper 120. If the number of material elements used in forming the upper 120 is reduced, waste may be reduced, and at the same time, the manufacturing efficiency and recyclability of the upper 120 can be improved. As described in more detail below, the knit component 116 of the upper 120 of the present disclosure can reduce waste and improve manufacturing efficiency and recyclability. In addition, the knit component 116 of the upper 120 can incorporate fewer seams or other discontinuities, thereby increasing the overall comfort of the footwear 100.

  The knitted components 116 may have common properties when formed from the same strand, yarn (or yarn type), or with a similar knitted structure. For example, using the same strand for different parts of the knitted component 116 can provide similar durability, strength, stretch, abrasion resistance, biodegradability, thermal properties and hydrophobicity. By using the same strand for multiple portions of the knitted component 116, in addition to physical properties, common aesthetic or tactile properties such as color, gloss and texture can be provided. Also, by using the same knit structure across different portions of the knit component 116, common physical and aesthetic characteristics can be provided.

<Configuration of knit components>
4-6 illustrate various embodiments of a knitted component 116 that may be incorporated into an article of footwear in the same manner as the embodiments of FIGS. 1-3. The knitted component 116 illustrated in FIGS. 4-6 is depicted separated from the rest of the footwear 100. However, each of the embodiments of the knitted component 116 described herein may be combined with the above-described elements of the footwear 100 to form an article of footwear 100 incorporating the knitted component 116. Should be understood.

  The knit component 116 may be a “unitary knit structure”. As defined herein and as used in the claims, the term “unitary knit structure” means that the knit component 116 is formed as a one-piece element by a knitting process. That is, the knitting process substantially forms the various shapes and structures of the knitted component 116 without requiring significant additional manufacturing steps or processes. The unitary knit structure includes at least one course in common (ie, sharing a common strand or yarn) and / or substantially between each portion of the knit component 116. May be used to form a knitted component having the structure or element comprising one or more courses of yarn or other knitted material joined to include a continuous course. With this configuration, a one-piece element having an integral knit structure is formed.

  The portions of the knitted component 116 may be joined together after the knitting process, but because the knitted component 116 is formed as a one-piece knit element, it still remains formed in a unitary knit structure. Also, the knitted component 116 has other elements added to it after the knitting process (eg, inlay strands, closure elements, logos, trademarks, tags with notes and material information, and other structural elements). Even in this case, it is still formed with an integral knit structure.

  4-6 illustrate an embodiment of the knitted component 116 when defining the majority of the upper 120 of the footwear product 100. As shown, the knit component 116 of the upper 120 may include a base portion 124 or a straw bell portion or a foot portion. Also, the knitted component 116 can include one or more sides 126. The base portion 124 can be configured to be disposed adjacent to the sole structure 110. For example, the base portion 124 can be directly or indirectly attached to the sole structure 110 so as to cover the sole structure 110. In additional embodiments, one or more parts of the base portion 124 (eg, the periphery of the base portion 124) may be attached to the sole structure 110 while other parts are removed or separated. Can be made. Further, the base portion 124 can be configured to extend under the wearer's foot. The side 126 can extend from the base portion 124 and can be configured to at least partially cover the wearer's foot. Also, the base portion 124 and the side portion 126 can cooperate to define a cavity 122 that receives the wearer's foot. Again, the base portion 124 and the side portion 126 can be formed with an integral knit structure as described above.

  As shown in the illustrated embodiment, the side 126 of the knitted component 116 includes a heel portion 128, an outer portion 130, an inner portion 132, a foot tip portion 134, and a tongue portion 136. Each of these may be formed of the same integral knit structure as the base portion 124. Thus, the knitted component 116 can be fitted and fitted tightly to the wearer's foot. Also, because of this structure, the knit component 116 can be formed relatively quickly to increase manufacturing efficiency.

  Also, as illustrated in FIG. 6 and described in detail, the knitted component 116 may include one or more extensible strands 158 combined with an integral knit structure of the knitted component 116. it can. For example, the strands 158 can be inserted into the course and / or wales of the knitted component 116 as described. The strand 158 can also be attached to the inner and / or outer surface of the knitted component 116.

  The strands 158 can be placed in the upper so as to extend across the sides and / or under the wearer's foot. The strand 158 can also be operably coupled to a closure member 154 such as a shoelace 155. Therefore, applying tension to the shoelace 155 can similarly apply tension to the strand 158. As a result, the strands 158 can provide support to the wearer's foot for increased comfort and better fit.

  The illustrated embodiment of the upper 120 and footwear 100 is configured to be worn on the wearer's left foot. However, it will be appreciated that footwear 100 can be configured to be worn on the right foot and can include a configuration similar to the illustrated embodiment.

  The footwear 100 can also be configured as a running shoe. However, footwear 100 also applies to various other athletic footwear types including, for example, baseball shoes, basketball shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, training shoes, walking shoes and hiking boots. May be. This concept may also apply to footwear types generally considered non-exercise, including dress shoes, loafers, sandals and work shoes. Accordingly, the concepts disclosed with respect to footwear 100 apply to a variety of footwear types.

<Exemplary shape configuration of knit component>
In the embodiment schematically illustrated in FIG. 13, the main elements of the knit component 116 form a plurality of interlocking loops that define various courses and wales (eg, using a knitting machine). ) It may be formed from at least one yarn 1138 or other strand to be manipulated. The yarns 1138 form each of the courses and wales in this configuration, although additional yarns may form one or more courses and / or wales.

  The properties that a particular type of yarn will impart to the area of the knitted component will depend in part on the material forming the various filaments and fibers within the yarn. For example, cotton provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretchable polyester provide considerable stretch and resilience, respectively, and stretchable polyester also provides recyclability. Rayon is excellent in gloss and provides moisture absorption. Wool also provides high hygroscopicity in addition to thermal insulation and biodegradability. Nylon is a durable, scratch-resistant material with relatively high strength. Polyester is a hydrophobic material that provides relatively high durability.

  Additional examples of suitable configurations for portions of the knitted component 116 are depicted in FIG. In this configuration, the knitted component 116 includes a yarn 1138 and another yarn 1139 (ie, multiple strands). Yarns 1138 and 1139 are spliced to form a plurality of interlocking loops that define a plurality of horizontal courses and vertical wales. That is, yarns 1138 and 1139 extend parallel to each other. The advantage of this configuration is that the respective properties of yarns 1138 and 1139 may be present in this area of knit component 1130. For example, if the color of yarn 1138 appears primarily on the surface of various stitches of knit element 1131 and the color of yarn 1139 appears primarily on the back of various stitches of knit element 1131, yarns 1138 and 1139 differ. You may have a color. As another example, if the yarn 1138 appears primarily on the first surface 1136 and the yarn 1139 appears primarily on the second surface 1137, the yarn 1139 is softer than the yarn 1138 and more resistant to the foot. It may be formed from a comfortable yarn.

  Further, as illustrated in FIGS. 13 and 14, the strands 1132 can be incorporated into an integral knit structure of the knit component 116. The strands 1132 can be extensible strand elements that provide support for the knitted component 116. In other words, the tension in the strand 1132 is such that the knit component 116 resists deformation, stretching during running, jumping, or other movement of the wearer's foot, or for the wearer's foot. It is possible to give support in other ways. It is also appreciated that the strand 158 of FIG. 6 (described above and described in detail below) can be incorporated into the knit component 116, similar to the strand 1132 of FIGS. I will.

  As described, the strands 1132 can be incorporated into or inserted into the unitary knit structure of the knit component 116 so that they can be incorporated during the knitting process on the knitting machine. For example, the strands 1132 can be inserted into a unitary knit structure so as to extend along one of the course and / or wales of the knit component 116 as illustrated in FIGS. As shown in FIGS. 13 and 14, the strands 1132 are arranged alternately (a) behind the loop formed from the yarn 1138 and (b) before the loop formed from the yarn 1138. Can do. In practice, the inlay strand 1132 is threaded to sew the unitary knit structure of the knit element 1131.

  The knitted component may include one or more strands or yarns formed from at least one of thermosetting polymers and natural fibers (eg, cotton, wool, silk). Other yarns or strands may be formed from a thermoplastic polymer material. In general, thermoplastic polymer materials melt when heated and return to a solid state when cooled. More specifically, a thermoplastic polymer material transitions from a solid state to a softened or liquid state when exposed to sufficient heat, after which the thermoplastic polymer material softens when sufficiently cooled. Transition from a state or liquid state to a solid state. Thus, thermoplastic polymer materials are often used to join two objects or elements together. In this case, the yarn is, for example, (a) one part of the yarn to another part of the yarn, (b) the yarn and inlay strand to each other, or (c) another element (eg, logo, trademark, A tag with writing and material information) may be used to join the knit component. Thus, a yarn may be considered a fusible yarn if it may be used to fuse or otherwise join portions of a knitted component together. Also, a yarn may generally be considered a non-fusible yarn if it is not formed from a material that allows parts of the knitted component to be fused or otherwise joined together. That is, the yarns may be non-fusible yarns, while the other yarns may be fusible yarns. In some configurations of the knitted component, the yarn (ie, non-fusible yarn) may be substantially formed from a thermoset polyester material, and the yarn (ie, fusible yarn) is , May be at least partially formed from a thermoplastic polyester material.

  The use of spliced yarn can provide advantages to the knit component. If the yarn is heated and fused to the yarn and inlay strand, this process may have the effect of making the structure of the knit component stiff or stiff. Also, (a) joining one part of the yarn to another part of the yarn, or (b) joining the yarn and the inlay strand together, the relative position of the yarn and the inlay strand is fixed or locked, Thereby, there exists an effect that stretch resistance and rigidity are provided. That is, the portions of the yarn do not slip relative to each other when fused to the yarn, thereby preventing twisting or permanent elongation of the knit element due to relative movement of the knit structure. Another advantage relates to limiting fraying if a portion of the knit component is damaged or one of the yarns breaks. Thus, the area of the knitted component can benefit from the use of both fusible and non-fusible yarns within the knitted element.

  In addition, it will be appreciated that the knit component can have variable zones that collectively form a unitary knit structure. For example, the knit component may be one of the following: a flat knit zone, a cylindrical knit zone, a 1 × 1 mesh knit zone, a 2 × 2 mesh knit zone, a 3 × 2 mesh knit zone, 1 × 1 A combination of at least two of a mock mesh knit zone, a 2 × 2 mock mesh knit zone, a 2 × 2 hybrid knit zone, a full gauge knit zone, a 1/2 gauge knit zone, and the like may be included. Accordingly, the knitted component 116 and the upper 120 can be constructed in accordance with the teachings of US Pat. No. 6,057,028 published on Sep. 20, 2012, which is hereby incorporated by reference in its entirety.

<Embodiments of upper and knit components>
Next, various embodiments of the upper 120 and the knit component 116 will be described in more detail. As shown, the upper 120 can define a longitudinal direction 125, a lateral direction 127, and a vertical direction 129, which refer to different configurations of the upper 120 in the following discussion. Will be used.

  As discussed above, the knit component 116 of the upper 120 can include a base portion 124 that is configured to be placed under the wearer's foot. FIG. 6 shows the contour of the wearer's foot so that the base portion 124 is generally defined with respect to the wearer's foot. Accordingly, the base portion 124 can extend continuously under the heel, sole, toe, arch, and / or directly below one or more portions of the other lower surface of the wearer's foot. In additional embodiments, the base portion 124 can include an opening to extend partially or discontinuously below the wearer's foot.

  The knitted component 116 may also include various sides 126 that extend from the base portion 124 to the periphery. The side 126 can be configured to cover and be in contact with at least a portion of the wearer's foot. In the illustrated embodiment, the side 126 of the knitted component 116 can substantially surround the base 124. It will also be appreciated that the base portion 124 and the side portion 126 can jointly define the inner surface 121 of the knit component 116 and the outer surface 123 of the knit component 116.

  For example, the side portion 126 can include a heel portion 128 disposed at one end of the base portion 124. The heel portion 128 can also extend upward from the base portion 124 in the vertical direction 129, as shown in FIG. The heel portion 128 can be configured to cover the heel and / or ankle area of the wearer's foot.

  The side 126 of the knitted component 116 may also include an outer portion 130 that is disposed forward of the heel portion 128 and may extend upward from the outer side of the base portion 124, as shown in FIG. it can. The outer portion 130 can be configured to cover and contact the outer area of the wearer's foot.

  Further, the side 126 of the knitted component 116 can include an inner portion 132 that is disposed in front of the heel portion 128 and opposite the outer portion 130 to the base portion 124. The inner portion 132 may further extend upward from the base portion 124 in the vertical direction 129, as shown in FIG. The inner portion 132 can be disposed on the opposite side of the base portion 124 in the lateral direction 127. The inner portion 132 can be configured to cover and contact the inner area of the wearer's foot or the instep.

  The heel portion 128, the outer portion 130 and the inner portion 132 can jointly define the horseshoe-like collar 133 of the upper 120. The collar 133 can be accessed into and out of the cavity 122 of the upper 120. Further, the outer edge portion 135 of the outer portion 130 and the inner edge portion 137 of the inner portion 132 can jointly define the throat 131 of the upper 120. The throat 131 can extend substantially parallel to the longitudinal direction 125, or the throat 131 can be disposed at an angle with respect to the longitudinal direction 125. Further, in the embodiment of FIG. 4, the throat 131 is positioned substantially at the center above the base portion 124, but the throat 131 is on one side with respect to the base portion 124 in the lateral direction 127. It can also be arranged. As will be described, the width of the throat 131 can be selectively varied by the closure member 154 to move the outer and inner edges 135, 137 toward and away from each other. As a result, the footwear 100 can be selectively tightened against the wearer's foot and can be loosened from the wearer's foot.

  In addition, the side 126 of the knitted component 116 can include a toe portion 134. As shown in FIG. 1, the toe portion 134 is disposed in the longitudinal direction 125 at the end opposite to the base portion 124 with respect to the heel portion 128 and in front of the outer and inner portions 130 and 132. Can do. Also, the foot portion 134 can be integrally connected to either the outer portion 130 or the inner portion 132, and the foot portion 134 can be spaced apart from the others. In the illustrated embodiment, for example, the foot portion 134 is integrally connected to the outer portion 130 and spaced from the inner portion 132. Therefore, when the upper 120 is in the disassembled state as shown in FIG. 4, a gap 139 can be defined between the foot tip part 134 and the inner part 132.

  Further, the side 126 of the knitted component 116 can include a tongue 136. As shown in FIG. 4, the tongue 136 may include a curved region 143 and a longitudinal region 145. As shown in FIG. 4, when the upper 120 is disassembled, the tongue portion 136 can extend substantially forward from the base portion 124, and the curved region 143 has an inner portion and a foot portion. Can be provided in the gap 139. The curved region 143 can also be curved so that the longitudinal region 145 extends generally rearward and at an angle relative to the inner portion 132, as shown in FIG. The curvature of the curved region 143 can be realized by having a knit course that extends substantially radially from the common area 151, as shown in FIG. The common area 151 can be an imaginary point spaced from the periphery of the curved area 143 between the tongue 136 and the inner part 132, as shown, or the common area 151 can be other It can be arranged in the place. Also, when the upper 120 is assembled, the curved region 143 can be rolled up to at least partially fill the gap 139, and the longitudinal region 145 of the tongue 136 includes the outer portion 130 and the inner portion. It can be placed in the throat 131 of the upper so as to cover the wearer's foot between the upper and lower parts. Further, when the upper 120 is assembled, the longitudinal region 145 of the tongue 136 can be removed and separated from the outer and / or inner portions 130, 132 as shown in FIG.

  As shown in FIGS. 4, 5 and 6, the base portion 124 and the heel portion 128 may define a heel cavity 148 configured to receive the heel of the wearer's foot ( (See FIG. 6). The heel cavity 148 can have an inner surface and / or an outer surface with a three-dimensional curvature. Also, the heel cavity 148 can have a convex outer surface. Accordingly, when the heel portion 128 extends from the base portion 124 in the vertical direction 129, the heel portion 128 can be slightly curved forward in the longitudinal direction 125. Further, when the heel portion 128 extends in the lateral direction 127, both sides of the heel portion 128 can be curved forward in the longitudinal direction 125 so as to join the outer portion and the inner portions 130 and 132. Accordingly, the heel cavity 148 can conform approximately to the shape of the wearer's heel and ankle.

  Further, as shown in FIGS. 4, 5 and 6, the base portion 124 and the toe portion 134 have a toe cavity 150 configured to receive the toe and other toe regions of the wearer's foot. Can be defined (see FIG. 6). The foot cavity 150 can have an inner surface and / or an outer surface with a three-dimensional curvature. Also, the foot tip cavity 150 can have a convex outer surface. Therefore, when the foot tip part 134 extends in the vertical direction 129 from the base part 124, the foot tip part 134 can be curved backward in the longitudinal direction 125. Further, when the foot tip portion 134 extends in the lateral direction 127, the foot tip portion 134 can be bent backward in the longitudinal direction 125 so as to be joined to the outer side portion 130.

  The three-dimensional curvature of the heel cavity 148 and / or the foot tip cavity 150 can be formed by an integral knit structure of the knit component 116. For example, as shown in FIG. 8, the heel portion 128 can include at least two tapered sections 170, 171. The tapered sections 170, 171 can have a boundary 173 that tapers in a generally lateral direction 127, as indicated by the dashed line. The tapered sections 170, 171 can each have multiple courses or rows of stitches, but successive courses have different lengths, thereby forming a tapered boundary 173. Can do. Thus, the tapered sections 170, 171 can have an eye shape, a rope-shaped egg shape, a biconvex shape, or a crescent shape.

  Also, the boundary 173 of the tapered section 170 is joined to the boundary 173 of the tapered section 171 of the unitary knit structure so as to form a knit component 116 having a three-dimensional curvature. This can create a visually distinct distortion along the joined boundary 173. The distortion can be a so-called full fashion mark extending along the joined boundary 173 of the knit component 116.

  In the embodiment of FIG. 8, tapered areas extend from the collar 133 to the base portion 124, and the majority of the heel portions 128 are joined along their respective boundaries to include those tapered areas. There are multiple tapered areas. Accordingly, most of the heel portion 128 can have a three-dimensional curvature. However, it is appreciated that the knitted component 116 can include any number of tapered sections 170, 171 in any portion of the knitted component 116 to form a three-dimensional curvature in the knitted component 116. It will be. Also, the tapered sections 170, 171 can be placed in any suitable direction on the knit component 116. For example, the toe portion 134 can similarly include a tapered section, but such a tapered section can taper in the vertical direction 129 in embodiments.

  The curved region 143 of the tongue 136 may include a plurality of tapered areas that provide curvature to the curved region 143. For example, the curved region 143 can include tapered sections 193, 195 that are knitted together and joined along the boundary 197. This can create a visually distinct distortion along the joined boundary 197. The distortion can be a so-called full fashion mark extending along the joined boundary 197 of the knit component 116. In addition, as described above, the course in the curved region 143 can extend radially from the common area 151 to provide a two-dimensional curvature.

  In some embodiments, the toe portion 134 can also include a plurality of openings 152 arranged to facilitate increasing the curvature of the toe portion 134. In the illustrated embodiment, the plurality of openings 152 can include one or more rows of through holes. The opening 152 reduces the amount of knitted material in the area of the toe portion 134 so that the toe portion 134 can be easily bent back toward the heel portion 128.

  The knitted component 116 may additionally include at least two edges 140, 142 that are configured to be joined together when the upper 120 is assembled. It will be appreciated that the first edge 140 can be the first longitudinal portion of the larger peripheral edge 199 of the knit component 116 shown in FIGS. It will also be appreciated that the second edge 142 can be the second longitudinal portion of the peripheral edge 199. The edges 140, 142 can be defined at any suitable location along the peripheral edge 199 and / or anywhere on the knit component 116. As illustrated in FIGS. 5 and 6, the first edge 140 can extend along the curved region 143 of the tongue 136 and in the lateral direction 127 adjacent to the foot portion 134. The base portion 124 may be partially extended. The second edge 142 can be curved along the toe portion 134, generally in the lateral direction 127, and the vertical direction 129 along the toe portion 134 to partially define the gap 139. Can extend downward. As shown in FIG. 4, the first edge portion 140 and the second edge portion 142 can be joined at a notch portion 141 defined in the base portion 124.

  As described above, the footwear 100 may further include a closure member 154 illustrated in FIG. The closure member 154 can selectively secure the upper 120 to the wearer's foot and can selectively release the upper 120 from the wearer's foot.

  As shown in FIG. 1, the closure member 154 can be a shoelace 155. Accordingly, the outer portion 130 can include one or more outer closure openings 156, such as through holes arranged in a row extending along the outer edge 135. Inner portion 132 may include similar inner closure openings 157 arranged in rows extending along inner edge 137. Openings 156 and 157 can receive shoelaces 155 so that shoelaces 155 can cross, zigzag, and stagger between outer portion 130 and inner portion 132.

  It will be appreciated that the openings 156, 157 can be configured differently than the through-hole shown in FIG. For example, the openings 156, 157 are configured to receive a closure member and are integrated into the knitted component 116 or removably attached to the knitted component 116, grommets, and other It can be defined by an appropriate configuration.

  It will also be appreciated that the closure member 154 can include structures other than laces 155 without departing from the scope of the present disclosure. For example, the closure member 154 could be a strap, clasp, pile tape, or other suitable closure member.

  Further, as shown in FIG. 6, the upper 120 can include at least one extensible strand 158 that is coupled to the base portion 124 and / or the side portion 126. The strand 158 can be bonded to any portion of the base portion 124 and / or the side portion 126. In addition, the strand 158 can be coupled to the base portion 124 and / or the side portion 126 in any suitable manner. For example, the strands 158 can be inserted into a course and / or wales of a unitary knit construction of the base portion 124 and the side portion 126 as described. Thus, the strand 153 can correspond to the strand 1132 described above and illustrated in FIGS. 13 and 14. The strand 158 can also be glued, fixed, penetrated, or otherwise bonded to the inner surface 121 or the outer surface 123 of the base portion 124 and / or the side portion 126.

  The strand 158, the knitted component 116 and the upper 120 are described in Dua et al., Co-owned US patent application Ser. No. 12 / 338,726, filed Dec. 18, 2008 and published as Jun. “Article of Footwear Having An Upper Incorporating A Knitted Component” and US Patent Application No. 13 / Huffa et al. Filed on Mar. 15, 2011 and published as U.S. Pat. These applications can include one or more of the teachings of “Article Of Footwear Incorporating A Knitted Component”, specification No. 048,514 (collectively referred to herein as “inlay strand projects”). Both are incorporated herein by reference in their entirety.

  The strand 158 can be elongated and flexible. The strand 158 can also include at least one yarn, cable, wire, thread, strand, filament, fiber, thread, rope, and the like. Also, the strand 158 can be rayon, nylon, polyester, polyacryl, silk, cotton, carbon, glass, aramid (eg, para-aramid fiber and meta-aramid fiber), ultrahigh molecular weight polyethylene, liquid crystal polymer, copper, aluminum, steel or other It can be formed from any suitable material. The individual filaments used for the strands 158 may be formed from a single material (ie, a single component filament) or multiple materials (ie, composite filaments). Similarly, different filaments may be formed from different materials. By way of example, the yarns used as strands 158 may include filaments that are each formed from a common material, may each include filaments that are formed from two or more different materials, or two each. You may include the filament formed from the above different materials. Similar concepts apply to threads, cables, ropes and the like. The thickness (diameter) of the strand 158 can be, for example, in the range of about 0.03 millimeters to 5 millimeters. The strand 158 can also have a substantially circular cross-section, an oval cross-section, or any other suitable shape.

  As an example, the strand 158 may be formed from bonded nylon 6.6 having a fracture or tensile strength of 3.1 kilograms and a weight of 45 tex. The strand 158 may also be formed from 45 tex bonded nylon 6.6 with a fracture or tensile strength of 6.2 kilograms. As a further example, the strand 158 may have an outer sheath that covers and protects the inner core.

  In some embodiments, the strands 158 can have a fixed length (eg, can be non-extensible). Also, in some embodiments, the strand 158 can be elastically extensible.

  In addition, in some embodiments, the strands 158 may include a thermoplastic material that is configured to adhere, bond, or fuse to the base portion 124 and / or the side portion 126 of the upper 120. it can. For example, selective heating can fuse the material of the strand 158 to the material of the base portion 124 and / or the side portion 126. As a result, the strand 158 can be included in accordance with the teachings of US Pat. No. 6,057,028 published on September 20, 2012 and incorporated by reference in its entirety.

  As illustrated in the embodiment of FIG. 6, the upper 120 can include a single strand 158 that extends continuously between the inner portion 132, the base portion 124, and the outer portion 130. . The strand 158 can also include one or more turns 159,160. The turns 159 and 160 can be 180 degrees or more. Specifically, the strand 158 can include a plurality of outer turns 159 arranged in a row along the outer edge 135, and the strand 158 is arranged in a row along the inner edge 137. A plurality of inner turns may be included. The strand 158 can also extend linearly between the pair of turns 159 and 160. In addition, the strand 158 can include a first end 164 disposed adjacent to the heel portion 128, and the strand 158 is disposed second adjacent to the foot portion 134. End 166 may be included. Also, the strands 158 can alternate between the outer and inner portions 130, 132 to become zigzag.

  Further, as illustrated in FIGS. 6 and 7, the knitted component 116 can define a path 162 between the inner surface 121 and the outer surface 123. Path 162 can be defined in any suitable manner. For example, in embodiments where the strands 158 are inserted into the knitted component 116, the path 162 can be defined through one or more courses or wales of the knitted component 116. Also, in some embodiments, the inner surface 121 can be defined by a layer of knitted material, the outer surface 123 can be defined by another layer of knitted material, and Multiple strands, filaments or single component filaments can extend between these three layers to form a spacing (eg, a so-called “spacer knit material”). In these embodiments, the path 162 can be defined between layers of knitted material and between a plurality of spacer strands. In additional embodiments, the inner surface 121 and the outer surface 123 can be surfaces that are stitched together and the path 162 can be defined between the surfaces.

  The path 162 can extend across any portion of the upper 120. For example, as shown by the dashed lines in FIG. 6, the upper 120 can define a plurality of paths 162, and each path 162 has an outer portion 130, a base portion 124, and an inner portion 132. Can extend continuously between. In the illustrated embodiment, each pathway 162 extends partially (outside) to the outer portion 130 such that the pathway 162 is continuous between the outer portion 130, the base portion 124, and the inner portion 132. Path), extends partially over the base 124 (base path) and partially over the inner part 132 (inner path). However, it will be appreciated that one or more paths 162 can be concentrated and spaced apart in any part of the upper 120.

  As shown in FIG. 7, the strand 158 extends longitudinally within one or more pathways 162 such that it extends between the outer portion 130, the base portion 124, and the inner portion 132. be able to. Further, the turns 159 and 160 of the strand 158 can be exposed from the path 162.

  The outer turns 159 can extend at least partially around each one of the outer closure openings 156, and the inner turns 160 can extend at least partially around each one of the inner closure openings 157. it can. Further, as shown in FIG. 1, shoelaces 155 can be received in respective pairs of outer closure openings 156 and outer turns 159, and each of inner closure openings 157 and inner turns 160 can be received. Shoelaces 155 can also be received within the pair. In other words, each combination of outer turn 159 and outer closure opening 156 can cooperatively receive and support lace 155 and also consists of inner turn 160 and inner closure opening 157. Each combination can also receive and support shoelaces 155.

  In some embodiments, the strands 158 can be loosely and movably received within the respective paths 162. For example, the strand 158 can slide longitudinally through the path 162. As a result, as shown in FIG. 9, the turns 159 and 160 can be pulled close to the respective closure openings 156 and 157. In additional embodiments, the first and / or second end portions 164, 166 of the strand 158 can be moved with respect to the base portion 124, the outer portion 130, and the inner portion 132 of the remaining portion of the strand 158. In this state, the base portion 124 can be fixed (for example, fused). In yet additional embodiments, the portion of the strand 158 between the end portions 164, 166 can be fused or otherwise secured to the base portion 124, the outer portion 130, and the inner portion 132.

  Therefore, even if tension is applied to the shoelace 155, the tension of the strand 158 can be similarly increased. For example, as shown in FIG. 10, if the shoelace 155 is loosened and in the non-fixed position, the tension of the strand 158 may be relatively low, thereby wearing the upper 120. It is possible to fit loosely around a person's foot. However, as shown by arrows 174 and 175, when the shoelace 155 is pulled and tension is applied, the shoelace 155 may pull the turns 159 and 160 and increase the tension of the strand 158. As a result, the strand 158 can be brought together by pulling the upper 120 close to the wearer's foot, as shown by arrows 176, 177, 178, 179 in FIG.

  It will be appreciated that in the embodiment shown in FIGS. 10 and 11, the strands 158 can provide support for various areas of the bottom of the wearer's foot. For example, the strand 158 can be disposed on an arch region 164 that is configured to be disposed on the bottom surface of the wearer's foot arch. Accordingly, the strands 158 in the arch region 164 can support the wearer's arch, particularly when the strands 158 are tensioned by the laces 155.

  It will also be appreciated that in the illustrated embodiment, the upper 120 can include only a single continuous strand 158 to provide support for such a foot. Therefore, the number of members of the upper 120 can be relatively reduced, and the upper 120 can be configured in an efficient manner.

<Assembly of footwear>
Next, the assembly of the footwear 100, the knitted component 116, and the upper 120 will be described according to the embodiment. For clarity, it is assumed that the knitted component 116 and the strand 158 are formed in the disassembled state shown in FIGS.

  To begin the embodiment relating to the assembly of the upper 120, the outer part 130 and the inner part 132 can be moved upward (folded) towards the position shown in FIG. The tongue 136 can then be rolled up so that the curved region 143 substantially closes the gap 139 and the longitudinal region 145 substantially closes the throat 131. Thus, the first and second edges 140, 142 can be placed in direct proximity to each other. The first and second edges 140, 142 can then be joined at the seam 144.

  The first and second edges 140, 142 can be joined at the seam 144 in any suitable manner. For example, the first and second edges 140, 142 can be joined using sewing, adhesive, tape, bonding, welding, fasteners or other suitable fasteners.

  In some embodiments, the seam 144 can be formed by stitching the edges 140, 142 together with the seam 146, as shown in FIGS. As noted above, while the upper 120 can be a knit element having multiple stitches, it will be appreciated that the seam 146 can be independent of the stitches of the knit component 116. In other words, the seam 146 may be formed using one or more threads, yarns, cables, or other strands that are attached after the knit component 116 is knitted. The seam 146 can also be a zigzag stitch or other suitable stitch. In addition, the edges 140, 142 can abut at the seam 144. For example, the edges 140, 142 can form a butt joint, or the edges 140, 142 can be partially overlapped to form a seam 144. In addition, the edges 140, 142 can be slightly spaced at the seam 144 using an adhesive bead or other material between the edges 140, 142 at the seam 144.

  The seam 144 can also extend over any suitable portion of the knit component 116. For example, in the embodiment of FIG. 3, the seam 144 can include a first end portion 147 disposed on the base portion 124 adjacent to the toe portion 134. The seam 144 can also include a second end 149 at the junction of the outer edge 135, the foot tip 134 and the tongue 136. Also, the seam 144 can extend continuously between the first and second end portions 147, 149 in some embodiments. For example, the seam 144 can include a first portion 181 that extends across the base portion 124 in a generally lateral direction 127 from the first end portion 147 toward the inner portion 132. The seam 144 can also include a second portion 183 that extends in a generally vertical direction 129 across the inner portion 132 and adjacent to the toe portion 134. Further, the seam 144 can include a third portion 185 that extends generally laterally toward the outer side portion 130 and is curved backward toward the second end portion 149. Thus, the seam 144 is continuous between the ends 147, 149 so as to extend from under the wearer's foot, around the inner area of the wearer's foot to the area above the wearer's foot. Can be extended.

  Also, the knit component 116 may have any number of seams 144. For example, as illustrated in the embodiment of FIG. 3, the knit component 116 of the upper 120 may have the only seam 144 necessary to give a three-dimensional shape as shown in FIGS. There is. This can facilitate manufacturing and reduce the time required to assemble the upper 120.

  Also, the seam 144 can be spaced from the heel portion 128 so that the heel portion 128 is seamless. As a result, even if the heel portion 128 deviates on the wearer's heel, the relatively smooth and seamless heel portion 128 rubs against the wearer's heel and hardly causes discomfort to the wearer. .

  Thereafter, as described above, the lace 155 can be passed through the outer and inner openings 156 and 157 and the outer and inner turns 159 and 160. The sole structure 110 can then be attached to the upper 120. Specifically, the midsole 112 can be attached to the outer surface 123 of the base portion 124, and the outsole 114 can be attached to the midsole 112. In additional embodiments, an additional insole can be inserted over and / or attached to the inner surface 121 of the base portion 124.

<Exemplary Knitting Process to Form Knit Components and Uppers>
The knitted component 116 can be knitted in any suitable direction. For example, the knitted component 116 can be formed from the heel portion 128 in the collar 133 and the knitted component 116 is formed to extend generally in the longitudinal direction 125 toward the toe portion 134. can do. The foot tip cavity 150 can be formed before the tongue 136. After that, the tongue 136 can be formed. Also, the three-dimensionally curved cavities and two-dimensionally curved portions of the knitted component 116 (eg, heel cavities 148, toe cavities 150, curved regions 143 and / or other areas) may be removed during the knitting process. It will be appreciated that they can be integrally formed. Specifically, the stitches at boundaries 173 and 197 can be held by their respective needles as the course of the subsequent stitch is added, and the stitches held at boundaries 173 and 197 are retained at boundaries 173 and 197. Can be knitted into each stitch throughout. Also, strands 158 can be inserted during the knitting process. The process can also be completed on any suitable machine such as a flat knitting machine.

  An exemplary automatic knitting process for forming a knitted component 116 with strands 158 will now be described with reference to FIGS. For purposes of explanation, a weft knitting process and a weft knitting machine will be described, however, the knitted component 116 and strand 158 may be formed in other ways without departing from the scope of the present disclosure. Thus, the knitted component 116 and the strand 158 can be formed in accordance with the teachings of U.S. Patent No. 6,053,097, filed Sep. 20, 2012, and incorporated herein by reference in its entirety.

  Referring to FIG. 15, a portion of a knitting machine 1200 including various needles 1202, rails 1203, standard feeder 1204, and combination feeder 1220 is depicted. The combination feeder 1220 is fixed to the front side of the rail 1203, while the standard feeder 1204 is fixed to the rear side of the rail 1203. The yarn 1206 passes through the combination feeder 1220, and the end of the yarn 1206 extends from the yarn supplying tip 1246 to the outside. Although a yarn 1206 is depicted, any other strand (eg, filament, thread, rope, strip, cable, chain or yarn) may pass through the combination feeder 1220. Another yarn 1211 passes through the standard feeder 1204 to form part of the knit component 1260 and a loop of yarn 1211 forming the top course of the knit component 1260 is provided at the end of the needle 1202. Are held by hooks.

  The knitting process described herein relates to the formation of a knitted component 1260 or a portion of a knitted component 1260. Accordingly, that portion of knitted component 1260 corresponds to base portion 124, heel portion 128, outer portion 130, inner portion 132, foot portion 134 and / or tongue portion 136 described above in connection with FIGS. can do. For illustration purposes, only a relatively small section of the knit component 1260 is shown in the drawings so that the knit structure can be illustrated. Also, the scale or ratio of the various elements of knitting machine 1200 and knitted component 1260 may be expanded to better illustrate the knitting process.

  Referring now to FIG. 16, standard feeder 1204 moves along rail 1203 and a new course is formed from yarn 1211 into knitted component 1260. More specifically, the needle 1202 pulls the section of yarn 1211 through the loop of the previous course, thereby forming a new course. Thus, moving the standard feeder 1204 along the needle 1202 can add a course to the knitted component 1260, whereby the needle 1202 manipulates the yarn 1211 to form an additional loop from the yarn 1211. It is possible to do.

  Continuing with the knitting process, as shown in FIG. 17, the feeder arm 1240 is now translating from the retracted position to the extended position. In the extended position, the feeder arm 1240 extends downward from the carrier 1230 such that the yarn feed tip 1246 is (a) centered between the needles 1202 and (b) below the intersection of the needle beds. Is arranged.

  Referring now to FIG. 18, the combination feeder 1220 moves along the rail 1203 and the yarn 1206 is located between the loops of the knit component 1260. That is, the yarns 1206 are arranged in an alternating pattern before some loops and behind other loops. Also, the yarn 1206 is placed in front of a loop held by a needle 1202 from one needle bed 1201, and the yarn 1206 is placed behind a loop held by a needle 1202 from the other needle bed. ing. Note that the feeder arm 1240 remains in the extended position to insert the yarn 1206 into the area below the needle bed intersection. Thereby, the yarn 1206 is effectively arranged in the course formed immediately before by the standard feeder 1204 of FIG.

  To complete the insertion of the yarn 1206 into the knitted component 1260, the standard feeder 1204 moves along the rail 1203 to form a new course from the yarn 1211, as illustrated in FIG. By forming a new course, the yarn 1206 is effectively knitted into the structure of the knitted component 1260 or otherwise integrated into the structure. At this stage, the feeder arm 1240 may also translate from the extended position to the retracted position.

  18 and 19 show the individual movement of the feeders 1204 and 1220 along the rail 1203. That is, FIG. 18 shows a first movement of the combination feeder 1220 along the rail 1203, and FIG. 19 shows a second subsequent movement of the standard feeder 1204 along the rail 1203. In many knitting processes, the feeders 1204 and 1220 are efficiently moved simultaneously to insert the yarn 1206 and form a new course from the yarn 1211. However, in order to place the yarn 1206 prior to the formation of a new course from the yarn 1211, the combination feeder 1220 moves prior to the standard feeder 1204 or moves in front of the standard feeder.

  The general knitting process outlined in the above description provides an example of how the strands 158 of FIGS. 1-6 can be placed on the base portion 124, outer portion 130 and / or inner portion 132 of the upper 120. To do. More specifically, due to the reciprocating motion of the feeder arm 1240, the strands 158 may be placed in a previously formed course before forming a new course.

  Continuing with the knitting process, as shown in FIG. 20, the feeder arm 1240 is now translated from the retracted position to the extended position. Then, as shown in FIG. 21, the combination feeder 1220 moves along the rail 1203, and the yarn 1206 is disposed between the loops of the knit component 1260. Thereby, the yarn 1206 is effectively arranged in the course formed by the standard feeder 1204 of FIG. To complete the insertion of the yarn 1206 into the knitted component 1260, the standard feeder 1204 moves along the rail 1203 to form a new course from the yarn 1211, as illustrated in FIG. By forming a new course, the yarn 1206 is effectively knitted into the structure of the knitted component 1260 or otherwise integrated into the structure. At this stage, the feeder arm 1240 may also translate from the extended position to the retracted position.

  Referring to FIG. 22, yarn 1206 forms a loop 1214 between two inlay sections. Note that in the description of turns 159 and 160 of FIGS. 1-6, strand 158 exits path 162 and then enters another path 162, thereby forming turns 159 and 160. The loop 1214 can be formed in a similar manner. That is, the loop 1214 is formed where the yarn 1206 reenters the knit structure after leaving the knit structure of the knit component 1260.

  Referring to FIG. 23, the combination feeder 1220 moves along the rail 1203 while in the retracted position and forms a course of the knit component 1260 while in the retracted position. Thus, by reciprocating the feeder arm 1240 between the retracted position and the extended position, the combination feeder 1220 can supply the yarn 1206 for knitting, tucking, float knitting and insertion.

<Additional Embodiment of Knit Component and Upper>
FIG. 12 illustrates an additional embodiment of the knit component 116 of the upper 220. The knit component 116 and upper 220 can be substantially similar to the knit component 116 and upper 120 described above, except as described.

  The upper 220 may include strands 258 that extend alternately across the inner portion 232, the base portion 224, and the outer portion 230, similar to the embodiments described above. The strands 258 can also penetrate one or more paths 262. However, the path 262 can be defined in the inner part 132 and the outer part 130, and the path 262 can be spaced from the base part 224.

  Accordingly, the longitudinal portion of the strand 258 extending across the base 224 can be exposed from the path 262. Also, these portions of the strand 258 can be removed from the base portion 224 and separated. Thus, in some embodiments, these portions of the strand 258 can be free to be attached directly to the sole structure 110.

  Also, as illustrated in FIG. 12, in some embodiments, the path 262 is different from the exposed turns 159, 160 illustrated in FIGS. It can be V-shaped so that it is embedded in and housed.

  In some additional embodiments, the knitted components may be joined along various edges that are configured to mate at different locations in the assembled upper. In an embodiment, the upper may include a one-piece knit element that extends around the foot and wraps the foot and covers the top and bottom of the wearer's foot. Various embodiments are within the scope of this disclosure.

  For example, additional embodiments of upper 320, knit component 316 and footwear product 300 are shown in FIGS. An exemplary method of manufacturing upper 320, knitted component 316 and footwear product 300 is also shown. Upper 320 and knitted component 316 can be substantially similar to the embodiments described above, except as described. As shown, the upper 320 can be substantially defined by a knit component 316. However, the upper 320 may include other structures or elements in addition to the knit component 316 without departing from the scope of the present disclosure.

  For reference, the upper 320 can be divided into three general regions, a foot tip region 311, a middle foot region 312 and a heel region 314. The toe region 311 can generally include a portion of the upper 320 corresponding to the anterior portion of the foot, including the toes and joints connecting the metatarsals and phalanges. The midfoot region 312 can generally include a portion of the upper 320 corresponding to the central portion of the foot including the arch portion. The heel region 314 can generally include the portion of the upper 320 that corresponds to the rear portion of the foot including the heel and ribs. The upper 320 can also include an outer side 315 and an inner side 317 that can extend through the toe region 311, the midfoot region 312 and the heel region 314, and on corresponding sides of the upper 320. Can respond. More specifically, the outer side portion 315 can correspond to an outer portion of the foot (ie, a surface facing away from the opposite foot), and the inner side portion 317 can correspond to an inner portion of the foot (ie, The surface facing the opposite foot). The toe region 311, the midfoot region 312, the heel region 314, the outer side 315 and the inner side 317 are not intended to delimit precise areas of the upper 320. Rather, the toe region 311, midfoot region 312, heel region 314, outer side 315 and inner side 317 are intended to represent a general area of the upper 320 to assist in the following description. ing.

  As illustrated in FIGS. 24-27, the knit component 316 of the upper 320 can include a base portion 324 or a straw bell portion or a lower foot portion. In some embodiments, the base portion 324 can be shaped like a sole. In other embodiments, the base portion 324 can have different shapes. The base portion 324 can be configured to be placed under the wearer's foot as described below. In other words, the base portion 324 can be configured to be overlaid by the wearer's sole as described below.

  The knitted component 316 can also include one or more portions extending from the base portion 324 adjacent to the base portion 324. One or more of these adjacent portions can be integrally connected to the base portion 324 and can be formed in an integral knit structure with the base portion 324. In addition, these adjacent portions can cooperate with the base portion 324 to define a cavity 322 within the upper 320 for receiving a wearer's foot.

  For example, in the embodiment illustrated in FIGS. 24-27, the knitted component 316 can include a heel portion 328 that at least partially defines a heel region 314 of the upper 320. The knitted component 316 can also include an outer portion 330 that at least partially defines the outer side 315 of the upper 320. Further, the knitted component 316 can include an inner portion 332 that at least partially defines an inner side 317 of the upper 320. In addition, the knitted component 316 can include a toe portion 334 that at least partially defines a toe region 311 of the upper 320. In some embodiments, the heel portion 328, the outer portion 330, the inner portion 332, and the toe portion 334 can each be formed in an integral knit structure with the base portion 324.

  Further, the knitted component 316 can include a throat portion 331. The throat portion 331 can be disposed between the outer portion 330 and the inner portion 332. In some embodiments, the throat portion 331 can be integrally attached to the outer portion 330, the inner portion 332, and / or the toe portion 334 and can be formed in an integral knit structure therewith. In the illustrated embodiment, the knitted component 316 can extend substantially continuously between the outer portion 330, the throat portion 331 and the inner portion 332. In other embodiments, the throat portion 331 is separated from the outer portion 330 and the inner portion 332 such that the throat portion 331 includes a tongue that can move within an opening between the outer portion 330 and the inner portion 332. can do.

  The knit component 316 of the upper 320 can also include a collar 333 that includes a rim 313. The rim 313 can define an opening to the cavity 322 in the upper 320. As shown in the illustrated embodiment, the collar 333 and the rim 313 can extend in an annular fashion around the inner portion 332, the throat portion 331, the outer portion 330 and the heel portion 328.

  Similar to the embodiments described above with respect to FIGS. 1-6, the knitted component 316 can include a knitted element 343 formed in a unitary knitted structure. In some embodiments, the knit element 343 can substantially define a base portion 324, a heel portion 328, an outer portion 330, an inner portion 332, a toe portion 334 and / or a throat portion 331.

  The knit component 316 can also include one or more extensible strands that are coupled to the knit element 343. There can be any suitable number of extensible strands, and the strands can extend across any portion of the knitted element 343. For example, in some embodiments, the knitted component 316 can include a first extensible strand 358 and a second extensible strand 359. The first extensible strand 358 can be coupled to the outer side 330 of the knit component 316 and disposed on the outer side 315 of the upper 320. The second extensible strand 359 can be coupled to the inner side 332 of the knit component 316 and disposed on the inner side 317 of the upper 320. In some embodiments, the first extensible strand 358 and / or the second extensible strand 359 is also coupled to the heel portion 328, the toe portion 334 and / or the base portion 324 of the knitted component 316. Can extend over them.

  Also, the first extensible strand 358 and the second extensible strand 359 can be attached to the knit element 343 in any suitable manner. In some embodiments, the first extensible strand 358 can be formed with an integral knit structure with the outer portion 330 and the second extensible strand 359 with an integral knit structure with the inner portion 332. Can be formed. For example, portions of the first extensible strand 358 and / or the second extensible strand 359 can be inserted into at least one course and / or wale of the knitted element 343. The other portions of the first extensible strand 358 and the second extensible strand 359 can be exposed or otherwise removed from the knit element 343. Further details of the first extensible strand 358 and the second extensible strand 359 are described below in more detail according to embodiments.

  Also, similar to the embodiments described above with respect to FIGS. 1-6, the knitted component 316 can include one or more seams 344. The seam 344 can be defined where two or more edges of the knit component 316 are joined. The seam 344 can be defined within any suitable area of the upper 320 and can span there. For example, the seam 344 can include a first end 347 and a second end 349, and the seam 344 can extend continuously between the first end 347 and the second end 349. it can. More specifically, in some embodiments, the first end 347 of the seam 344 is generally disposed on the rim 313 of the collar 333 on either the inner side 317 or the outer side 315 of the upper 320. The second end 349 can be generally disposed in the foot region 311 of the upper 320. The seam 344 can also be curved across different portions of the knit component 316, as described in more detail below.

  Similar to the embodiments described above with respect to FIGS. 1-4, the seam 344 can be secured in a variety of ways without departing from the scope of the present disclosure. For example, the seam 344 can be secured using sewing, adhesive, tape, bonding, welding, fasteners or other suitable fasteners. In embodiments where the seam 344 is secured by sewing, the sewing can be independent of the stitches of the knit component 316. The sewing can be zigzag stitching or other suitable stitches. In addition, the edges joined at the seam 344 can abut one another. In other embodiments, the edges can overlap each other at seams 344.

  28 and 29, the knit element 343 of the knit component 316 will be described in more detail according to the embodiment. 28 and 29, the knit element 343 is shown in plan view in an exploded state. As shown, the knitted element 343 can be generally asymmetric. The knitted element 343 may also include an inner surface 321 illustrated in FIG. 28 and an outer surface 323 illustrated in FIG. The knitted element 343 can also include an outer peripheral edge 339. The outer peripheral edge 339 can be defined by the first edge 340, the second edge 342, and the rim 313 of the collar 333. The first edge 340 and the second edge 342 can merge at the joint 337. Also, the first edge 340 and the rim 313 can merge at the first corner 335. The second edge 342 and the rim 313 can merge at the second corner 341. As shown, the first edge 340 can extend continuously between the joint 337 and the first corner 335, and the second edge 342 can be the joint 337 and the second corner 341. And the rim 313 can extend continuously between the first corner 335 and the second corner 341. Further, in some embodiments, the first edge 340, the second edge 342, and / or the rim 313 can be curved.

  The knitted element 343 can be formed in a unitary knitted structure so as to define a base portion 324, an outer portion 330, an inner portion 332, a throat portion 331, a heel portion 328 and a toe portion 334. The first side 390 of the base portion 324 can be defined by the first edge 340 of the knitted element 343. Further, the outer portion 330, the throat portion 331 and the inner portion 332 can extend from the second side portion 391 of the base portion 324. The second side portion 391 of the base portion 324 can face the first side portion 390. As illustrated, in the embodiment illustrated in FIG. 28, the outer portion 330 can extend away from the base portion 324 away from the first edge 340. Further, the throat portion 331 can extend from the outer portion 330 in a direction away from the base portion 324. In addition, the inner portion 332 can extend from the throat portion 331 away from the outer portion 330, and the inner portion 332 can terminate at the second edge 342.

  As illustrated in the embodiment of FIG. 28, the toe portion 334 has a knit element 343 such that the toe portion 334 is partially defined by the second edge 342 adjacent to the joint 337. Can be arranged. Further, the foot portion 334 can be in contact with the inner portion 332, the outer portion 330 and the throat portion 331. Further, the heel portion 328 may be partially defined by the first edge 340 and partially defined by the rim 313 adjacent to the first corner 335.

  As shown in FIG. 28, the inner surface 321 of the knitted element 324 of the heel 328 can have a concave three-dimensional curvature. Accordingly, the heel portion 328 of the knit element 324 can define a heel cavity 348. It will be appreciated that other portions of the knitted element 324 can also have a three-dimensional curvature, and that additional cavities can define respective cavities.

  Also, as illustrated in FIG. 28, the collar 333 can extend continuously between the first edge 340 and the second edge 342. In addition, the collar 333 can extend from the inner portion 332, the throat portion 331, the outer portion 330 and the heel portion 328.

  The knitted element 343 can also include two or more areas having different characteristics. For example, depending on the type of yarn used in each area, the stitch density within the area, or other reasons, some areas of the knitted element 343 may have higher stretch than the other areas. Also, some portions of the knitted element 343 can be substantially continuous, while other areas can include multiple openings. For example, as illustrated in FIG. 28, the base portion 324 can include a plurality of openings 352. The openings 352 can be positioned in a pattern such that the base 324 has a mesh-like appearance. In some embodiments, the base 324 can have a 4 × 4 knitted mesh pattern to form the opening 352.

  In addition, as illustrated in FIG. 28, the base portion 324 may include a border line 353 that surrounds the opening 352. The border line 353 can have a relatively smooth continuous appearance. It will be appreciated that the opening 352 can reduce the weight of the knit element 343. Further, the opening 352 can reduce the surface area of the base portion 324 attached to the sole structure 310. Therefore, the flexibility of the base part 324 and / or the sole structure 310 can be improved. It will also be appreciated that other areas of the knitted element 343 can include openings 352 and / or border lines 353 without departing from the scope of the present disclosure.

  Further, the knit component 316 can include a first extensible strand 358 and a second extensible strand 359 that are coupled to the knit element 343. Embodiments of the first extensible strand 358 and the second extensible strand 359 will now be described in more detail.

  As shown in FIGS. 28 and 29, the first extensible strand 358 can include a first end 361 and a second end 363. Both the first end 361 and the second end 363 can be disposed adjacent to the first edge 340. The first end 361 and the second end 363 can also be spaced apart from each other along the first edge 340. Between the first end 361 and the second end 363, the first extensible strand 358 can extend back and forth, and can go back and forth between the first edge 340 and the throat 331. . Thus, as illustrated in the embodiment of FIGS. 28 and 29, the first extensible strand 358 can extend across and connect to the base portion 324, the outer portion 330 and the heel portion 328. .

  More specifically, the first extensible strand 358 can include a plurality of attachment portions 365 attached to the knit element 343 and extending between the first edge 340 and the throat portion 331. . In some embodiments, the mounting portion 365 can be inserted into the course or wales of the knitted element 343, as described above. In addition, the mounting portion 365 can extend perpendicular to the first edge portion 340. Further, the mounting portions 365 can be separated from each other with respect to the first edge portion 340. A representative first mounting portion is shown at 366 in FIGS. 28 and 29 and a representative second mounting portion is shown at 368.

  The first extensible strand 358 can also include a plurality of exposed portions 367 extending along the first edge 340 between adjacent pairs of mounting portions 365. The exposed portion 367 can be exposed and removed from the knit element 343. As one example, FIGS. 28 and 29 include an exemplary third exposed portion indicated at 364. As shown in the figure, the third exposed portion 364 extends continuously between the first mounting portion 366 and the second mounting portion 368. Further, the third exposed portion 364 may extend between the first mounting portion 366 and the second mounting portion 368 generally along the first edge portion 340.

The second extensible strand 359 can include a first end 371 and a second end 373. The first end 371 and the second end 373 can be disposed adjacent to the second edge 342. The first end 371 and the second end 373 can also be spaced apart from each other along the second edge 342. The second extensible strand 359 extends back and forth, and can also go back and forth between the second edge 342 and the throat 331. Thus, similar to the first extensible strand 358, the second extensible strand 359 includes a plurality of spaced attachment portions 375 extending perpendicular to the second edge 342 and a second edge 342. And a plurality of exposed portions 377 extending between each pair of mounting portions 375. Also, as shown in the embodiment of FIGS. 28 and 29, the second extensible strand 359 can extend across the inner portion 332 and can be coupled thereto.

  Here, the assembly of the knit component 316, the upper 320 and the footwear product 300 will be described. The knit component 316 can be formed by the knitting process detailed above. Accordingly, the knitted component 316 can include a knitted element 343, a first extensible strand 358 and a second extensible strand 359, as shown in FIGS.

  Next, as illustrated in FIG. 30, moving the first edge 340 and / or the second edge 342 toward the other can result in a knit component 316 having a three-dimensional curvature.

  For example, in some embodiments shown in FIGS. 30 and 31, the knit component 316 can be supported by a support member 369 to facilitate this assembly process. As shown, the support member 369 can be shaped like an anatomical foot and can be referred to as a “shoe shape”. In this manner, the base portion 324 can be overlaid under the support member 369, and the support member 369 can be received in the heel cavity 348 of the knit component 316. In some embodiments, the knitted component 316 can be temporarily secured to the support member 369 along the first edge 340 using a pin or other fastener.

  Next, as shown in FIG. 30, the inner portion 332, the toe portion 334, and the throat portion 331 are pulled up and placed over the support member 369 so that the knit component 316 substantially wraps around the support member 369. Can do. In other words, the inner portion 332 can move adjacent to the first side 390 of the base portion 324, the second corner 341 can move adjacent to the first corner 335, and the second edge 342. Can move adjacent the first edge 340. Accordingly, the knitted component 316 can largely define the cavity 322 in the upper 320. The second edge 342 can also be temporarily secured to the support member 369 at this location using pins or other fasteners.

  A seam 344 can then be formed by joining the first edge 340 and the second edge 342 of the knit component 316. The first edge 340 can be joined to the second edge 342 by any suitable method, such as sewing, adhesive, fasteners, or other fasteners.

  As illustrated in the embodiment of FIG. 32, for example, the seam 344 is formed by sewing 379. Sewing 379 can be included by hand stitching or can be formed automatically. Sewing 379 can be included in any suitable pattern, such as a cross-stitch or other type. Further, as illustrated in FIG. 32, the sewing 379 can be added in a direction extending from the joint portion 337 to the rim 313. In some embodiments, the sewing 379 can be added in the opposite direction.

  When the first edge 340 and the second edge 342 are joined by sewing 379, the knit component 316 can have a sock-like structure, and the knit component 316 substantially covers the support member 369. Can be housed and enclosed. Also in this configuration, the knit component 316 can define the upper 320 of the footwear product 300. In other embodiments, additional bodies, members, logos, tags or other items can be added to the knit component 316 to form the upper 320.

  Note that once the knit component 316 is assembled, the first end 347 of the seam 344 can be positioned on the inner side 317 of the rim 313 of the collar 333, as illustrated in the embodiment of FIG. . Also, the first corner 335 and the second corner 341 of the knit element 343 can merge to form the first end 347 of the seam 344. The first portion 381 of the seam 344 can extend vertically from the first end 347 along the inner side 317 toward the base 324. The second portion 382 of the seam 344 can extend continuously from the first portion 381 and can extend forward in the longitudinal direction toward the toe portion 334. Also, the second portion 382 can be disposed between the inner portion 332 and the base portion 324, and can be curved in two or three dimensions. Further, the third portion 383 can extend continuously upward from the second portion 382 and away from the base portion 324. Further, the fourth portion 384 of the seam 344 can continuously extend from the third portion 383 in the outward direction along the foot region 311 toward the outer portion 330, and the fourth portion 384 of the seam 344. May terminate at the second end 349. Note also that the joint 337 can be the second end 349 of the seam 344.

  With this configuration, the embodiment of seam 344 helps improve the comfort of the wearer's foot and / or fit to footwear product 300. For example, the first end 347 and the first portion 381 of the seam 344 can extend along the inner side 317 of the upper 320. In other words, the seam 344 can be spaced from the heel region 314 of the upper 320, and the heel region 314 can be largely seamless. Therefore, the upper 320 can be in close contact with and supported by the wearer's heel. Further, the upper 320 is less likely to rub the wearer's heel uncomfortablely.

  Further, the second portion 382 of the seam 344 can have an arcuate curvature that is configured to substantially overlap the anatomical arch of the wearer's foot. Thus, the wearer is less likely to step on the seam 344 directly when walking, running or jumping. Thus, the upper 320 can better support the wearer's foot, and the upper 320 is likely to be comfortable.

  In addition, once the upper 320 is assembled, the sole structure 310 can be attached to the knit component 316 as illustrated in FIGS. The sole structure 310 can be of any suitable type, and the sole structure 310 can be mounted over the base 324 of the knit component 316. For example, the sole structure 310 can include one or more features that enhance the flexibility of the sole structure 310 and the footwear 300. The features can include recesses, grooves, sipes, areas thinner than the surrounding area, or other features of the sole structure 310. As illustrated in FIGS. 33 and 34, the sole structure 310 can include one or more bent grooves 303 that enhance the flexibility of the sole structure 310. In some embodiments, the flexure groove 303 can extend between the inner side 317 and the outer side 315.

  As described above, the border line 353 of the base portion 324 can provide a surface suitable for being attached to the sole structure 310. The region of the base portion 324 surrounded by the border line 353 can also be attached to the sole structure 310. The sole structure 310 can be attached using adhesives, fasteners or other fasteners. In addition, in some embodiments, the sole structure 310 can cover at least a portion of the seam 344. For example, the sole structure 310 can cover the second portion 382 and a portion of the third portion 383 of the seam 344. In addition, the seam 344 can be substantially concealed by the sole structure 310 so that the upper 320 appears largely continuous.

  Also, as described above, the base portion 324 of the upper 320 can include one or more openings 352. An area between the openings 352 of the base portion 324 can also be attached to the sole structure 310. For example, in the embodiment shown in FIG. 34, the sole structure 310 can be joined to the area between the openings 352 of the base portion 324. Also, in some embodiments, the support member 369 can include a surface that is unlikely to join the sole structure 310. For example, the support member 369 can be made at least partially from Teflon or other suitable material that is difficult to bond to the sole structure 310 when the sole structure 310 is attached to the upper 320.

  Further, when the upper 320 is assembled, the exposed portion 367 of the first extensible strand 358 and the exposed portion 377 of the second extensible strand 359 can extend along the seam 344 and can be aligned with the seam 344. Remember that you can. In some embodiments, the sewing 379 can hold the exposed portion 367 of the first extensible strand 358 and the exposed portion 377 of the second extensible strand 359 combined. Accordingly, the first extensible strand 358 and the second extensible strand 359 can be held in place relative to the knit element 343.

  Also, when the upper 320 is assembled, the attachment portions 365 of the first extensible strand 358 can be substantially aligned with the attachment portions 375 of the second extensible strand 359 across the seam 344. This alignment can make the upper 320 more aesthetically pleasing since both the outer side 315 and the inner side 317 can appear to be substantially the same. Also, the first extensible strand 358 and the second extensible strand 359 generally support corresponding areas of the outer side 315 and the inner side 317, respectively, for increased comfort and performance. Can do.

  As demonstrated by the above description, the seam 344 can define a boundary between the base portion 324 and the inner portion 332 of the knit component 316. The seam 344 can also define the boundary between the base portion 324 and the toe portion 334 of the knit component 316. However, it will be appreciated that the seam 344 can split any individual portion of the knit component 316. For example, in some embodiments, the seam 344 can divide the base 324 into two or more subsections. Similarly, the seam 344 can divide another portion of the knit component 316 without departing from the scope of the present disclosure.

  Further, the knit component 316 may be configured such that the seam 344 extends downwardly from the rim 313 of the outer side 315 of the upper 320 toward the base 324 without departing from the scope of the present disclosure. Let's go. Even in these embodiments, the heel region 314 could be seamless. Therefore, the upper 320 can improve the comfort as described above, and can provide support to the wearer's heel.

  In some additional embodiments, the knitted component could be configured such that the seam extends across other areas of the upper. For example, in some embodiments, one end of the seam could extend along the back side of the heel. Also, in some embodiments, extensible strands could be placed against the sole structure to improve certain characteristics of the footwear. For example, extensible strands can be placed against the sole structure to support the flexibility of the footwear product and / or improve the aesthetics of the footwear.

  For example, additional embodiments of an article of footwear 400 according to the present disclosure are shown. In some embodiments, the footwear product 400 can be substantially similar to the embodiment illustrated in FIGS. 24-34, except as described below.

  As illustrated in FIGS. 35 and 36, the upper 420 can include a knit component 416 having a knit element 443. The knitted element 443 is similar to the embodiment described above with respect to FIGS. 24-34 in that the collar 433 includes a base 424, a heel 428, an outer 430, an inner 432, a foot 434, a throat 431, and a rim 413. Can be defined.

  However, as illustrated in FIG. 36, the seam 444 of the knit component 416 has a first end that terminates between the outer side 415 and the inner side 417 of the upper 420 at the rim 413 of the heel region 414. A portion 447 can be included. The first portion 481 of the seam 444 can extend downward from the first end 447 toward the base portion 424. The second portion 482 of the seam 444 can extend longitudinally from the first portion 481 toward the toe portion 434, as shown in FIG. The remaining portion of the seam 444 can be similar to the embodiment illustrated in FIGS.

  Thus, in some embodiments, the seam 444 of the knit component 416 can divide the heel portion 424 of the knit component 416 into a plurality of portions. More specifically, the heel portion 424 of the knit component 416 can include a first portion 487 and a second portion 489 that are disposed on opposite sides of the seam 444. In other words, the first portion 487 and the second portion 489 can be joined at the seam 444 and can cooperate to define the heel portion 424 of the knit component 416. It will be appreciated that other areas of the knitted component 416 can be divided by the seam 444 as well.

  Further, as illustrated in FIG. 37, the knitted component 416 can include one or more three-dimensional curved surfaces. For example, the first portion 487 of the heel portion 424 can have each surface having a three-dimensional curvature, and the second portion 489 can also have a surface having a three-dimensional curvature. The degree of curvature can be less than the curvature of the heel cavity 348 shown in FIG. It will be appreciated that other portions of the knitted component 416 can also include a three-dimensional curved surface.

  Further, similar to the embodiment of FIGS. 24-34, the first extensible strand 458 and the second extensible strand 459 include one or more portions that are substantially aligned on opposite sides of the seam 444. be able to. For example, the portion 465 of the first extensible strand 458 and the portion 475 of the second extensible strand 459 can be substantially aligned across the seam 444. Other portions of the first extensible strand 458 can similarly be aligned with respective portions of the second extensible strand 459 across the seam 444.

  The first extensible strand 458 and the second extensible strand 459 can also be placed in place with respect to the sole structure 410. For example, as illustrated in FIG. 38, the bend groove 403 can overlap the portion 465 of the first extensible strand 458 and the portion 475 of the second extensible strand 459 and is aligned vertically with these portions. be able to. Accordingly, the flex grooves 403 can provide greater flexibility to the footwear 400, and the first extensible strand 458 and the second extensible strand 459 provide a higher support force above the flex grooves 403. Can be provided to the area. In addition, this alignment can improve the aesthetics of the footwear 400.

The above description of the embodiments has been set forth for purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or configurations of a particular embodiment are generally not limited to that particular embodiment, but can be substituted where applicable and are not specifically illustrated or described. Even so, it can be used in selected embodiments. The same may be changed in many ways. Such modifications are not to be regarded as a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.
CROSS REFERENCE TO RELATED APPLICATIONS This application is filed on Mar. 4, 2013, entitled "Article of Footwear Incorporating A Knitted Component With Integrally Knit Contoured Portion", co-pending US Patent Application No. 13/783. , 900 (Attorney Docket No. 51-3172), the entire disclosure of which is incorporated herein by reference.

Claims (31)

Sole structure,
It is connected to the sole structure, a footwear and a upper comprising two Tsu bets components formed in one body knitted structure,
A first edge and a second edge;
And 1 Tsunobe over scan portion that will be disposed adjacent to the sole structure,
The heel, the toe,
An inner side and an outer portion that is formed respectively integrally knit construction with the base part,
Extending from hand or both of the inner portion and the outer portion, and a collar with a rim,
The second edge is joined to the first edge at the seam of the knit component to receive the foot on the base, the heel, the toe, the inner and the outer To form a cavity of
The base part is located adjacent to either the outer part or the inner part in the knit component,
The seam has a first end and a second end, the first end generally being a collar of one or both of the inner side and the outer side of the upper. An article of footwear positioned on the rim of the footwear, wherein the second end is spaced from the first end. An article of footwear comprising a sole structure and an upper including a knit component connected to the sole structure and formed in an integral knit structure,
The knit component has an asymmetric shape with respect to the longitudinal axis in a state of being flattened,
A first edge and a second edge;
A base portion having a shape of the sole structure and disposed adjacent to the sole structure in a state of being flattened;
The heel, the toe,
An inner part and an outer part each formed of an integral knit structure with the base part;
A collar with a rim extending from one or both of the inner portion and the outer portion,
The second edge is joined to the first edge at the seam of the knit component to receive the foot on the base, the heel, the toe, the inner and the outer To form a cavity of
The base part is located adjacent to either the outer part or the inner part in the knit component,
The seam has a first end and a second end, the first end being generally a collar rim of one of the inner side and the outer side of the upper. An article of footwear, wherein the second end is spaced from the first end. The article of footwear according to claim 1, wherein the base portion is located in the knitted component adjacent to the first edge. The seam includes a first portion and a second portion, the first portion extends downward from the first end toward the base portion, and the second portion is the first portion. The footwear product according to claim 1 , wherein the footwear product continuously extends from the foot toward the toe portion. The upper further includes a toe region defined at least in part by the toe portion of the knit component;
The second end of the seam is positioned in the toe region generally adjacent to the outer side;
The seam further includes a third portion and a fourth portion;
The first portion extends downward from the first end toward the base portion, and the second portion is continuous from the first portion and between the base portion and the inner portion. Extending toward the toe region, the third portion extending continuously upward from the second portion and extending away from the base portion, and the fourth portion continuing from the third portion. 5. The article of footwear recited in claim 4 , wherein the article of footwear extends along the toe region and terminates at the second end of the seam. It said second portion has an anatomical arch and substantially superimposed luer over Ji curved legs to be received in the cavity, article of footwear according to claim 5 of the seam. The upper also includes a toe region that is at least partially defined by the toe portion of the knit component, wherein the second end of the seam is positioned in the toe region. Or the footwear product according to claim 2 . The knit component includes a knit element and an extensible strand formed in an integral knit structure with the knit element, the knit element comprising the base portion, the heel portion, the toe portion, the inner portion, and the Substantially defining an outer portion, wherein the extensible strand includes a first portion extending along the knit element toward the seam, the extensible strand being substantially aligned with the seam. 3. An article of footwear according to claim 1 or claim 2 comprising a second part. The first portion is inserted into the knit element, the second portion is exposed from the knit element, and the extensible strand has a third portion inserted into the knit element. 9. An article of footwear according to claim 8 , further comprising: the second portion extending continuously between the first portion and the third portion. The knit component includes a knit element, a first extensible strand formed with an integral knit structure with the knit element, and a second extensible strand formed with an integral knit structure with the knit element. Wherein the first extensible strand includes a first portion extending perpendicular to the seam and the second extensible strand extends perpendicular to the seam. comprises portions, the first portion and the second portion are located on opposite sides of the seam, the first portion and the second portion are substantially aligned, claim 1, wherein Item 2. The footwear product according to item 2 . The sole structure includes a bent groove, and the first portion and the second portion are substantially aligned with each other in a longitudinal direction, and the first portion and the second portion are perpendicular to the bent groove. The footwear product of claim 10 , wherein the footwear product is substantially aligned with the footwear product. The article of footwear according to claim 1 , wherein the base portion includes a plurality of openings, and the base portion includes a substantially continuous border line surrounding the plurality of openings. The knitted component further includes a throat area defined between the inner portion and the heel portion, wherein the throat area is integrally attached to both the outer side and the inner side of the upper. The footwear product according to claim 1 , wherein the footwear product is formed of a single knit structure. A Runi Tsu preparative components to form the upper of the article of footwear, the upper is attached to the sole structure, said knitted component,
One base portion having a first side defined at least in part by a first edge of the knit component and disposed adjacent to the sole structure;
A heel part and a foot part formed of an integral knit structure with the base part;
An inner portion and an outer portion extending from a second side portion of the base portion facing the first side portion, wherein one of the inner portion and the outer portion is a second of the knit component. The inner portion and the outer portion, at least partially defined by an edge of
The second edge is joined to the first edge at a seam to position the one of the inner and outer portions adjacent to the first side of the base; and The other of the inner portion and the outer portion is configured to be positioned adjacent to the second side portion of the base portion, and the second edge portion includes the base portion, the heel portion, the toe portion, said such that the inner portion and the outer portion is defined by cooperatively empty sinus Ru accept legs are configured to be joined to the first edge, knitted component . 15. The knit component of claim 14 , wherein at least one of the heel portion and the toe portion includes a surface having a three-dimensional curvature that defines a cavity. 16. The knit component of claim 15 , wherein the heel portion includes the face having a three-dimensional curvature that defines a heel cavity. Further comprising a collar having an azure beam forming image an opening to the cavity, the first edge and the second edge are joined at the first end of the seam, before Symbol first 15. A knit component according to claim 14 , wherein one end is generally disposed on the rim of the collar. A knit element and an extensible strand, wherein the knit element substantially defines the base portion, the toe portion, the heel portion, the inner portion and the outer portion, wherein the extensible strand is Formed of a unitary knit structure with the knit element, wherein the extensible strand includes a first portion extending along the knit element toward one of the first edge and the second edge. 15. The knit component of claim 14 , wherein the extensible strand includes a second portion that is substantially aligned with the one of the first edge and the second edge. The first portion is inserted into the knit element, the second portion is exposed from the knit element, and the extensible strand has a third portion inserted into the knit element. 20. The knit component of claim 18 , further comprising: the second portion disposed between the first portion and the third portion. A knitted element, a first extensible strand, and a second extensible strand;
The knit element substantially defines the base portion, the toe portion, the heel portion, the inner portion and the outer portion,
The first extensible strand and the second extensible strand are formed in an integral knit structure with the knit element;
The first extensible strand includes a first portion extending orthogonal to the first edge, and the second extensible strand is orthogonal to the second edge. includes a second portion extending both when the first portion and the second portion Ru are arranged on both sides of the seam, are substantially aligned with each other, knit construction according to claim 14 element. A method of manufacturing a footwear product comprising:
A base portion having a first side at least partially defined by a first edge of the knitted component;
A heel part and a foot part formed of an integral knit structure with the base part;
An inner portion and an outer portion extending from a second side portion of the base portion facing the first side portion, wherein one of the inner portion and the outer portion is a second of the knit component. Knitting a knit component formed in a unitary knit structure to have an inner portion and an outer portion, at least partially defined by the edges of the
Moving the second edge to the first edge to position the one of the inner side and the outer side adjacent to the first side of the base and the inner side Positioning the other of the part and the outer part adjacent to the second side of the base part;
The second edge is joined to the first edge with a seam of the knit component, and the base, the heel, the toe, the inner and the outer parts receive the foot. and it is defined the sky sinus in cooperation with that,
Also included from the knitted component is an inner side that is at least partially defined by the inner portion of the knitted component and an outer side that is at least partially defined by the outer portion of the knitted component. Forming an upper for footwear products;
Including methods. Knitting the knit component includes forming a color of the knit component, the collar including a rim;
Joining the second edge to the first edge includes causing the rim to define an opening to the cavity, the seam being a first end and a second end. The first end is generally positioned on the rim of the collar at one of the inner side and the outer side of the upper, and the second end is the first The method of claim 21 , wherein the method is spaced from the end of the. Knitting the knit component includes forming a color of the knit component, the collar including a rim;
Forming the upper includes forming the upper to include a heel region between the inner side and the outer side of the upper;
Joining the second edge to the first edge includes causing the rim to define an opening to the cavity, the seam being a first end and a second end. The first end is positioned on the rim of the collar generally at the heel region between the inner side and the outer side of the upper, and the second end is The method of claim 21 , wherein the method is spaced from the first end. The inner portion is at least partially defined by the second edge of the knitted component, the outer part is adjacent to said second side of said base portion, according to claim 21 Method. The method of claim 21 , further comprising attaching the sole structure to the knit component such that the sole structure is adjacent to the base portion of the knit component. Joining the second edge to the first edge with the seam includes forming the seam with a first end, a first portion, and a second portion, 23. The portion according to claim 21 , wherein the second portion extends downward from the first end toward the base portion, and the second portion extends continuously from the first portion toward the foot portion. The method described. Joining the second edge to the first edge at the seam,
Defining a toe region of the upper with at least a portion of the toe portion of the knit component;
Forming the second end of the seam in the toe region generally adjacent to the outer side;
Forming the seam with the first portion, the second portion, the third portion, and the fourth portion, wherein the first portion extends downwardly from the first end to the base. The second portion extends continuously from the first portion toward the toe portion between the base portion and the inner portion, and the third portion is the second portion. The fourth portion extends from the third portion continuously along the toe region, and extends from the base portion to the second portion. 27. The method of claim 26 , wherein the method terminates at an end. Joining the second edge to the first edge with the seam substantially overlaps the anatomical arch of the foot receiving the seam in the cavity. in comprising defining in a over Ji curved method of claim 26. Knitting the knit component includes knitting the knit component with an extensible strand formed of a knit element and an integral knit structure of the knit element, the knit element comprising the base portion, Forming the heel portion, the toe portion, the inner portion and the outer portion, and joining the second edge to the first edge at the seam is the stretchable strand. The method of claim 21 , comprising extending a first portion of the stretchable strand along the knit element to the seam and substantially aligning a second portion of the extensible strand with the seam. Knitting the knit component
Inserting the first portion of the extensible strand into the knit element;
Leaving the second portion of the extensible strand exposed from the knit element;
Inserting a third portion of the extensible strand into the knit element, wherein the second portion extends continuously between the first portion and the third portion. 30. The method of claim 29 . Knitting the knit component comprises forming the knit component with an integral knit structure of the knit element, a first extensible strand formed with an integral knit structure with the knit element, and the knit element. And joining the second edge to the first edge at the seam includes a first portion of the first extensible strand. Extending to substantially align with a second portion of the second extensible strand, the first portion of the first extensible strand and the second portion of the second extensible strand. The method of claim 21 , wherein portions are disposed on opposite sides of the seam and extend perpendicular to the seam.

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