TW202126206A - Footwear article including circular knit structures - Google Patents

Abstract

An aspect of the disclosure is a footwear article. The footwear article includes a double layer knitted upper having a foot bed, an upper portion continuous with the foot bed, an ankle opening, and an inner void for receiving a foot of a wearer. The double layer knitted upper has an outer knit layer defining an exterior surface of the double layer knitted upper. The double layer knitted upper also has an inner knit layer monolithically knit to the outer knit layer. The inner knit layer has a plurality of inner knit regions that spatially correspond to the plurality of outer knit regions of the outer knit layer. The outer knit layer and the inner knit layer substantially define the foot bed and the upper portion of the double layer knitted upper.

Description

Footwear including circular knit structure

The present disclosure relates to footwear articles including circular knitted structures and methods for manufacturing such footwear articles.

The conventional article of footwear has a sole and an upper attached to the sole. Historically, footwear manufacturing has been a labor-intensive sewing and assembly operation. The panels of the upper material are cut into a certain size and stitched together to make the upper. Several different techniques are used to attach the sole to the upper to make a finished article of footwear. Recent developments in footwear design use knitting techniques to form parts of footwear, especially uppers. In some cases, flat knitting is used to form flat knitted fabric blanks. The flat knitted fabric blank is formed into a specific shape so that it can be folded or wrapped into a nearly finished shoe upper. Once the upper is formed, the sole component or other durable structure is attached to the knitted upper in accordance with conventional footwear manufacturing techniques. Although some stitching is required to make a shoe upper using flat knitting, fewer stitching steps are required compared to conventional shoe manufacturing. Although plain weaving will increase material utilization, because it minimizes fabric cutting, plain weaving has inherent design limitations and low production efficiency.

The embodiments of the present disclosure are a kind of footwear article, a kind of knitted blank and a kind of Methods of manufacturing footwear articles and knitting blanks. The article of footwear includes a double-layer knitted upper having an insole, an upper portion continuous with the insole, an ankle opening, and an inner space for receiving the wearer's foot. The double-layer knitted upper has an outer knitted layer that defines the outer surface of the double-layer knitted upper. The double-layer knitted upper also has an inner knitted layer that is integrally knitted to the outer knitted layer. The inner knitted layer has a plurality of inner knitted regions corresponding to the plurality of outer knitted regions of the outer knitted layer in space. The outer knitted layer and the inner knitted layer generally define the insole and upper part of the double-layer knitted upper.

10: Footwear

11: Forefoot area

12: Midfoot area

13: heel area

14: Inside

15: outside

18: belt

20: Sole components

22a-22d: tabs

24a-24d: Fastening parts

30: upper knitting components

31: Internal void

32: Ankle opening

41: Insole

42: toe part

44: Midfoot

46: heel part

48: Ankle part

50: Outer surface

51: Edge

52: inner surface

54: Binder

60: Outer knitted layer

62a: The first outer knitting area

62b: The second outer knitting area

62c: The third outer knitting area

62d: The fourth outer knitting area

62e: The fifth outer knitting area

62f: The sixth outer knitting area

80: inner knitted layer

82a: The first inner knitting area

82b: The second inner knitting area

82c: The third inner knitting area

82d: the fourth inner knitting area

82e: the fifth inner knitting area

82f: The sixth inner knitting area

82g: the seventh inner knitting area

130: Circular knitted blank

132: first end

134: The second end

142: The first toe part

144a: The first upper part

144b: The first lower part

146: The first heel part

148: The first ankle part

152: toe opening

154: Seam

156: Panel

160: The first knitting section

180: The second knitting section

242: second toe part

244a: second upper part

244b: The second lower part

246: The second heel part

248: The second ankle part

252: toe opening

254: Seam

300: Footwear

301: first layer

302: second layer

400: Footwear

401: first layer

402: second layer

403: Lace System

500: footwear items

501: first layer

502: second layer

504: Shoe collar part

505: Welding Strengthening Parts

506: Lockstitch operation

600: footwear items

601: first layer

602: second layer

603: Lace System

607: Ventilation Area

608: Pore

610: Strengthened Area

610a: heel cup

610b: toe cup

700: footwear items

701: first layer

702: second layer

703: Lacing System

708: Porosity

709a: Strip

709b: Strip

709c: Strip

710: Strengthened Area

710a: heel cup

800: footwear items

801: first layer

802: second layer

803: Lace System

808: Porosity

811: Parts

900: footwear items

901: first layer

902: second layer

903: Lacing System

908: Porosity

910: Strengthened Area

910a: heel cup

910b: toe cup

950-954: footwear items

960-965: functional layer

K: direction

Figure 1 is a side view of an article of footwear according to an embodiment of the present disclosure;

Figure 2 is an exploded view of the article of footwear shown in Figure 1;

Figure 3 is a cross-sectional view of the article of footwear taken along line 3-3 in Figure 1;

Figure 4 is a side view of a knitted blank used to form the components of the article of footwear illustrated in Figures 1 to 3;

Figure 5 is a side view of the inside of a knitted blank used to form the components of the article of footwear illustrated in Figures 1 and 2, showing the part of the knitted blank is removed to make the ankle part of the article of footwear; and

Fig. 6 is a side view of a double-layer knitted footwear component formed from the knitted blank shown in Fig. 4.

Figure 7 illustrates an article of footwear according to an embodiment of the present disclosure;

Figure 8 illustrates an article of footwear including a lacing system according to an embodiment of the present disclosure;

Figure 9 illustrates an article of footwear including a collar according to an embodiment of the present disclosure;

Figure 10 illustrates an article of footwear including a plurality of features according to an embodiment of the present disclosure;

Figure 11 illustrates an article of footwear including a plurality of features according to an embodiment of the present disclosure;

Figure 12 illustrates an article of footwear including a lacing system according to an embodiment of the present disclosure;

Figure 13 illustrates an article of footwear including a lacing system according to an embodiment of the present disclosure;

Figure 14 illustrates an example article of footwear including a functional layer according to an embodiment of the present disclosure.

An embodiment of the present disclosure includes an article of footwear including a circular knitted fabric formed as a double-layer knitted upper of the article of footwear 10. The article of footwear 10 is disclosed as having a configuration suitable for walking or running. The concepts associated with footwear can also be applied to a variety of other sports footwear types, including, for example, baseball shoes, basketball shoes, cross-training shoes, cycling shoes, sneakers, tennis shoes, football shoes, sprint shoes, and hiking shoes. These concepts can also be applied to footwear types that are generally regarded as non-sports, including dance shoes, loafers, sandals and work boots. The concepts disclosed in this application are applicable to a wide range of footwear types.

Referring to FIGS. 1 to 3, the article of footwear 10 includes a sole component 20 and an upper knitted component 30. For reference purposes, the article of footwear 10 can be divided into three general areas: the forefoot area 11, the midfoot area 12 behind the forefoot area, and the heel area 13. The forefoot region 11 generally includes the parts of the footwear 10 corresponding to the toes and the joints connecting the metatarsals and the phalanges. The midfoot area 12 generally includes a portion of the article of footwear 10 that corresponds to the arch area of the foot. The heel area 13 generally corresponds to the back part of the foot. The article of footwear 10 also includes an inner side 14 and an outer side 15, which extend through each of the zones 11 to 13 and correspond to opposite sides of the article of footwear 10. The outer side 15 corresponds to the outer area of the foot, that is, the surface facing away from the other foot, and the inner side 14 corresponds to the inner area of the foot, that is, the surface facing the other foot. The areas 11 to 13 and the sides 14 to 15 are intended to represent the general area of the article of footwear 10. In addition to the article of footwear 10, the zones 11 to 13 and the sides 14 to 15 can also be applied to the sole component 20 and/or the upper knitted component 30.

Continuing with Figures 1 to 3, the sole component 20 is fastened to the upper knitted component 30, and when the article of footwear 10 is worn, the sole component extends between the foot and the ground. The sole assembly 20 may include a midsole, an outsole, and a lining (not shown). The midsole is fastened to the upper knit assembly 30, as explained further below. The midsole can be made of compressible polymer foam elements, for example, polyurethane or vinyl ethyl acetate The foam is formed, and the compressible polymer foam element will attenuate the ground reaction force and provide cushioning when compressed between the foot and the ground during walking, running or other ambulatory activities. The outsole is fastened to the lower surface of the midsole and may be formed of a wear-resistant rubber material that is textured to impart traction. The structure and characteristics of the sole component 20 or any sole component used with the upper knitted component 30 may vary considerably.

The article of footwear 10 includes a plurality of tabs 22 a to 22 d, which extend upward from the sole component 20 along the inner side 14 and the outer side 15 of the article of footwear 10. The plurality of protruding pieces 22 a to 22 d include fastening members 24 a to 24 d in the form of openings, grooves, and/or hooks that receive the belt 18.

Continuing with FIGS. 1 to 3, the upper knitted component 30 forms an internal void 31 in the article of footwear 10 for receiving the foot and securing the foot relative to the sole component 20. The void 31 is molded to accommodate the foot and extends along the outer side of the foot, along the inner side of the foot, above the foot, around the heel, and under the foot. The gap can be entered through an ankle opening 32 located at least in the heel area 13. The strap 18 extends through the portion of the upper knitted component 30, as described above, and allows the wearer to modify the size of the upper knitted component 30 to fit the proportions of the foot. The strap 18 allows the wearer to tighten the upper knitted component 30 around the foot, and the strap 18 allows the wearer to loosen the upper knitted component 30 to help the foot enter the gap 31 and move out of the gap through the ankle opening 32.

Continuing to Fig. 1 to Fig. 3, the shoe upper knitted component 30 is a double-layer knitted shoe upper having a substantially integral circular knitted fabric structure. The double-layer knitted upper has an insole 41, a toe portion 42, a middle foot portion 44 (sometimes referred to as an upper portion 44) continuous with the toe portion 42, a heel portion 46 adjacent to and continuous with the midfoot portion 44, and an ankle opening 32 The ankle part 48. The insole 41 extends along the midfoot portion 44 from the toe portion 42 to the heel portion 46. The sole assembly 20 is attached to the insole 41. In an alternative embodiment, a liner (not shown) is positioned along the insole 41 within the double-layer knitted upper. The toe portion 42, the midfoot portion 44, the heel portion 46 and the ankle portion 48, and the insole 41 generally refer to the area of the upper knitted component 30.

2 and 3, the double-layer knitted shoe upper has an outer knitted layer 60 and an inner knitted layer 80. The outer knitted layer 60 and the inner knitted layer 80 together form the toe portion 42, the midfoot portion 44, the double-layer knitted upper The heel portion 46 and the ankle portion 48. However, the outer knitted layer 60 defines the outer surface 50 of the double-layer knitted upper, and the inner knitted layer defines the inner surface 52 of the double-layer knitted upper. Therefore, it can be said that the outer knitted layer 60 forms the outer surface (not numbered) of the toe portion 42, the midfoot portion 44, the heel portion 46, and the ankle portion 48. In contrast, the inner knitted layer 80 defines the inner surface (not numbered) of the toe portion 42, the midfoot portion 44, the heel portion 46, and the ankle portion 48. In addition, both the outer knitted layer 60 and the inner knitted layer 80 substantially define the insole 41 of the double-layer knitted upper. The outer knitted layer 60 and the inner knitted layer 80 may define an edge 51 along the ankle opening 32. The optional fastener 54 can be provided along the edge 51 of the ankle opening 32.

The double-layer knitted upper includes consolidating the outer knitted layer 60 to the inner knitted layer 80, thereby forming at least one attachment component of the double-layer knitted upper. The attachment member may be any material that fuses the outer knitted layer 60 and the inner knitted layer 80 together. Because the inner and outer knitted layers have a circular knitted structure, due to the different knitted structures formed in the knitting area described below, each layer has floating yarns on the side surface. When the double-layer knitted shoe upper is formed, the floating yarn from the outer knitted layer 60 faces the floating yarn from the inner knitted layer 80. When the floating yarn is pulled or stratified or deformed in other ways, the floating yarn will produce barbs and deform the knitted structure. The attachment component solves this problem by consolidating the outer knitted layer and the inner knitted layer together. In particular, the attachment component joins the yarn from the outer knitted layer 60 to the yarn from the inner knitted layer 80. This combination minimizes the deformation of the knitted structure during use. The attachment component also joins the inner and outer knitted layers together so that the two layers do not slide relative to each other. The attachment component provides stability for the double-layer knitted upper. In one example, the attachment component may include a binding yarn. The binding yarn may include parts of the knitting stitches, and may be embedded or added during knitting. When the binding yarn is exposed to a desired temperature (below the glass transition temperature), the binding yarn will melt, thereby consolidating the outer knitted layer 60 and the inner knitted layer 80 together. The binder yarn may be a thermoplastic polyurethane yarn. In another example, the binder yarn is a low-melting thermoplastic yarn whose melting temperature is lower than the melting temperature of the yarns used to form the outer knitted layer 60 and the inner knitted layer 80. In alternative embodiments, the attachment component may be a low-melting adhesive film, a low-melting adhesive non-woven mesh, or an adhesive coating. In yet another alternative embodiment, the attachment member may be a binding yarn that adheres the outer layer and the inner layer together.

The outer knitted layer 60 has a plurality of outer knitted regions 62a to 62f, and the inner knitted layer 80 has a plurality of inner knitted regions 82a to 82g. The inner and outer knitted areas contain selected fabric structural elements. The selected fabric structural elements may include specific knitting stitches and/or certain yarns are present. In addition, selected fabric structural elements may include the absence of certain knitting stitches and/or yarns. One or more of the plurality of outer knitted regions 62a to 62f of the outer knitted layer 60 may spatially correspond to one or more of the plurality of inner knitted regions 82a to 82g. In the embodiment where the inner knitting area corresponds spatially to the outer knitting area, the inner knitting area completely or partially underlies the outer knitting area. For example, each of the inner knitting regions 82a to 82e underlies the respective outer knitting regions 62a to 62d. However, the outer knitted layer 60 and the inner knitted layer 80 may include different knitted regions in different positions from each other.

Figure 2 illustrates a plurality of outer knitting regions 62a to 62f. As illustrated, the plurality of outer knitting regions includes a first outer knitting region 62a along a portion of the toe portion 42 and the insole 41. The first outer knitting area 62a may be referred to as a front toe knitting area. The second outer knitted area 62b extends across the top of the toe portion 42. The second outer knitting area 62b may be referred to as an upper toe knitting area. The third outer knitted area 62c spans the top portion of the midfoot portion 44 and extends behind the toe portion 42. The third outer knitting area 62c may be referred to as an upper midsole knitting area. The fourth outer knitted area 62d extends across the heel portion 46. The fourth area 62d is called the outer heel area. The fifth outer knitted area 62e forms the remaining area of the outer knitted layer. The sixth outer knitted area 62f is located above the outer heel portion 46 along the ankle portion 48. As far as the knitted structure and/or yarn are concerned, each of the outer knitted regions 62a to 62f may have different fabric structural elements. Alternatively, in terms of the knitted structure and/or yarn, each of the outer knitted regions 62a to 62f may have a similar knitted structure. In one example, the upper midsole knit area 62c may include binder yarns. The binder yarn can be, for example, a thermoplastic polyurethane yarn. The binding yarns can help consolidate the outer knitted layer 60 and the inner knitted layer 80 together.

As best shown in FIGS. 2 and 4, the inner knitted layer 80 includes a plurality of inner knitted regions 82a to 82g including selected fabric structural elements. The regions 82a to 82g are not shown in FIG. 2 but are illustrated as part of the knitted blank 130 in FIG. 4. As illustrated, the plurality of inner knitted regions includes a first inner knitted region 82a along a portion of the toe portion and the insole. The first inner knitting area 82a can be called the front toe knitting Area. The second inner knitted area 82b extends across the top of the toe portion. The second inner knitting area 82b may be referred to as an upper toe knitting area. The third inner knitted area 82c spans the top portion of the midsole portion and extends behind the toe portion. The third inner knitting area 82c may be referred to as an upper midsole knitting area. The fourth inner knitted area 82d extends across the heel portion. The fourth zone 82d is called the inner heel zone. The fifth inner knitted area 82e forms the remaining area of the inner knitted layer 80. The sixth inner knitted area 82g spans the bottom portion of the midsole portion and extends behind the toe portion. The sixth inner knitting area 82g may be referred to as the lower midsole knitting area 82g. The seventh inner knitted area 82f is positioned along the ankle portion. As far as the knitted structure and/or yarn are concerned, each of the inner knitted regions 82a to 82g may have different fabric structural elements. Alternatively, in terms of the knitted structure and/or yarn, each of the inner knitted regions 82a to 82g may have a similar knitted structure. In one example, the upper midsole knitting area 82c and/or the lower midsole knitting area 82g may include binding yarns. As described above, the binder yarn may be a thermoplastic polyurethane yarn. The binding yarns can help consolidate the outer knitted layer 60 and the inner knitted layer 80 together.

The double-layer knit upper can have a variety of circular knit structures. For example, the double-layer knit upper may include a single-jersey knit structure, a double-sided knit structure, a rib knit structure, a pile knit structure, or other types of weft knit structures. In addition, different areas of the double-layer knitted shoe upper may include different knitting stitches, such as floating stitches, pinch stitches, dropped stitches, and other knitting stitches known to those skilled in the art. In one example, the outer knitted toe regions 62a, 82a of the outer layer and/or inner layer may include a cushioning knitted structure. Similarly, the heel regions 62d and 82d of the outer layer and/or the inner layer may have a cushioning knitted structure. The cushion knitted structure includes knitted loops.

The double-layer knit upper can be formed of any type of yarn, such as spun yarn or continuous filament yarn. The spun yarn may include natural fibers, synthetic fibers, or a blend of natural and synthetic fibers. Natural fibers include cotton, wool, bamboo, flax, hemp or others. Synthetic fibers may include polyethylene terephthalate (PET), polyolefin, polyamide 6, polyamide 6,6, polylactic acid (PLA) fiber, viscose rayon, acrylic, or other fiber types. Suitable thermoplastic synthetic staple fibers can be monocomponent or bicomponent type fibers. A variety of spinning types can be used, such as ring spinning, start spinning, air-jet spinning, compact spinning, etc. Continuous filament yarns can include either or both of monocomponent or bicomponent filament types. The continuous filament yarn can be polyethylene terephthalate, polyolefin and/or polyamide 6, polyamide 6,6, polylactic acid filament. The yarns used in knitted fabrics can have a certain range of yarn counts. For example, in one example, the count of the knitting yarn may range from about 50 denier to about 250 denier (or higher). The yarn is not limited to the denier range. Binder yarns are used in selected areas of the outer knitted layer 60 and the inner knitted layer 80 to help consolidate the outer layer and the inner layer together. The binder yarn may be a low melting point thermoplastic yarn, or a yarn such as a thermoplastic polyurethane yarn.

Another embodiment of the present disclosure is a method for forming an article of footwear 10. The method may include forming a knitting stage form of the circular knitting blank 130. After the knitting stage, the method may include an assembly stage in which the circular knitted blank 130 is formed into the upper knitted component 30 and the sole component 20 is attached to the insole 41 of the upper knitted component 30. Referring to FIGS. 4 to 6, the circular knitted blank 130 has a first knitted section 160 that defines an outer knitted layer 60 and a second knitted section 180 that defines an inner knitted layer 80. The circular knitted blank 130 is folded onto itself to define a double-layer knitted upper such that the inner knitted layer 80 forms an inner void 31 within the article of footwear 10.

In the knitting stage, a circular knitting machine (not shown) commonly used by those familiar with this technology is used. The circular knitting machine may be a double needle machine including two needle cylinders. Alternatively, a circular knitting machine with a needle cylinder and a dial can be used. For the purpose of illustration and clarity, a knitting machine with two needle cylinders is used below to describe the knitting process. It should be understood that other types of knitting machines can be used. Each needle cylinder has a plurality of needles arranged around the circumference of the needle cylinder, wherein each needle is accommodated in a movable track. The cam assembly engages the needle along each needle barrel. The rotational movement of the cam assembly (or the relative movement of the needle cylinder) causes the needles to move up and down on the track in a manner called a knitting cycle in the art to form mutually connected courses of knitting yarn loops. The knitting course defines a circular knitted fabric blank 130. By changing the knitting cycle and/or holding certain needles in place during knitting, specific knitting stitches and/or patterns can be formed into the circular knitting blank 130. Circular knitting machines and basic circular knitting processes are common to those who are familiar with this technology. Various circular knitting systems can be used Processes, such as tubular circular knit, narrow tubular circular knit jacquard, single jersey circular knit jacquard, double-sided circular knit jacquard knit.

Referring to FIG. 4, the circular knitted blank 130 has a first end 132 and a second end 134. The circular knitted blank 130 is formed to have a first knitted section 160 defining a first end 132 and a second knitted section 180 defining a second end 134. As described above, the circular knitting blank 130 includes interconnected rows of knitting loops, which are called courses. The first “course” of the knitted blank 130 is located at the first end 132. As shown in FIG. 4, the circular knitting blank 130 is formed row by row in the direction K shown in FIG. 4 until the circular knitting blank 130 is completed. Therefore, during the knitting phase, the first knitting section 160 is knitted first, and then the second knitting section 180 and the first knitting section 160 are formed in a single monolithic fabric.

The circular knitted fabric blank 130 starts with the knitting of the first toe portion 142 of the first knitting section 160 of the needle cylinder. Next, the circular knitting machine knits the middle bottom part including the first upper part 144a and the first lower part 144b. Next, the first heel portion 146 of the first knitting section 160 is knitted adjacent to the first lower portion 144b. During the knitting of the first heel portion 146, the knitting machine can selectively place needles to change the knitting direction to form the desired curve of the first heel portion 146. After the first heel portion 148 is formed, the circular knitting machine knits the first ankle portion 148 of the first knitting section 160 adjacent to the first heel portion 148 and the first upper portion 144a. At this time, the first knitting section 160 is substantially completed. The first knitted section 160 includes a double knitted upper outer knitted layer 60, as explained below. Therefore, when the knitting machine forms the first knitting section 160, different knitting regions 62a to 62f are made in the circular knitted fabric blank 130, as shown.

The knitting process is continued to form the second knitting section 180. During this knitting phase, the second ankle portion 248 of the second knitting section 180 is formed adjacent to the first heel portion 148. The circular knitting machine knits the second heel portion 246 adjacent to and continuous with the second ankle portion 248. The second upper part 244a and the second lower part of the second knitting section 180 of the circular knitting machine 244b is knitting. The knitting process is continued, and the second toe portion 242 of the second knitting section 180 adjacent to the second upper portion 244a and the second lower portion 244b is formed. The second toe portion 242 is formed to the end 134 to complete the knitted blank 130. When the knitting machine forms the second knitting section 180, different knitting areas 82a to 82g are formed in the respective areas of the circular knitted fabric blank 130. As explained, the formed circular knitted blank 130 is substantially a tubular structure with two flat cloth covers connected as an ankle part.

Additional yarn courses can be added to facilitate the transition to the next knitted blank formed by the circular knitting machine. An optional cutting device is used to cut the finished circular knitted blank 130 from the knitting machine. The circular knit blank 130 is pushed out of the knitting machine for later processing.

The completed circular blank 130 may have toe openings 152 and 252 at the toe portion 142 and the toe portion 242, respectively. The toe openings 152 and 252 can be closed with seams 154 and 254, as shown in FIG. 5. In an alternative embodiment, the circular knit blank 103 may be formed to automatically close the toe openings 152 and 252 using bridge stitches, inlaid yarns, or the like.

The circular blank 130 can be cut by removing the panel 156 from the circular knitted blank 130 to form the ankle opening 32. In an alternative embodiment, the circular knit blank 103 may be formed to define the ankle opening 32 during knitting. In this embodiment, the circular knitted blank 130 may be formed along the edge of the ankle opening 32 to prevent abrasion and provide a location for attaching the fastener 54 (FIG. 1 and FIG. 6).

When the circular knitted blank 130 is completed, the second knitted section 180 is folded into the first knitted section 160 to form a double-layer knitted upper of the article of footwear. At this stage, the double-layer knitted upper includes an outer knitted layer 60 defined by the first knitted section 160 and an inner knitted layer 80 defined by the second knitted section 180. In this state, at least two of the plurality of outer knitted regions 62a to 62d of the outer knitted layer 60 spatially correspond to at least two of the plurality of inner knitted regions. According to the illustrated embodiment, the inner knitting regions 82a to 82e lie below the outer knitting regions 62a to 62e.

The method may include positioning the liner component along the lower portion of the first knitted section before folding. Therefore, the lining component is arranged between the outer knitted layer and the inner knitted layer.

The method may include attaching the sole directly to the outer knitted layer of the double-layer knitted upper. Attaching the sole to the outer knitted layer includes positioning the double-layer knitted upper over a positioning member of an injection molding device (not shown). Then, the sole component is injection molded onto the outer knitted layer of the double-layer knitted upper. In addition, the method may include injection molding a plurality of tabs 22a-22d along the inner and outer sides of the double-layer knitted upper. The injection molding process can melt TPU yarns in specific knitting areas, thereby bonding the outer knitted layer to the inner knitted layer to form an integral double-layer knitted upper.

The circular knitted double-layer knit upper as described herein has several advantages. When using a single fabric structure, multiple knitted structures can be realized across different areas of the upper. The specific knitted structure can be designed into different areas of the footwear article according to needs. In addition, a complex three-dimensional shape that better fits the anatomical structure of the wearer's foot can be formed during the knitting process. Because the circular knitted upper is made to fit the wearer's foot, fewer assembly steps are required before attaching the upper to the sole to make a finished article of footwear. The fewer overall components of the finished footwear article reduce the complexity of the supply chain and increase production efficiency and output. In addition, the circular knitted double-layer shoe upper can be manufactured at a relatively fast rate, thereby further increasing the production efficiency.

The article of footwear 300 may include multiple layers, or may be continuous so as to form a whole. The article of footwear 300 may include a first layer 301 and a second layer 302. The first layer 301 and the second layer 302 may include soft materials such as fabrics. The first layer 301 and the second layer 302 may be generally tubular or may include other shapes. The second layer 302 may include a rigid material such as leather or plastic. The first layer 301 and the second layer 302 may be circular knitted, plain woven, or formed by other manufacturing methods or other materials. The second layer 302 may be folded or inverted to be disposed adjacent to at least a part of the first layer 301. The second layer 302 may include at least a portion of the interior or exterior of the article of footwear 300. The article of footwear 300 may include additional layers that may provide additional functionality.

As shown in FIG. 7, the article of footwear 300 may include a first layer 301 and a second layer 302. The first layer 301 and the second layer 302 may include a generally tubular shape. The first layer 301 may comprise suitable for forming footwear At least a part of the outer part of the article 300 is waterproof and breathable material. The first layer 301 may be coated with a spray coating to provide waterproofness and may also be breathable. The second layer 302 may include a soft material suitable for fitting the feet of the wearer and providing comfort. The second layer 302 may be or may include a comfort liner. When the second layer 302 is folded into the first layer 301, the second layer 302 defines the inside of the article of footwear 300 and the first layer 301 defines the outside of the article of footwear 300. Although referring to the first layer 301 and the second layer 302, other configurations may be used. For example, you can switch between layers or combine the characteristics of each layer.

One problem in conventional circular knitting applications is that it is difficult to stitch or bond other materials to circular knit uppers because the uppers have a finished 3D shape.

As an example, most heat presses and stitching machines have been optimized to smoothly handle the web. When the circular knitted shoe upper has a 3D shape, the typical flattening operation may be inappropriate.

As another example, 3D direct injection can be used to apply additional structure, cushioning, lace details, etc. to a circular knitted upper. This manufacturing process can be implemented on a shoe surface that can be finished in 3D shape.

As illustrated in Figure 8, article of footwear 400 may include multiple layers, or may be continuous to form a one-piece body. The article of footwear 400 may include a first layer 401 and a second layer 402. The first layer 401 and the second layer 402 may include soft materials such as fabrics. The first layer 401 and the second layer 402 may be generally tubular or may include other shapes. The second layer 402 may include a rigid material such as leather or plastic. The first layer 401 and the second layer 402 may be circular knitted, plain woven, or formed by other manufacturing methods or other materials. The second layer 402 may be folded or inverted to be disposed adjacent to at least a part of the first layer 401. The second layer 402 may include at least a portion of the interior or exterior of the article of footwear 400. The article of footwear 400 may include additional layers that may provide additional functionality.

As shown in FIG. 8, the article of footwear 400 may include a first layer 401, a second layer 402 and a lace system 403. The lacing system 403 may include shoelaces, eyelets, straps, Velcro or other types of fasteners. The lacing system 403 may be arranged adjacent to a part of the first layer 401, a part of the second layer 402, or a part of the two layers 401, 402. The first layer 401 and the second layer 402 may include circular The knitting is generally tubular in shape. The second layer 402 can be folded into the first layer 401. The second layer 402 may define the inner portion of the article of footwear 400 and the first layer may define the outer portion of the article of footwear 400. As shown, the lacing system 403 may be arranged circumferentially around the second layer 402. When the second layer 402 is folded into the first layer 401, the lace system 403 can be disposed between the first circular knitted layer 401 and the second circular knitted layer 402 of the article of footwear 400.

As illustrated in Figure 9, article of footwear 500 may include multiple layers, or may be continuous so as to form a whole. The article of footwear 500 may include a first layer 501 and a second layer 502. The first layer 501 and the second layer 502 may include soft materials such as fabrics. The first layer 501 and the second layer 502 may be generally tubular or may include other shapes. The second layer 502 may include a rigid material such as leather or plastic. The first layer 501 and the second layer 502 may be circular knitted, plain woven, or formed by other manufacturing methods or other materials. The second layer 502 may be folded or inverted to be disposed adjacent to at least a part of the first layer 501. The second layer 502 may include at least a portion of the interior or exterior of the article of footwear 500. The article of footwear 500 may include additional layers that may provide additional functionality.

As shown in FIG. 9, the article of footwear 500 may include a first layer 501, a second layer 502 and a collar portion 504. As shown, the first layer 501 may comprise a generally tubular shape. The first layer 501 can be circularly knitted. The second layer 502 may include a flat rectangular shape. The second layer 502 can be plain woven. The second layer 502 may include one or more weld reinforcements 505 for fastening the second layer 502 to the first layer 501. The second layer 502 may be configured for use in a lockstitch operation 506 such as lockstitching, molding, or screen printing. The second layer 502 may be configured to fold into or around the first layer 501 to define the collar portion 504. The second layer 502 may be configured to be disposed circumferentially around the outer portion of the first layer 501 to define the collar portion 504. The second layer 502 can also be disposed adjacent to the foot, ankle, or another part of the first layer 501 to define other features.

Figure 10 illustrates an article of footwear 600, which may include multiple layers, or may be continuous so as to form a whole. The article of footwear 600 may include a first layer 601 and a second layer 602. The first layer 601 and the second layer 602 may include soft materials such as fabrics. The first layer 601 and the second layer 602 can be substantially tubular or Can contain other shapes. The second layer 602 may include a rigid material such as leather or plastic. The first layer 601 and the second layer 602 may be circular knitted, plain woven, or formed by other manufacturing methods or other materials. The second layer 602 may be folded or inverted to be disposed adjacent to at least a part of the first layer 601. The second layer 602 may include at least a portion of the interior or exterior of the article of footwear 600. The article of footwear 600 may include additional layers or features that may provide additional functionality.

As shown in FIG. 10, the article of footwear 600 may include a first layer 601 and a second layer 602. The first layer 601 may be generally tubular. The first layer 601 can be circularly knitted. The second layer 602 may include a hard or rigid material such as leather, rubber, or plastic suitable to define at least a portion of the exterior of the article of footwear 600. The second layer 602 can be plain woven. The second layer 602 may be configured to be disposed at least adjacent to the outer portion of the first layer 601. The second layer 602 may include a reinforced area 610. For example, as shown, the reinforcement zone 610 may define a heel cup 610a and a toe cup 610b. The second layer 602 may include pores 608 that define the lacing system 603 or other functions. Aperture 608 may include lace holes or perforations that are configured to receive laces or straps.

The article of footwear 600 may further include one or more ventilation zones 607 that provide ventilation. The ventilation area 607 may be generally triangular or planar or may have other shapes. As shown, the first layer 601 and the second layer 602 may include a plurality of ventilation areas 607. When inverted to form the article of footwear 600, the ventilation area 607 of the first layer 601 may correspond to the ventilation area 607 of the second layer 607, and may be configured to be disposed adjacent to the ventilation area of the second layer.

The article of footwear 700 may include multiple layers, or may be continuous so as to form a whole. The article of footwear 700 may include a first layer 701 and a second layer 702. The first layer 701 and the second layer 702 may include soft materials such as fabrics. The first layer 701 and the second layer 702 may be generally tubular or may include other shapes. The second layer 702 may include a rigid material such as leather or plastic. The first layer 701 and the second layer 702 may be circular knitted, plain woven, or formed by other manufacturing methods or other materials. The second layer 702 may be folded or inverted to be disposed adjacent to at least a part of the first layer 701. The second layer 702 may contain At least part of the interior or exterior of the article of footwear 700. The article of footwear 700 may include additional layers that may provide additional functionality.

As illustrated in FIG. 11, the article of footwear 700 may include a first layer 701 and a second layer 702. The first layer 701 and the second layer 702 may be continuous so as to define a whole. The second layer 702 may be configured to be inverted to be adjacent to the outer surface of the first layer 701. The first layer 701 and the second layer 702 may include one or more features. As shown, the second layer 702 may include a plurality of stripes 709a, 709b, 709c. The strips 709a, 709b, 709c may include knitted materials, rigid materials, or a combination of knitted and rigid materials to define different characteristics. As shown, the first strap 709a can include a reinforced area 710 that can define a heel cup 710a. The second strap 709b can include an aperture 708 that can define the tether system 703.

The article of footwear 800 may include multiple layers, or may be continuous so as to form a whole. The article of footwear 800 may include a first layer 801 and a second layer 802. The first layer 801 and the second layer 802 may include soft materials such as fabrics. The first layer 801 and the second layer 802 may be generally tubular or may include other shapes. The second layer 802 may include a rigid material such as leather or plastic. The first layer 801 and the second layer 802 may be circular knitted, plain woven, or formed by other manufacturing methods or other materials. The second layer 802 may be folded or inverted to be disposed adjacent to at least a part of the first layer 801. The second layer 802 may include at least a portion of the interior or exterior of the article of footwear 800. Article of footwear 800 may include additional layers that may provide additional functionality.

As illustrated in FIG. 12, the article of footwear 800 may include a first layer 801 and a second layer 802. The first layer 801 may be generally tubular. The first layer 801 can be circularly knitted. The second layer 802 may include an irregular planar shape. The second layer 802 can be plain woven. The article of footwear 800 may further include a lacing system 803. As shown, the second layer 802 can include features 811 that are configured to extend through at least a portion of the first layer 801. The component 811 may be configured to be removably received in the aperture 808 in the first layer 801. The component 811 may include loop hooks to define an article of footwear 800 having a through feature.

The article of footwear 900 may include multiple layers, or may be continuous so as to form a whole. The article of footwear 900 may include a first layer 901 and a second layer 902. The first layer 901 and the second layer 902 may include soft materials such as fabrics. The first layer 901 and the second layer 902 may be generally tubular or may include other shapes. The second layer 902 may include a rigid material such as leather or plastic. The first layer 901 and the second layer 902 may be circular knitted, plain woven, or formed by other manufacturing methods or other materials. The second layer 902 may be folded or inverted to be disposed adjacent to at least a part of the first layer 901. The second layer 902 may include at least a portion of the interior or exterior of the article of footwear 900. Article of footwear 900 may include additional layers that may provide additional functionality.

As illustrated in FIG. 13, the article of footwear 900 may include a first layer 901 and a second layer 902. The first layer 901 may comprise a generally tubular shape. The first layer 901 can be circularly knitted. The second layer 902 may include a flat irregular shape. The second layer 902 can be plain woven. The second layer 902 may be inverted to be adjacent to the outer surface of the first layer 901. The second layer 902 may include a lacing system 903. As shown, the second layer 902 may include an aperture 908 (e.g., lace hole) that defines the lace system 903. The second layer 902 can include a strengthening zone 910 that can define a heel cup 910a and a toe cup 910b that provide structure and integrity to the exterior of the article of footwear 900.

Figure 14 illustrates example articles of footwear 950-954 that may include functional layers 960-965. The functional layers 960 to 965 may include insoles, midsoles, insulating materials, cloth covers, shoe collars, and other functional features in the article of footwear 950 to 954. As described and shown, one or more functional layers may be inserted between two knitted layers (e.g., circular knitted layers), such as using folding techniques or other techniques. The functional layer may include a waterproof material or membrane or a breathable waterproof membrane. The functional layer can be a pre-molded laminate or a composite material. The functional layer can be a spray coating. The functional layer can be directly injected into 3D. The functional layer can be applied in other configurations or on other surfaces. As a non-limiting example, a problem that the present disclosure is solving is that although circular knitting is faster, it may be difficult to stitch or combine things to the circular knit upper because of the 3D shape of the finished shoe upper. At present, most of the hot presses and stitching machines in the advanced technology have been optimized to smoothly handle the coils. As an illustrative example, 3D direct injection is an application of additional structure, cushioning, The method of shoelace details and so on. This process can be implemented on a fully completed shoe with a 3D shape.

As shown, the functional layer 960 may include a built-in sockliner in the midsole of the article of footwear 950. The functional layer 961 may include a knitted insole (for example, a pad knitted fabric) in the article of footwear 951. The functional layer 962 may include embedded insulating materials in the article of footwear 952. The functional layer 963a may include a clip-in midsole in the article of footwear 953. The midsole can include features that can extend through the first and/or second layer, such as outsole lugs. The lugs can be configured to engage the ground. As an example, one or more of the first layer or the second layer may include apertures to allow lugs from the clip-in midsole to extend therethrough. Various configurations of lugs can be used, such as the configuration at the heel and the configuration at the forefoot. The functional layer 963b may include a clip-in foam collar in the article of footwear 953. The functional layer 964 may include the general upper and outsole in the article of footwear 954. The functional layer 965 may include a customized inner cloth cover in the article of footwear 954.

State

This disclosure includes at least the following aspects:

Aspect 1: An article of footwear comprising: a double-layer knitted upper having an insole, an upper portion continuous with the insole, an ankle opening, and an inner space for receiving the wearer's foot; and a sole , Which is at least attached to the insole of the double-layer knitted upper, the double-layer knitted upper having:

a) The outer knitted layer, which defines the outer surface of the double-layer knitted upper, and the outer knitted layer has a plurality of outer knitted areas; and

b) The inner knitted layer, which is knitted as a whole to the outer knitted layer, and the inner knitted layer forms an inner gap, wherein the inner knitted layer has a plurality of inner knitted regions corresponding to the outer knitted regions of the outer knitted layer in space, wherein the outer knitted layer The layer and the inner knitted layer generally define the insole and upper portion of the double-layer knitted upper.

Aspect 2. The article of footwear according to aspect 1, further comprising a midsole positioned between the outer knitted layer and the inner knitted layer along the insole.

Aspect 3. Such as the footwear article of aspect 1, wherein the outer knitted layer and the inner knitted layer are integral circular knitted fabrics.

Aspect 4. Like the article of footwear in aspect 1, wherein the outer knitted layer and the inner knitted layer each define a tubular knitted shape.

Aspect 5. The article of footwear according to aspect 1, wherein the inner knitted layer is integrally knitted to the outer knitted layer around at least a part of the ankle opening.

Aspect 6. The article of footwear according to aspect 5, wherein the outer knitted layer and the inner knitted layer define the edge of the strip along at least a part of the ankle opening.

Aspect 7. The article of footwear according to aspect 1, wherein the outer knitted layer and the inner knitted layer include a fastener along at least a portion of the ankle opening.

Aspect 8. The article of footwear according to aspect 1, which further comprises at least one attachment component for consolidating the outer knitted layer and the inner knitted layer together.

Aspect 9. The article of footwear according to aspect 8, wherein at least one attachment member joins the yarns of the outer knitting layer to the yarns of the inner knitting layer.

Aspect 10. The article of footwear according to aspect 8, wherein at least one attachment component is a binding yarn.

Aspect 11. The article of footwear according to aspect 10, wherein the binding yarn is a thermoplastic polyurethane yarn.

Aspect 12. The footwear article of aspect 10, wherein the binding yarn is a low melting point thermoplastic yarn.

Aspect 13. The article of footwear in aspect 10, wherein the outer knitted layer includes a first yarn, the inner knitted layer includes a second yarn, and wherein the melting temperature of the binding yarn is lower than the melting temperature of the first yarn and the second yarn .

Aspect 14. As in the article of footwear in aspect 8, at least one of the attachment components is an adhesive film.

Aspect 15. Such as the article of footwear in aspect 8, in which at least one of the attachment parts is low Melting point adhesive mesh.

Aspect 16. The article of footwear according to aspect 8, wherein at least one of the plurality of outer knitted regions includes at least one attachment component.

Aspect 17. The article of footwear according to aspect 16, wherein the double-layer knitted upper has a toe portion, wherein the first outer knitted area of the plurality of outer knitted areas in the outer knitted layer extends across the upper portion behind the toe portion, wherein the first outer knitted area The knitting area contains at least one attachment part.

Aspect 18. The article of footwear according to aspect 8, wherein at least one of the plurality of inner knitted regions includes at least one attachment component.

Aspect 19. Such as the footwear article of aspect 18, wherein the second outer knitted area of the plurality of outer knitted areas extends across the toe portion, and the second inner knitted area of the plurality of inner knitted areas underlies the second outer knitted area, wherein At least one of the second outer knitting area and the second inner knitting area includes at least one attachment member.

Aspect 20. The article of footwear according to aspect 18, wherein the plurality of inner knitted regions include an inner middle region along the insole, and the inner middle region includes at least one attachment member.

Aspect 21. The article of footwear according to aspect 1, wherein the double-layer knitted upper has a heel part connecting the insole to the ankle part, and the heel part has a cushioning knitted structure.

Aspect 22. The article of footwear according to aspect 1, wherein the double-layer knitted upper has a toe portion, and the toe portion has a cushioning knitted structure.

Aspect 23. The article of footwear as in aspect 1, which further includes a plurality of tabs extending upward from the sole along the inner and outer sides of the article of footwear.

Aspect 24. The article of footwear as in aspect 23, wherein the plurality of tabs include fastening components configured to receive the strap.

Aspect 25. A circular knitting blank for forming footwear articles and having a first end and a second end. The circular knitting blank includes: a first circular knitting section with a defining circle The first toe portion, the first upper portion, the first lower portion connected to the first upper portion, the first heel portion, and the first ankle portion connected to the first heel portion of the first end of the knitted blank, wherein A circular knitting section has a first plurality of knitting areas each having a different knitting structure; and a second circular knitting section having a second ankle part integrally knitted to the first ankle part and connected to the second ankle part The second heel part, the second upper part connected to the second ankle part, the second lower part connected to the second upper part and the second heel part, and the first of the circular knitted blank and the circular knitted blank The second toe portion of the second end opposite to the end, wherein the second circular knitting section includes a second plurality of knitting areas each having a different knitting structure; wherein the first plurality of knitting areas corresponds to the second plurality of knitting areas, So that when the first circular knitting section is folded into the second circular knitting section, the first plurality of knitting regions overlap with the second plurality of knitting regions.

State 26. Like the circular knitted blank of aspect 25, it further includes an opening at the junction of the first ankle part and the second ankle part.

State 27. The circular knitted blank as in aspect 25, which further includes at least one attachment member configured to join the first circular knitted section and the second circular knitted section together.

State 28. A method for forming an article of footwear, comprising: circularly knitting a tubular knitted blank having a first knitting section and a second knitting section, wherein a) the first knitting section includes a first toe part, and a second knitting section. The lower portion, the first upper portion, the first heel portion adjacent to the first lower portion, and the first ankle portion adjacent to the first heel portion and the first upper portion, and b) the second knitted section includes The second toe part, the second lower part, the second upper part, the second heel part adjacent to the second lower part, and the second ankle part adjacent to the second heel part and the second upper part; the first knitting area The section is folded into the second knitted section to form a double-layer knitted upper of the article of footwear. The double-layer knitted upper includes an outer knitted layer defined by the second knitted section and an inner knitted layer defined by the first knitted section , Wherein the inner knitted layer defines the inner void of the double-layer knitted upper; and the sole is directly attached to the outer knitted layer of the double-layer knitted upper.

State 29. Such as the method of aspect 28, wherein circular knitting includes the following operations in sequence:

a. Knit the first toe part of the first knitting section;

b. Knit the first upper part and the first lower part of the first knitting section;

c. Knitting the first heel portion of the first knitting section adjacent to the first lower portion;

d. Knit the first ankle portion of the first knitted section adjacent to the first heel portion and the first upper portion;

e. Knit the second ankle portion of the second knitting section adjacent to the first heel portion;

f. Knit the second heel portion of the second knitting section adjacent to the second ankle portion;

g. Knit the second upper part and the second lower part of the second knitting section; and

h. Knit the second toe part of the second knitting section adjacent to the second upper part and the second lower part.

State 30. The method of aspect 28, wherein attaching the sole to the outer knitted layer comprises: positioning the double-layer knitted upper above the positioning member of the injection molding device; injection molding the sole onto the outer knitted layer of the double-layer knitted upper ; And along the inner and outer sides of the double-layer knitted upper, a plurality of tabs are injection molded, wherein the plurality of tabs are configured to receive the belt.

State 31. An article of footwear comprising: a first circular knitted layer defining at least a part of an outer surface; and a second circular knitted layer coupled to the first circular knitted layer, the second circular knitted layer being configured to When folded into or around the first circular knitted layer, it is arranged adjacent to at least a part of the first circular knitted layer.

State 32. The article of footwear according to aspect 31, wherein the second circular knitted layer extends from the first circular knitted layer into an integral body.

State 33. The article of footwear according to aspect 31, wherein the first circular knitted layer comprises a substantially tubular shape.

State 34. The article of footwear according to aspect 31, wherein the second circular knitted layer comprises a substantially tubular shape.

State 35. The footwear article of aspect 31, wherein the second circular knitted layer includes a planar shape.

State 36. The article of footwear according to aspect 31, wherein the first circular knitted layer includes a waterproof and breathable material, and wherein the second circular knitted layer includes a comfort lining.

State 37. The article of footwear according to aspect 31, further comprising a lace system disposed adjacent to at least a part of the second circular knitted layer so that the second circular knitted layer is folded to the first circular knitted layer In the middle, at least a part of the lacing system is inserted between the second circular knitted layer and the first circular knitted layer.

State 38. The article of footwear according to aspect 37, wherein at least a part of the lacing system is circumferentially arranged around the second circular knitted layer.

State 39. The article of footwear as in aspect 31, wherein the first circular knitted layer comprises a substantially tubular shape, and wherein the second circular knitted layer comprises a planar shape, and wherein the planar second circular knitted layer is configured to be folded to the first A circular knit layer in or around was previously used for leveling operations.

State 40. For the footwear article of aspect 39, the flattening operation includes one or more of sewing, fusion, molding, or screen printing.

State 41. The article of footwear as in aspect 39, wherein the planar second circular knitted layer includes one or more weld strengthening zones.

State 42. The article of footwear according to aspect 31, wherein the first circular knitted layer includes a collar, and wherein the planar second circular knitted layer is configured to at least partially circumferentially surround the outer surface of the first circular knitted layer .

State 43. The article of footwear as in aspect 31, wherein the first circular knitted layer comprises a substantially tubular shape, and wherein the second circular knitted layer is configured to be folded adjacent to the outer surface of the first circular knitted layer The outer surface is adjacent to one or more of the ankle portion or the midfoot portion of the first circular knitted layer.

State 44. Such as the article of footwear in aspect 43, wherein the first circular knitted layer includes one or more ventilation zones, and wherein the second circular knitted layer is configured to be adjacent to the ventilation zone when folded on the first circular knitted layer At least part of it.

State 45. The article of footwear as in aspect 44, wherein the second circular knitted layer includes one or more features that are configured to be disposed adjacent to the portion of the ventilation zone.

State 46. The article of footwear as in aspect 45, wherein one or more of the features include voids.

State 47. The article of footwear as in aspect 43, wherein the second circular knitted layer includes a warp configuration to be disposed adjacent to one or more features of the first circular knitted layer.

State 48. The article of footwear as in aspect 47, wherein one or more of the features include apertures, lace holes, heel cups, or a combination thereof.

Aspect 49. The article of footwear as in aspect 47, wherein one or more of the features include a through portion that is configured to extend through a portion of the first circular knitted layer.

Aspect 50. The article of footwear as in aspect 31, wherein the first circular knitted layer includes a substantially tubular shape, and wherein the second circular knitted layer is configured to be folded to be disposed adjacent to the outer surface or the inner surface of the first circular knitted layer.

State 51. Such as the footwear article of aspect 50, which further includes a functional layer, and when the second circular knitted layer is folded into or on the first circular knitted layer, the functional layer is inserted between the first circular knitted layer and the second circular knitted layer. Between circular knit layers.

State 52. For the footwear article of aspect 51, the functional layer includes an insole.

State 53. For the footwear article of aspect 51, the functional layer includes a midsole.

State 54. The article of footwear as in aspect 51, wherein the functional layer includes an insulating material.

State 55. For the footwear article of aspect 51, the functional layer includes a shoe collar.

State 56. Such as the article of footwear in aspect 50, wherein the second circular knitted layer includes pores, The second circular knitted layer is configured to be rolled up.

State 57. An article of footwear, which contains:

The first circular knitted layer, which defines at least a part of the outer surface; and

The second layer is coupled to the first circular knitted layer, and the second layer is configured to be disposed adjacent to at least a portion of the first circular knitted layer when folded into or around the first circular knitted layer.

State 58. The article of footwear as in aspect 57, wherein the second layer includes a flat shape.

State 59. The article of footwear as in aspect 58, wherein the flat shape is configured for a flattening operation before being folded into or around the first circular knitted layer.

State 60. For the footwear article of aspect 57, the second layer is flat woven.

State 61. The article of footwear as in aspect 57, wherein the second layer includes one or more weld strengthening zones.

State 62. The article of footwear as in aspect 57, wherein the first circular knitted layer comprises a generally tubular shape, and wherein the second layer is configured to be folded to be disposed adjacent to the outer surface of the first circular knitted layer.

State 63. The article of footwear according to aspect 57, wherein the first circular knitted layer includes a collar, and wherein the second layer is configured to at least partially circumferentially surround the outer surface of the collar of the first circular knitted layer.

State 64. The article of footwear as in aspect 57, wherein the first circular knitted layer includes one or more ventilation zones, and wherein the second layer is configured to be adjacent to at least a portion of the ventilation zones when folded on the first layer.

State 65. The article of footwear as in aspect 57, wherein the second layer includes one or more features that are configured to be disposed adjacent to the first circular knitted layer.

State 66. The article of footwear as in aspect 65, wherein one or more of the features include an aperture, a lacing system, a lace hole or a heel cup, a toe cup, or a combination thereof.

State 67. Such as the article of footwear in aspect 65, wherein one or more of the features include the configuration To extend through at least a part of the first circular knitted layer through part.

State 68. Such as the footwear article of aspect 57, which further includes a functional layer, and when the second layer is folded into or on the first circular knitted layer, the functional layer is inserted between the first circular knitted layer and the second layer .

State 69. For the footwear article of aspect 68, the functional layer includes an insole.

State 70. Such as the article of footwear in technical solution 68, wherein the functional layer includes a midsole.

State 71. For example, the article of footwear according to technical solution 68, wherein the functional layer includes an insulating material.

State 71. For example, the article of footwear according to technical solution 68, wherein the functional layer includes a shoe collar.

This disclosure describes specific embodiments and their detailed construction and operation. The embodiments described herein are only illustrated by way of illustration and not limitation. In view of the teachings herein, those skilled in the art will recognize that there may be a range of equivalents to the exemplary embodiments described herein. Most notably, other embodiments are possible. Modifications may be made to the embodiments described herein, and there may be equivalents to the components, parts or steps constituting the described embodiments. For the sake of clarity and conciseness, some aspects of the components or steps of some embodiments are not presented in improper details, and those skilled in the art will be obvious to those skilled in the art in view of the teachings herein, such details, and/or such details therein It will confuse the understanding of the more relevant aspects of the embodiment.

10: Footwear

18: belt

20: Sole components

22a-22d: tabs

24a-24d: Fastening parts

30: upper knitting components

41: Insole

42: toe part

44: Midfoot

46: heel part

48: Ankle part

54: Binder

62a: The first outer knitting area

62b: The second outer knitting area

62c: The third outer knitting area

62d: The fourth outer knitting area

62e: The fifth outer knitting area

62f: The sixth outer knitting area

82c: The third inner knitting area

Claims (20)

An article of footwear, which includes: A first circular knitted layer; A second circular knitted layer coupled to the first circular knitted layer, the second circular knitted layer is configured to be disposed adjacent to the first circular knitted layer when folded into or around the first circular knitted layer At least a part of the first circular knitted layer; and A functional layer, when the second circular knitted layer is folded into or around the first circular knitted layer, the functional layer is inserted between the first circular knitted layer and the second circular knitted layer . The article of footwear according to claim 1, wherein the functional layer includes one or more of a waterproof membrane, a breathable waterproof membrane, or a spray coating. An article of footwear, which includes: A first circular knitted layer that defines at least a part of an outer surface; and A second circular knitted layer coupled to the first circular knitted layer, the second circular knitted layer is configured to be disposed adjacent to the first circular knitted layer when folded into or around the first circular knitted layer At least a part of the first circular knitted layer. The article of footwear according to claim 3, wherein the second circular knitted layer extends from the first circular knitted layer as a whole. The article of footwear according to claim 3, wherein the first circular knitted layer comprises a substantially tubular shape. The article of footwear according to claim 3, wherein the second circular knitted layer comprises a substantially tubular shape. The article of footwear according to claim 3, wherein the second circular knitted layer includes a plane shape. Such as the article of footwear of claim 3, wherein the first circular knitted layer comprises waterproof and transparent Air material, and wherein the second circular knitted layer includes a comfortable lining. For example, the article of footwear according to claim 3, which further includes a lace system, the lace system is arranged adjacent to at least a part of the second circular knitted layer, so that the second circular knitted layer is folded to the first When in the circular knitted layer, at least a part of the lacing system is inserted between the second circular knitted layer and the first circular knitted layer. The article of footwear according to claim 9, wherein at least a part of the lace system is circumferentially arranged around the second circular knitted layer. The article of footwear according to claim 3, wherein the first circular knitted layer comprises a substantially tubular shape, and wherein the second circular knitted layer comprises a planar shape, wherein the planar second circular knitted layer is configured to It is used for leveling operation before being folded into or around the first circular knitted layer. Such as the article of footwear of claim 11, wherein the flattening operations include one or more of sewing, fusion, molding, or screen printing. The article of footwear according to claim 11, wherein the second circular knitted layer of the plane includes one or more welding strengthening zones. The article of footwear according to claim 11, wherein the first circular knitted layer includes a collar, and wherein the planar second circular knitted layer is configured to surround at least an outer surface of the first circular knitted layer Partly arranged circumferentially. The article of footwear according to claim 3, wherein the first circular knitted layer comprises a substantially tubular shape, and wherein the second circular knitted layer is configured to be folded adjacent to an outer surface of the first circular knitted layer It is provided that the outer surface is adjacent to one or more of an ankle portion or a midfoot portion of the first circular knitted layer. The article of footwear according to claim 15, wherein the first circular knitted layer includes one or more ventilation zones, and wherein the second circular knitted layer is configured to be folded on the first circular knitted layer Adjacent to at least a part of the ventilation areas. The article of footwear according to claim 15, wherein the second circular knitted layer includes one or more features configured to be adjacent to the first circular knitted layer, and wherein the one or more features include an aperture, Shoelace holes or a heel cup or a combination thereof. The article of footwear according to claim 15, wherein the second circular knitted layer includes one or more features of the warp configuration to be disposed adjacent to the first circular knitted layer, wherein the one or more features include the warp configuration to A through portion extending through a portion of the first circular knitted layer. The article of footwear according to claim 3, wherein the first circular knitted layer comprises a substantially tubular shape, and wherein the second circular knitted layer is configured to be folded adjacent to an outer surface of the first circular knitted layer Or set on an inner surface. For example, the article of footwear of claim 3, which further includes a functional layer, and when the second circular knitted layer is folded into or around the first circular knitted layer, the functional layer is inserted into the first circular knitted layer Between the knitted layer and the second circular knitted layer, the functional layer includes an insole, a midsole, an insulating part or a collar.

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