US20180317594A1 - Knitted component with a surface area formed with high-tenacity yarn - Google Patents

Knitted component with a surface area formed with high-tenacity yarn Download PDF

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Publication number
US20180317594A1
US20180317594A1 US15/970,049 US201815970049A US2018317594A1 US 20180317594 A1 US20180317594 A1 US 20180317594A1 US 201815970049 A US201815970049 A US 201815970049A US 2018317594 A1 US2018317594 A1 US 2018317594A1
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United States
Prior art keywords
yarn
exposed
knitted component
surface area
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US15/970,049
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English (en)
Inventor
Ashleigh S. Brinkman
Erin C. Stevens
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Nike Inc
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Nike Inc
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Publication date
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Priority to US15/970,049 priority Critical patent/US20180317594A1/en
Publication of US20180317594A1 publication Critical patent/US20180317594A1/en
Assigned to NIKE, INC. reassignment NIKE, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BRINKMAN, ASHLEIGH S., Stevens, Erin C., BARTYS, SAMUEL L.
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/10—Patterned fabrics or articles
    • D04B1/12—Patterned fabrics or articles characterised by thread material
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B1/00—Footwear characterised by the material
    • A43B1/02—Footwear characterised by the material made of fibres or fabrics made therefrom
    • A43B1/04—Footwear characterised by the material made of fibres or fabrics made therefrom braided, knotted, knitted or crocheted
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02—Uppers; Boot legs
    • A43B23/0205—Uppers; Boot legs characterised by the material
    • A43B23/0215—Plastics or artificial leather
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02—Uppers; Boot legs
    • A43B23/0245—Uppers; Boot legs characterised by the constructive form
    • A43B23/0255—Uppers; Boot legs characterised by the constructive form assembled by gluing or thermo bonding
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/011—Dissimilar front and back faces
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/011—Dissimilar front and back faces
    • D10B2403/0114—Dissimilar front and back faces with one or more yarns appearing predominantly on one face, e.g. plated or paralleled yarns
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/03—Shape features
    • D10B2403/032—Flat fabric of variable width, e.g. including one or more fashioned panels
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2501/00—Wearing apparel
    • D10B2501/04—Outerwear; Protective garments
    • D10B2501/043—Footwear

Definitions

  • a variety of articles are formed from textiles.
  • articles of apparel e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear
  • containers e.g., backpacks, bags
  • upholstery for furniture e.g., chairs, couches, car seats
  • textiles are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines.
  • One particular object that may be formed from a textile is an upper for an article of footwear.
  • Conventional articles of footwear generally include two primary elements: an upper and a sole structure.
  • the upper is secured to the sole structure and forms a void within the article of footwear for comfortably and securely receiving a foot.
  • the sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground.
  • the sole structure may include a midsole and an outsole.
  • the midsole may be formed from a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities.
  • the outsole may be secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material.
  • the upper of the article of footwear generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel area of the footwear.
  • a lacing system is often incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the void within the upper.
  • the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.
  • One general aspect of the present disclosure includes a knitted component with a first surface and a second surface, the first surface facing opposite the second surface, the first surface including at least a first yarn and the second surface including at least a second yarn.
  • the first and second yarns may be different.
  • the first surface and the second surface may be secured via a knit structure of the knitted component, where the first surface includes an exposed first surface area, where at least 65% of the exposed first surface area is formed of the first yarn, and where the first yarn has a tenacity of at least 5 grams per denier (g/d).
  • Another general aspect of the present disclosure includes a method including the steps of knitting a first layer of a knitted component and knitting a second layer of the knitted component.
  • the first layer may have a first surface and the second layer may have a second surface, the first surface facing opposite the second surface.
  • the first layer may include at least a first yarn and the second layer may include at least a second yarn, the first and second yarns being different.
  • the first layer and the second layer may be secured via a knit structure of the knitted component, where the first surface includes an exposed first surface area, where at least 65% of the exposed first surface area is formed of the first yarn, and where the first yarn has a tenacity of at least 5 grams per denier (g/d).
  • FIG. 1 is an illustration showing an article of footwear formed with an upper, the upper including a knitted component in accordance with an embodiment of the present disclosure.
  • FIG. 2 is an illustration showing the knitted component for the upper depicted in FIG. 1 as it may appear after formation on a knitting machine.
  • an article is an article of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear, or the like).
  • the article may be an upper configured for use in an article of footwear.
  • the upper may be used in connection with any type of footwear.
  • Illustrative, non-limiting examples of articles of footwear include a basketball shoe, a biking shoe, a cross-training shoe, a global football (soccer) shoe, an American football shoe, a bowling shoe, a golf shoe, a hiking shoe, a ski or snowboarding boot, a tennis shoe, a running shoe, and a walking shoe.
  • the upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal.
  • FIG. 1 is an illustration showing an article of footwear 100 formed with an upper 102 , where the upper 102 is substantially formed as a textile component, such as a knitted component 106 .
  • the upper 102 may be secured to at least one sole structure 104 .
  • the upper 102 may include a lateral side 108 and a medial side 110 .
  • the area where the sole structure 104 joins the upper 102 may be referred to as a biteline 112 .
  • the upper 102 may be joined to the sole structure 104 in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, etc.
  • the upper 102 may extend partially or completely around a foot of a wearer and/or may be integral with the sole structure 104 , and a sockliner may or may not be used.
  • the sole structure 104 may include a midsole (not shown) and an outsole.
  • the upper 102 may additionally include a throat area 114 extending from and an ankle opening 116 leading to a void 118 , and a collar 120 may at least partially surround the ankle opening 116 .
  • the void 118 of the article of footwear 100 may be configured (e.g., sized and shaped) to receive and accommodate a foot of a person.
  • the throat area 114 may be generally disposed in a midfoot area 122 of the upper 102 .
  • the midfoot area 122 of the upper 102 may be located between a heel area 124 and a toe area 126 .
  • an optional tongue such as the depicted tongue 128 may be disposed in the throat area 114 .
  • the tongue 128 may be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included (or in combination with a tongue), the lateral and medial sides of the throat area 114 may be joined together.
  • the article of footwear 100 may include a fastening element, such as a shoelace 130 . Any other suitable type of fastening element may be used, a strap, a cable-tensioning system, and/or any other suitable device.
  • the upper 102 may be configured to secure to and communicate with the fastening element such that the fastening element may adjust and/or tighten the upper 102 around a foot of a wearer.
  • the upper 102 may include a set of apertures for receiving the fastening element, but other suitable element(s) may alternatively be used.
  • At least a portion of the upper 102 , and potentially substantially the entirety of the upper 102 may be formed of the knitted component 106 (or another suitable textile component). Forming the upper 102 with the knitted component 106 may provide the upper 102 with advantageous characteristics including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof.
  • a particular degree of elasticity for example, as expressed in terms of Young's modulus
  • a particular single layer or multi-layer knit structure e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure
  • a particular material e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex
  • yarns of a particular size e.g., denier
  • the knitted component 106 may also provide desirable aesthetic characteristics by incorporating yarns having different colors, textures or other visual properties arranged in a particular pattern.
  • the yarns themselves and/or the knit structure formed by one or more of the yarns of the knitted component 106 may be varied at different locations such that the knitted component 106 has two or more portions with different properties (e.g., a portion forming the throat area 114 of the upper 102 may be relatively elastic while another portion may be relatively inelastic).
  • the knitted component 106 may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light).
  • the knitted component 106 may include yarns formed of a thermoplastic polymer material (e.g., a polyurethane, polyamide, polyolefin, and/or nylon) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to the solid state when cooled.
  • the thermoplastic polymer material may provide the ability to heat and then cool a portion of the knitted component 106 to thereby form an area of bonded or continuous material (herein referred to as a “fused area”) that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example.
  • FIG. 2 is an illustration showing the knitted component for the upper 102 as it may appear after formation on a knitting machine.
  • the knitted component 106 may be formed as a continuous and integral one-piece element during a knitting process, such as a weft knitting process (e.g., with a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine may substantially form the knit structure of the knitted component 106 without the need for significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component 106 may be formed separately as distinct integral one-piece elements and then the respective elements attached. After the knitting process, the upper 102 may go through one or more post-processing steps.
  • the upper 102 may be attached to other elements of the article of footwear (e.g., the sole structure 104 of FIG. 1 ), may be placed over a foot-shaped last, and/or may be steamed or otherwise treated to be formed into its wearable shape.
  • the knitted component 106 may be formed of one or more types of yarn.
  • a “yarn” shall mean an elongated, continuous length of at least one fiber or strand suitable for use in the production of textiles by hand or by machine, including (but not limited to) textiles made using weaving, knitting, crocheting, braiding, sewing, embroidery, or ropemaking techniques. Thread is a type of yarn commonly used for sewing, for example. While yarns can be made using fibers formed of natural, regenerated, and synthetic materials, the manufacturing articles of footwear and performance athletic apparel may utilizes yarns formed from synthetic polymer fibers, as synthetic polymers fibers typically provide the durability and consistency required for these products and for producing them in high volume.
  • Synthetic polymer fibers are generally formed in continuous strands using techniques such as melt extrusion, reaction spinning, solution dry spinning, and solution wet spinning.
  • the thickness and other cross-sectional characteristics of the synthetic polymer fibers can affect the properties of the fibers and yarns incorporating them.
  • the properties of synthetic polymer fibers (and yarns incorporating them) can also be affected by processes such as drawing (i.e., stretching) the fibers, annealing (i.e., hardening) the fibers, and/or crimping the fibers.
  • the color of the synthetic polymer fibers can be altered by adding pigments or dyes to the polymeric material, for example, before or during fiber formation, or by dyeing the fibers before or after forming them into a yarn.
  • Three basic forms of synthetic polymer fibers are typically used to make yarn: relatively long and continuous filaments; tow, which are formed of many continuous filaments loosely joined side by side; and staple (cut) fibers.
  • the length of synthetic polymer staple fibers typically used to form spun synthetic yarns ranges from about 0.5 inches to about 18 inches in length.
  • a wide variety of synthetic polymers can be used to form fibers.
  • Commodity polymers commonly used to make fibers include polyesters, such as polyethylene terephthalate (PET); polyamides, such as nylon 6,6, nylon 6, and nylon 12; and polyolefins such as polyethylene and polypropylene.
  • PET polyethylene terephthalate
  • Polyamides such as nylon 6,6, nylon 6, and nylon 12
  • polyolefins such as polyethylene and polypropylene.
  • Polyacrylonitrile copolymers are used to make acrylic fibers.
  • Other copolymer such as polyester copolymers and polyamide copolymers can also be used to form synthetic polymer fibers.
  • Elastane, a polyester-polyurethane copolymer is one such example.
  • Polyurethane including thermoplastic polyurethane (TPU)
  • TPU thermoplastic polyurethane
  • High performance synthetic polymer fibers can be made from polymeric materials including aramid and ultra-high molecular weight polyethylene (UHMWPE).
  • the material used to form the fibers can include pigments or dyes, fillers, processing aids, and the like.
  • Types of yarn which can be formed using synthetic polymer fibers include filament yarns (including monofilament yarns) and spun yarns.
  • Synthetic polymer filament yarns are formed of continuous elongated filaments which can be twisted or grouped together.
  • Monofilament yarns are formed of a single elongated, continuous filament of a synthetic polymer material.
  • Spun yarns are made by twisting staple fibers together to make a cohesive strand.
  • the process of forming a yarn from staple fibers typically includes carding and drawing the fibers to form sliver, drawing out and twisting the sliver to form roving, and spinning the roving to form a strand. Multiple strands can be plied (twisted together) to make the spun yarn thicker.
  • Synthetic polymer spun yarns can be formed using a single type of fiber, such as a single type of synthetic polymer fiber, by using a blend of more than one type of synthetic polymer fiber, as well as by using blends of one or more type of synthetic polymer fibers with natural and/or regenerated fibers.
  • synthetic polymer continuous filament yarns can be formed from continuous filaments of a single type of synthetic polymer, can be formed from continuous filaments formed from more than one type of synthetic polymer, or can be formed from a combination of continuous fibers formed from a regenerated material with synthetic polymer continuous filaments formed of one or more types of synthetic polymers.
  • the linear mass density or weight per unit length of a yarn can be expressed using various units, including denier (D) and tex. Denier is the mass in grams per 9000 meters. The linear mass density of a single filament of a fiber can also be expressed using denier per filament (DPF). Tex is the mass in grams per 1000 meters; decitex (dtex) is the mass in grams per 10,000 meters.
  • tenacity is understood to refer to the amount of force (expressed in units of weight, for example: pounds, grams, centinewtons or other units) needed to rupture a yarn (i.e., the breaking force or breaking point of the yarn), divided by the linear mass density of the yarn expressed, for example, in (unstrained) denier, decitex, or some other measure of weight per unit length.
  • the amount of force needed to break a yarn may be determined by subjecting a sample of the yarn to a known amount of force by stretching the sample until it breaks, for example, by inserting each end of a sample of the yarn into the grips on the measuring arms of an extensometer, subjecting the sample to a stretching force, and measuring the force required to break the sample using a strain gauge load cell.
  • Suitable testing systems can be obtained from Instron (Norwood, Mass., USA).
  • Yarn tenacity and yarn breaking force are distinct from burst strength or bursting strength of a textile, which is a measure of the maximum force that can be applied to the surface of a textile before the surface bursts.
  • the minimum tenacity required is approximately 1.5 grams per denier (g/D).
  • Most synthetic polymer continuous filament yarns formed from commodity polymeric materials generally have tenacities in the range of about 1.5 g/D to about 4 g/D.
  • polyester filament yarns that may be used in the manufacture of knit uppers for article of footwear have tenacities in the range of about 2.5 g/D to about 4 g/D.
  • Filament yarns formed from commodity synthetic polymeric materials which are considered to have high tenacities generally have tenacities in the range of about 5 g/D to about 10 g/D.
  • filament yarns formed of aramid typically have tenacities of about 20 g/D
  • filament yarns formed of ultra-high molecular weight polyethylene (UHMWPE) having tenacities greater than 30 g/D are available from Dyneema (Stanley, N.C., USA) and Spectra (Honeywell-Spectra, Colonial Heights, Va., USA).
  • yarns may include one or more elastomeric filaments to provide the yarn with a particular degree of elasticity.
  • Elastic filaments may include, for example, latex, spandex, or elastane (which are often referred to as Lycra).
  • a fiber of elastic material e.g., a fiber of spandex
  • the elastomeric filaments When incorporated into a yarn (which may additionally include other materials, such as polyester), the elastomeric filaments may provide the yarn with elasticity such that the yarn has the ability to elongate (i.e., increase in length) without rupturing when subjected to a tensile force and then recover to its original length when relieved from the tensile force.
  • Some yarns may have substantially no, or very little, elasticity.
  • a monofilament yarn made of an inelastic synthetic polymer material may have maximum elongation of less than 5% (e.g., the maximum length of the yarn when subjected to a tensile force approaching its breaking force is less than 5% of its length when not subjected to a tensile force), and it is contemplated that a such a yarn could have a maximum elongation of 1%, 0.5%, or even less.
  • Other yarns, such as yarns formed of textured polyester may have a maximum elongation of between about 20% and about 40%.
  • a yarn incorporating spandex (with or without other materials), for example, may have a maximum elongation of 100%, 200%, 300%, or more.
  • the knitted component 106 may be a single layer knitted component or it may be a multi-layer knitted component.
  • An example of a multi-layer knitted and associated method of forming the multi-layer knitted component is fully described in U.S. patent application Ser. No. 15/443,808, filed Feb. 27, 2017, which is herein incorporated by reference in its entirety.
  • the knitted component 106 may be a two-layer knitted component with a first layer forming a first surface 134 (e.g., outer surface) and a second layer forming the second surface 136 (e.g., inner surface) as described in further detail below.
  • first and second layers may both be knitted layers, and they will be referred to herein as the “first layer” and the “second layer.” While more than (or less than) two layers could be included, this description generally describes the knitted component 106 as having two layers for simplicity of description. Further, it is contemplated that different portions of the knitted component 106 could have a different number of layers (e.g., a portion corresponding to the throat area 114 may have one layers, while a portion corresponding to the medial side 110 and the lateral side 108 may have more than one layer).
  • the first and second layers of the knitted component 106 may be separately formed or integrally formed, and one or both layers may be formed during a knitting or other textile manufacturing process.
  • the first layer defining the first (outer) surface 134 and the second layer forming the second (inner) surface 136 may be formed during a single knitting process (e.g., simultaneously on a knitting machine).
  • the first and second layers may be formed on a flat knitting machine with two needle beds. The first layer may be primarily formed on a front needle bed, and the second layer may be primarily formed on a back needle bed, or vice versa.
  • the first layer and the second layer may be integral and tightly bound together such that they are inseparable and/or are not readily distinguishable (visually or otherwise).
  • the knitted component 106 may have at least one location where the first layer and the second layer are separable and/or form a pocket therebetween, which may be filled with an insert or other filler material (e.g., a cushioning material). It is contemplated that the first layer and the second layer may be attached only at the edges of the knitted component 106 or the first and second layers may be attached at additional points by a tie stitch at any one or more points on the upper.
  • the knitted component 106 may have some areas where the layers are substantially bound or attached together (in an indistinguishable manner, or not) and other areas where they are substantially separable and/or distinguishable.
  • Separable first and second layers may be formed by a tubular knitting process where the yarns forming the first layer are knitted only on one bed of a knitting machine and the yarns of the second layer are knitted only on a second bed of the knitting machine.
  • the knitted component 106 may be formed of two or more layers that are knitted or otherwise formed separately and then joined together by, for example, a sewing or stitching process, by using an adhesive, or by another suitable bonding/attachment technique.
  • the first layer defining the first surface 134 of the knitted component 106 may be primarily formed by a first yarn 138 such that the exposed surface area 142 of the first surface 134 is primarily formed by the material defining the first yarn 138 .
  • the first layer of the knitted component 106 may be fully or substantially fully formed substantially of the first yarn 138 , at least in certain areas or zones.
  • the second layer defining the second surface 136 of the knitted component 106 may be primarily formed by a second yarn 140 such that the exposed surface area of the second surface 136 is primarily formed by the material defining the second yarn 140 .
  • the second layer of the knitted component 106 may be fully formed or substantially fully formed of the second yarn 140 , at least in certain areas or zones. It is noted that, for simplicity, only two yarns (representing two yarn types) are described, but more than two yarn types may be included, and the features described herein may apply to more than two yarn types.
  • the second yarn 140 may be incorporated into the first layer and the first yarn may be incorporated into the second layer at least at some locations, and the proportion (i.e., percentage of exposure on a surface area) of each yarn type exposed on each surface may vary.
  • the exposure of each yarn may be specifically selected to provide the surfaces with certain surface characteristics.
  • the amount of the first yarn 138 incorporated into the first layer relative to other yarn types may be optimized such that a desirable amount of material forming the first yarn 138 is exposed on the first surface.
  • a particular surface area it may be desirable for at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or even more of the material that is exposed on the first surface 134 at an exposed surface area 142 to be the material provided by the first yarn.
  • a particular surface area on the second surface 136 it may be desirable for at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or even more of the material that is exposed on the second surface 136 to be the material provided by the second yarn.
  • the two layers may optionally have an inverse composition of material types (but this is not required).
  • the exposed surface area of the first surface 134 may have a composition of about 70% of the material provided by the first yarn and about 30% of the material provided by the second yarn, while the exposed surface area of the second surface 136 may have an opposite composition (e.g., 70% of material provided by the second yarn and 30% of material provided by the second yarn).
  • an exposed portion of a surface is about 70% (or more) formed by a high tenacity yarn (e.g., a polyethylene terephthalate filament yarn from National Spinning (Washington, N.C., USA) with a tenacity of about 6 g/D, and/or a polyethylene terephthalate filament yarn from Far Eastern New Century (Taipei, Taiwan) with a tenacity of about 7 g/D), and 30% (or less) formed of another yarn (e.g., a synthetic polymer continuous filament yarn formed having a tenacity in the range of about 1.5 g/D to about 4 g/D), that exposed portion of the surface has a desirable grip (e.g., friction coefficient) for use in shoe configured for rope climbing in at least one direction (e.g., in a vertical direction with respect to the shoe) and also had desirable anti-abrasiveness and durability.
  • a desirable grip e.g., friction coefficient
  • the first surface 134 of the knitted component 106 may be primarily formed by the first yarn 138 (at least at one area), and the first yarn 138 may be a high tenacity yarn. That is, the first yarn 138 may have a tenacity of at least 5 grams per denier (g/D), and in some embodiments the first yarn 138 may have a tenacity of about 6 grams per denier (g/D) or higher, about 7 grams per denier (g/D) or higher, about 10 grams per denier (g/D) or higher, or even about 20 grams per denier (g/D) or higher.
  • the portion of the exposed surface area 142 of the first surface 134 may be at least 1 square centimeter in area, such as at least 4 square centimeters in area, at least 9 square centimeters in area, etc.
  • the second surface 136 may be formed of the above-described second yarn, which may have a tenacity less than 4 grams per denier (g/D).
  • the second yarn 140 may be a polyester yarn having suitable softness, anti-abrasiveness, flexibility, compressibility, and/or other characteristics that are associated with comfortable contact with a foot and/or sock of a wearer.
  • the knitted component 106 may include a first zone 150 and a second zone 152 , where at least one surface has a different composition of exposed yarns in the first zone 150 with respect to the second zone 152 .
  • the exposed surface area 142 may be located in the first zone 150
  • the second zone may have an exposed second surface area 154 .
  • less than 65% of the exposed second surface area 154 may be formed of the first yarn.
  • at least 50% of the exposed first surface area may be formed of the second yarn 140 .
  • This non-limiting embodiment may provide the ability to use a different knit structure (e.g., a single-layer knit structure) that has suitable elasticity, comfort-related characteristics, and/or other characteristics that are desirable in certain areas of the upper (such as the throat area).
US15/970,049 2017-05-05 2018-05-03 Knitted component with a surface area formed with high-tenacity yarn Abandoned US20180317594A1 (en)

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US201762502291P 2017-05-05 2017-05-05
US15/970,049 US20180317594A1 (en) 2017-05-05 2018-05-03 Knitted component with a surface area formed with high-tenacity yarn

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EP (1) EP3619349A1 (zh)
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US20190343208A1 (en) * 2018-05-08 2019-11-14 Siu Sing CHING Baseball cap with knitted and air permeable seamless crown formed as a one whole piece
US20200100563A1 (en) * 2018-09-28 2020-04-02 Puma SE Article of footwear having an upper assembly
USD885719S1 (en) 2018-08-29 2020-06-02 Puma SE Shoe
USD891738S1 (en) 2018-08-29 2020-08-04 Puma SE Shoe
USD891739S1 (en) 2018-08-29 2020-08-04 Puma SE Shoe
USD913647S1 (en) 2018-08-29 2021-03-23 Puma SE Shoe
US11013292B2 (en) 2018-09-28 2021-05-25 Puma SE Article of footwear having a sole structure
WO2021142251A1 (en) * 2020-01-08 2021-07-15 Nike Innovate C.V. Upper for an article of footwear having two yarn types
US20210395925A1 (en) * 2018-11-19 2021-12-23 Kondo Cotton Spinning Co., Ltd. Knit fabric production method, fabric production method, and sewn product production method
US20220330656A1 (en) * 2021-04-15 2022-10-20 Puma SE Article of footwear having a shoe upper assembly
US11659892B2 (en) * 2018-08-08 2023-05-30 Nike, Inc. Lightweight knitted upper and methods of manufacture

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US20190343208A1 (en) * 2018-05-08 2019-11-14 Siu Sing CHING Baseball cap with knitted and air permeable seamless crown formed as a one whole piece
US11659892B2 (en) * 2018-08-08 2023-05-30 Nike, Inc. Lightweight knitted upper and methods of manufacture
USD891739S1 (en) 2018-08-29 2020-08-04 Puma SE Shoe
USD891738S1 (en) 2018-08-29 2020-08-04 Puma SE Shoe
USD885719S1 (en) 2018-08-29 2020-06-02 Puma SE Shoe
USD913647S1 (en) 2018-08-29 2021-03-23 Puma SE Shoe
US20200100563A1 (en) * 2018-09-28 2020-04-02 Puma SE Article of footwear having an upper assembly
US11013292B2 (en) 2018-09-28 2021-05-25 Puma SE Article of footwear having a sole structure
US11925234B2 (en) * 2018-09-28 2024-03-12 Puma SE Article of footwear having an upper assembly
US20210395925A1 (en) * 2018-11-19 2021-12-23 Kondo Cotton Spinning Co., Ltd. Knit fabric production method, fabric production method, and sewn product production method
US11959198B2 (en) * 2018-11-19 2024-04-16 Kondo Cotton Spinning Co., Ltd. Knit fabric production method, fabric production method, and sewn product production method
WO2021142251A1 (en) * 2020-01-08 2021-07-15 Nike Innovate C.V. Upper for an article of footwear having two yarn types
CN114929054A (zh) * 2020-01-08 2022-08-19 耐克创新有限合伙公司 具有两种纱线类型的用于鞋类制品的鞋面
US11572642B2 (en) 2020-01-08 2023-02-07 Nike, Inc. Upper for an article of footwear having two yarn types
US11846048B2 (en) 2020-01-08 2023-12-19 Nike, Inc. Upper for an article of footwear having two yarn types
US20220330656A1 (en) * 2021-04-15 2022-10-20 Puma SE Article of footwear having a shoe upper assembly

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CN110998000A (zh) 2020-04-10
EP3619349A1 (en) 2020-03-11
CN110998000B (zh) 2022-04-08

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