HK1190891B - Article of footwear having a knit upper with a polymer layer - Google Patents

Abstract

An article of footwear (10) has an upper (30) and a sole structure (20) secured to the upper. The upper includes a knitted component (40) and a polymer layer (50). The knitted component is formed of unitary knit construction and extends along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper. The polymer layer is bonded to the knitted component and may form a majority of an exterior surface of the upper. The polymer layer may be formed from a thermoplastic polymer material. The knitted component (40) includes various tubes (42) in which strands (43) are located.

Description

Article of footwear having a knitted upper with a polymer layer

Background

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 on the interior of the footwear for comfortably and securely receiving the footwear of the foot. The sole structure is secured to a lower surface of the upper to be positioned between the foot and the ground. In some articles of athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a ground reaction force attenuating polymer foam material to attenuate stresses on the foot and leg during walking, running, and other ambulatory activities. An outsole is secured to a lower surface of the midsole and forms the ground-contacting portion of the sole structure that is formed from a durable, wear-resistant material. The sole structure may also include a sockliner disposed within the void and adjacent a lower surface of the foot to enhance footwear comfort.

The upper 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. In some articles of footwear, such as basketball shoes and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. The entry to the void on the interior of the upper is generally provided by an ankle opening in the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby allowing the foot to be inserted into and removed from the void within the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly the circumference, to accommodate feet having different dimensions. In addition, 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.

The upper is typically constructed from a variety of materials. For example, the upper of athletic footwear may be formed from multiple material elements. The materials may be selected based on a variety of properties, including, for example, stretch resistance, abrasion resistance, flexibility, breathability, compressibility, and moisture absorption. With respect to the exterior of the upper, the toe area and the heel area may be formed of leather, synthetic leather, or a rubber material to impart a relatively high degree of wear-resistance. Leather, synthetic leather, and rubber materials may not exhibit the desired degree of flexibility and breathability for various other areas of the exterior. Thus, other areas of the outer portion may be formed of, for example, a synthetic textile. Accordingly, the exterior of the upper may be formed from multiple material elements that each impart different properties to the upper. The central or central layer of the upper may be formed from a lightweight polymer foam material that provides cushioning and enhances comfort. Similarly, the interior of the upper may be formed of a comfortable and absorbent fabric that removes perspiration in the area immediately surrounding the foot. Various material elements and other components may be joined with adhesives or stitching. Accordingly, a conventional upper is formed from multiple material elements that each impart different properties to different areas of the footwear.

SUMMARY

An article of footwear is disclosed below as having an upper and a sole structure secured to the upper. The upper includes a knitted component and a polymer layer. The knitted component is formed of unitary knit construction (unitaryknit construction) and extends along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper. The polymer layer is bonded to the knitted component and may form a majority of an exterior surface of the upper. The polymer layer may be formed from a thermoplastic polymer material.

A method of manufacturing an article of footwear is also disclosed. The method includes forming a knitted component having a first surface and an opposing second surface using a flat knitting process. The polymer layer is bonded to the first surface of the knitted component. In addition, the knitted component and the polymer layer are incorporated into an upper of the article of footwear.

The benefits and features of novelty characterizing aspects of the present invention are pointed out with particularity in the appended claims. To gain an improved understanding of these benefits and novel features, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various configurations and concepts related to the invention.

Drawings

The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings.

Fig. 1 is a perspective view of an article of footwear.

FIG. 2 is a lateral side elevational view of the article of footwear.

FIG. 3 is a medial side elevational view of the article of footwear.

Fig. 4 is a top plan view of the article of footwear.

Fig. 5A-5D are cross-sectional views of the article of footwear, as defined by section lines 5A-5D in fig. 2, respectively.

Fig. 6 is a top plan view of an upper component that forms a portion of an upper of an article of footwear.

Figure 7 is an exploded top plan view of the upper component.

Fig. 8A-8C are side views corresponding with fig. 2 and depicting additional configurations of the article of footwear.

Detailed description of the invention

The following discussion and accompanying figures disclose an article of footwear having an upper that includes a knitted component and a polymer layer. An article of footwear is disclosed having a general configuration suitable for walking or running. Concepts associated with footwear that includes an upper may also be utilized with a variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, soccer shoes, tennis shoes, soccer shoes, sprinting shoes, and hiking boots, for example. The concepts may also be applied to footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed herein may be used with a variety of footwear styles.

General footwear construction

In fig. 1-5D, article of footwear 10 is depicted as including a sole structure 20 and an upper 30. For reference purposes, footwear 10 may be divided into three general regions: forefoot region 11, midfoot region 12, and heel region 13. Forefoot region 11 generally includes portions of footwear 10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 12 generally includes portions of footwear 10 corresponding with an arch area of the foot. Heel region 13 generally corresponds with a rear portion of the foot that includes the calcaneus bone. Footwear 10 also includes a lateral side 14 and a medial side 15 that extend through each of regions 11-13 and correspond with opposite sides of footwear 10. More specifically, lateral side 14 corresponds with an exterior region of the foot (i.e., a surface that faces away from the other foot), and medial side 15 corresponds with an interior region of the foot (i.e., a surface that faces toward the other foot). Regions 11-13 and sides 14-15 are not intended to demarcate precise areas of footwear 10. Rather, regions 11-13 and sides 14-15 are intended to represent general areas of footwear 10 to aid in the following discussion. In addition to footwear 10, regions 11-13 and sides 14-15 may also be utilized in sole structure 20, upper 30, and individual elements thereof.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when footwear 10 is worn. The primary elements of sole structure 20 are a midsole 21, an outsole 22, and a sockliner 23. Midsole 21 is secured to a lower surface of upper 30 and may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In still other configurations, midsole 21 may incorporate a fluid-filled bladder that supplements ground reaction force attenuation properties, or midsole 21 may be primarily formed from a fluid-filled bladder. Outsole 22 is secured to a lower surface of midsole 21 and may be formed of a wear-resistant rubber material that is textured to impart traction. Sockliner 23 is positioned within upper 30 and is positioned to extend under a lower surface of the foot. Although this configuration for sole structure 20 provides an example of a sole structure that may be used with upper 30, a variety of other conventional or non-conventional configurations for sole structure 20 may also be utilized. Accordingly, the structure and features of sole structure 20, or any sole structure used with upper 30, may vary significantly.

Upper 30 defines a void within footwear 10 for receiving and securing a foot relative to sole structure 20. The cavity is shaped to receive the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Access to the void is provided by an ankle opening 31 positioned in at least heel region 13. A lace 32 extends through portions of upper 30, as described in greater detail below, and allows the wearer to modify dimensions of upper 30 to accommodate feet of different proportions. More specifically, lace 32 allows the wearer to tighten upper 30 around the foot, and lace 32 allows the wearer to loosen upper 30 to facilitate entry and removal of the foot from the void (i.e., through ankle opening 31). In addition, upper 30 includes a tongue 33 that extends under lace 33.

A majority of upper 30 is formed from knitted component 40 and polymer layer 50. For example, knitted component 40 may be manufactured by a flat knitting process and extend through each of regions 11-13, along both lateral side 14 and medial side 15, over forefoot region 11, and around heel region 13. In addition, knitted component 40 forms an interior surface of upper 30. As such, knitted component 40 defines at least a portion of the void within upper 30. Knitted component 40 may also extend under the foot in some configurations. For purposes of example in the various figures, however, strobel sock 34 is secured to knitted component 40 and forms a majority of the portion of upper 30 that extends under the foot. In this configuration, insole 23 extends over strobel sock 34 and forms a surface on which the foot rests.

Polymer layer 50 forms an exterior surface of upper 30 and is secured to an exterior area of knitted component 40. In general, polymer layer 50 is placed adjacent knitted component 40 and secured to knitted component 40 to form an exterior surface of upper 30. As with knitted component 40, polymer layer 50 extends through each of regions 11-13, along both lateral side 14 and medial side 15, over forefoot region 11, and around heel region 13. Although polymer layer 50 may extend into footwear 10 and over other areas of knitted component 40, polymer layer 50 is depicted as being primarily positioned to form an exterior surface of upper 30. Although polymer layer 50 is depicted as forming a majority of the exterior surface of upper 30, polymer layer 50 may not be present in other areas to expose portions of knitted component 40.

The combination of knitted component 40 and polymer layer 50 provides various benefits to footwear 10. By way of example, the combination of knitted component 40 and polymer layer 50 imparts a relatively tight and glove-like fit to upper 30. When formed as a soccer shoe, for example, a relatively tight and glove-like fit may provide the wearer with enhanced feel and control of the ball. Polymer layer 50 may also be utilized to reinforce areas of upper 30. For example, polymer layer 50 may limit stretch in knitted component 40 and may enhance the wear or abrasion resistance of upper 30. Polymer layer 50 may also impart abrasion resistance to footwear 10. In addition, forming footwear 10 in this configuration may provide uniform fit and compliance to the foot, a seamless interior with enhanced comfort to the wearer, relatively light weight, and support to the foot without an overlay (overlay).

Knitted component configuration

Knitted component 40 incorporates various knitting types that impart different properties to different areas of upper 30. As an example depicted in fig. 1, 4, and 5A, knitted component 40 forms a plurality of apertures 41 in forefoot region 11 that extend through upper 30, while many other areas of upper 30 have a more continuous or less-apertured configuration. In addition to imparting greater permeability that allows air to circulate within upper 30, apertures 41 may enhance both the flexibility and stretchability of upper 30 in forefoot region 11. To facilitate many of these benefits, the polymer layer 50 may also have holes corresponding to the locations where holes 41 are present. As additional examples, other properties that may be altered by selecting a particular knit type for a particular area of knitted component 40 include permeability to liquids, directionality of stretch or stretch resistance in knitted component 40, rigidity of knitted component 40, and compressibility of knitted component 40. Additional examples of knitted components for footwear uppers having areas with different knit types to impart different properties may be found in U.S. patent No. 6,931,762 to Dua and U.S. patent No. 7,347,011 to Dua et al, both of which are incorporated herein by reference in their entirety. As a related matter, for example, the knit density within knitted component 40 may vary among different areas of upper 30 to create a less permeable or stiffer portion. Accordingly, knitted component 40 may exhibit different properties in different zones depending on the particular type of knitting selected for the zone.

Knitted component 40 may also incorporate various yarn types that impart different properties to different areas of upper 30. Moreover, knitted component 40 may impart a variety of different properties to different areas of upper 30 by combining various yarn types and various stitch types. The properties that a particular type of yarn will impart to a region of knitted component 40 depend in part on the materials that form the various filaments and fibers within the yarn. For example, cotton provides a soft hand, a natural aesthetic, and biodegradability. The elastic polyester and the stretched polyester each provide substantial stretch and recovery, while the stretched polyester also provides recyclability. Rayon provides high gloss and moisture absorption. Wool provides high moisture absorption in addition to thermal insulation. Nylon is a durable and wear-resistant material with high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects associated with the yarns may affect properties of upper 30. For example, the yarns may be monofilament or multifilament yarns. The yarn may also include different filaments each formed of a different material. The yarn may also include filaments each formed of two or more different materials, such as bicomponent yarns having filaments with a sheath-core configuration or two halves formed of different materials. Different twists and turns, as well as different deniers, may affect the properties of upper 30 in which the yarns are located. Accordingly, both the materials forming the yarns and other aspects of the yarns may be selected to impart various properties to different areas of upper 30.

Knitted component 40 may incorporate a variety of knit structures in addition to knit types and yarn types. Referring to fig. 2 and 3, for example, knitted component 40 includes various tubes 42 in which threads 43 are located. Tube 42 is generally a hollow structure formed from two overlapping and at least partially coextensive layers of knitted material, as depicted in fig. 5B and 5C. While the sides or edges of one layer of knitted material forming tube 42 may be secured to the other layer, the central region is generally not secured so that other elements (e.g., thread 43) may be positioned between the two layers of knitted material and through tube 42. Other examples of knitted components for footwear uppers having overlapping or at least partially coextensive layers may be found in U.S. patent application publication No. 2008/0110048 to Dua et al, which is incorporated herein by reference.

Tube 42 extends upwardly along lateral side 14 and medial side 15. Each tube 42 is adjacent to at least one other tube 42 to form a tube pair. Generally, one of the wires 43 passes through a first tube 42 of the tube pair, extends outwardly from an upper end of the first tube 42, forms a loop 44, extends into an upper end of a second tube 42 of the tube pair, and passes through the second tube 42. That is, each thread 43 passes through at least two tubes 42, and the exposed portions of the threads 43 form loops 44. Note that loop 44 is positioned between knitted component 40 and polymer layer 50, as depicted in fig. 5B. In this configuration, the polymer layer 50 effectively secures the position of the loop 44 around the aperture 41 through which the lace 32 passes. That is, loop 44 extends around lace aperture 41 in knitted component 40, polymer layer 50 secures the position of loop 44 around lace aperture 41, and lace 32 may be threaded through both loop 44 and lace aperture 41 to form a lace system in footwear 10.

A single wire 43 may be threaded through only two adjacent tubes 42 (i.e., a single pair of tubes) such that the wire 43 forms a single loop 44. In this configuration, for example, the terminal portion in the line 43 exits the lower ends of two adjacent tubes 42 and may be secured to the sole structure 20 under the strobel sock 34 to prevent the terminal portion from being pulled through one of the tubes 42. The presence of the polymer layer 50 may also be used to fix the position of the end portion. In further configurations, a single wire 43 may pass through each of the tubes 42, passing through multiple tube pairs and forming multiple loops 44. In other configurations, one thread 43 may pass through each tube 42 positioned on lateral side 14 and another thread 43 may pass through each tube 42 positioned on medial side 15. Thus, in general, a single wire 43 is threaded through at least one tube pair to form at least one loop 44, but may be threaded through multiple tube pairs to form multiple loops 44.

Referring to fig. 1-4, lace 32 extends through each of loops 44 and also through various apertures 41, apertures 41 being formed in knitted component 40 adjacent each loop 44. As discussed above, loops 44 are positioned between knitted component 40 and polymer layer 50, and polymer layer 50 effectively secures the position of loops 44 around apertures 41 through which lace 32 passes. The combination of lace 32, apertures 41 through which lace 32 extends, various tubes 42, strands 43, and loops 44 on both medial side 14 and lateral side 15 provide an efficient lacing system for upper 30. Tension may also be created in strands 43 when lace 32 is in tension (i.e., when the wearer ties lace 32). In the absence of thread 43, other portions of knitted component 40 may be subjected to tension and stresses resulting from tying lace 32. However, the presence of the wire 43 provides a separate element that is subject to tension and stress. Moreover, a majority of knitted component 40 may generally be stretch-formed when under tension by selecting a knit type and a yarn type to allow upper 30 to conform with the contours of the foot. In contrast with upper 30, however, strands 43 may generally be non-stretchable.

For example, the thread 43 may be formed from a variety of materials and may have the configuration of a rope, cord, webbing, cable, yarn, filament, or chain. In some configurations, threads 43 are positioned within tubes 42 during the knitting process that forms knitted component 40. Likewise, threads 43 may be formed from any generally one-dimensional material that may be utilized in a knitting machine or other device that forms knitted component 40. As used with respect to this disclosure, the term "one-dimensional material" or variations thereof is intended to generally include materials that exhibit an elongation that is significantly greater in length than in width and thickness. Thus, suitable materials for thread 43 include various filaments, fibers, and yarns formed from rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramid (e.g., para-aramid and meta-aramid fibers), ultra-high molecular weight polyethylene, and liquid crystal polymers. In addition to filaments and yarns, other one-dimensional materials may be utilized for the threads 43. While one-dimensional materials will typically have a cross-section in which the width and thickness are substantially equal (e.g., a circular or square cross-section), some one-dimensional materials may also have a width that is slightly greater than the thickness (e.g., a rectangular, oval, or other elongated cross-section). Despite having a larger width, a material may be considered one-dimensional if its length is significantly greater than the width and thickness of the material.

Another structure formed by knitted component 40 is a padded collar (collar) 45 that extends at least partially around ankle opening 31. Referring to fig. 1-3, collar 45 exhibits a greater thickness than many other portions of knitted component 40. In general, collar 45 is formed from two overlapping and at least partially coextensive layers of knit material (i.e., tube structures) and a plurality of floating yarns 46 extending between the layers, as depicted in fig. 5D. Although the sides or edges of one layer of knit material forming collar 45 may be secured to other layers of knit material, the central region is generally not secured. Likewise, the layer of knitted material effectively forms a tube or tubular structure similar to tube 42, and floats 46 may be positioned or placed between the two layers of knitted material to pass through the tube. That is, floating yarns 46 extend between layers of knitted material, generally parallel to the surface of the knitted material, and also penetrate and fill the interior volume between the layers. A majority of knitted component 40 is formed from yarns that are mechanically manipulated to form a knit structure, while floating yarns 46 are generally free or otherwise disposed within the interior volume between the layers of knitted material forming the exterior of collar 45.

Tube 42 includes a single thread 43 and collar 45 includes a plurality of floats 46 extending across the area between the layers of knit material. Accordingly, knitted component 40 may generally form a tube structure having one or more yarns within the tube structure. Moreover, floating yarns 46 may be formed from a variety of materials and may be positioned within collar 45 during the knitting process that forms knitted component 40. Likewise, floats 46 may be formed from any generally one-dimensional material that may be utilized in a knitting machine or other device that forms knitted component 40.

The presence of floating yarns 46 imparts a compressible aspect to collar 45, thereby enhancing comfort in the area of ankle opening 31 of footwear 10. Many conventional articles of footwear incorporate polymer foam elements or other compressible materials into the collar region. In contrast to conventional articles of footwear, collar 45 provides a compressible structure with floating yarns 46.

The combination of tubes 42 and strands 43 provide upper 30 with structural elements that are resistant to stretching, for example, in a lacing system. Similarly, the combination of collar 45 and floating yarns 46 provide upper 30 with structural elements that are, for example, compressed to impart greater comfort around ankle opening 31. While these knit structures provide different benefits to upper 30, these knit structures are similar in that each includes (a) a tube structure formed from two overlapping and at least partially coextensive layers of knit material formed of unitary knit construction and (b) at least one yarn, thread, or other one-dimensional material that is placed or otherwise positioned within the tube structure and extends through at least a portion of the length of the tube structure.

Transverse knitting process

Knitted component 40 may be manufactured using a flat knitting process. Flat knitting is a method for manufacturing periodically rotating knitted materials (i.e., materials are knitted from alternating sides). The two sides (also referred to as faces) of the material are conventionally designed as a front side (i.e., the side facing outward, toward the viewer) and an opposite side (i.e., the side facing inward, away from the viewer). Although flat knitting provides a suitable means for forming knitted component 40, other knitting processes may be utilized depending on the features incorporated into knitted component 40. Examples of other knitting processes that may be utilized include wide tube circular knitting (widettube circular knitting), narrow tube circular knitting jacquard (narrowtubeluknigunjacquard), single knit circular knitting jacquard (singerlektnicircuknigunqtuard), double knit circular knitting jacquard (doulbertnicircularknikinjacquard), knit rib fabric (warpknitrickricot), knit raschel (warpknitraschel), and double knit bar raschel (doubletendelebrandchell).

A benefit of utilizing a flat knitting process to manufacture knitted component 40 is that each of the features discussed above may be imparted to knitted component 40 by the flat knitting process. That is, the flat knitting process may form knitted component 40 to have, for example, (a) various knit types that impart different properties to different areas of upper 30, (b) various yarn types that impart different properties to different areas of upper 30, (c) a knitted component having the configuration of overlapping knit layers in tubes 42, (d) a material, such as yarn 43, that is placed in tubes 42, (e) a knitted component having the configuration of overlapping knit layers in collar 45, and (f) floating yarns between the layers of knit material in collar 45. Moreover, each of these features, as well as others, may be incorporated into knitted component 40 through a single flat knitting process. Likewise, a flat knitting process may be utilized to generally form upper 30 with various properties and structural features that may be advantageous for footwear 10.

Although one or more yarns may be mechanically manipulated by an individual to form knitted component 40 (i.e., knitted component 40 may be formed manually), a flat knitting machine may provide an efficient way to form a relatively large number of knitted components 40. The flat knitting machine may also be used to vary the dimensions of knitted component 40 to form upper 30 suitable for use with footwear having different sizes based on one or both of the length and width of the foot. In addition, flat knitting machines may be used to change the configuration of knitted component 40 to form upper 30 suitable for use with both a left foot and a right foot. Various aspects of knitted component 40 may also be varied to provide a customized fit for an individual. Thus, the use of a mechanical flat knitting machine may provide an efficient way of forming multiple knitted components 40 having different sizes and configurations.

Knitted component 40 incorporates various features and structures formed from unitary knit construction. In general, features and structures are formed from unitary knit construction when incorporated into knitted component 40 by a flat knitting process rather than other processes (e.g., sewing, bonding, molding) that occur after the flat knitting process. By way of example, portions of tube 42 and collar 45 are formed from overlapping and at least partially coextensive layers of knit material, and the sides or edges of one layer may be secured to the other layer. The two layers of knitted material are generally formed during the flat knitting process and do not involve a supplemental sewing, bonding or molding process. Thus, the overlapping layers are formed from unitary knit construction by a flat knitting process. As another example, the area of knitted component 40 formed by the type of knitting that defines aperture 41 is formed from unitary knit construction by a flat knitting process. As another example, floating yarns 46 are formed of unitary knit construction.

An additional benefit of utilizing a flat knitting process to form knitted component 40 is that three-dimensional aspects may be incorporated into upper 30. Upper 30 has a curved or otherwise three-dimensional structure that extends around and conforms to the shape of the foot. For example, the flat knitting process may form an area of knitted component 40 having a certain curvature to complement the shape of the foot. An example of a knitted component for a footwear upper having three-dimensional aspects may be found in U.S. patent application publication No. 2008/0110048 to Dua et al, which is incorporated herein by reference.

In fig. 6 and 7, knitted component 40 and polymer layer 50 are depicted separately from footwear 10. Whereas many textile material edges are cut to expose the ends of the yarns forming the textile material, knitted component 40 may be formed to have a finished configuration. That is, flat knitting or other knitting techniques may be used to form knitted component 40 such that ends of yarns within knitted component 40 are substantially absent from edges of knitted component 40. A benefit of the finish configuration formed by flat knitting is that the yarns forming the edges of knitted component 40 are less likely to unravel, which is an inherent problem with using weft knit materials. By forming the finished edge, the integrity of knitted component 40 is enhanced and less or no post-processing steps are required to prevent unraveling. In addition, loose yarns are less likely to detract from the aesthetic appearance of upper 30. In other words, the finished configuration of knitted component 40 may enhance the durability and aesthetic qualities of upper 20 while increasing manufacturing efficiencies.

Knitted component 40 provides one example of a configuration suitable for upper 30 of footwear 10. Depending on the intended use of the article of footwear, the desired properties of the article of footwear, and the advantageous structural properties of the article of footwear, a knitted component similar to knitted component 40 may be formed, for example, by flat knitting to have desired characteristics. That is, flat knitting may be used to (a) position a particular knitting type in a desired area of a knitted component, (b) position a particular yarn type in a desired area of a knitted component, (c) form overlapping knit layers similar to the tube 42 and the footwear field 45 in the desired area of the knitted component, (d) place lines or floats similar to the lines 43 and floats 46 between the knit layers, (e) form three-dimensional aspects in the knitted component, and (f) impart a finished edge. More specifically, any of the features discussed above may be mixed and matched within a knitted component to form specific properties or structural attributes for a footwear upper.

Polymer layer configuration

Polymer layer 50 is positioned adjacent knitted component 40 and secured to knitted component 40 to form an exterior surface of upper 30. Various structures may be used for the polymer layer 50 including, for example, polymer films, polymer meshes, polymer powders, and non-woven fabrics. With any of these configurations, a number of polymer materials may be used for the polymer layer 50, including polyurethane, polyester polyurethane, polyether polyurethane, and nylon. Although the polymer layer 50 may be formed from a thermoset polymer material, many configurations of the polymer layer 50 are formed from a thermoplastic polymer material (e.g., a thermoplastic polyurethane). Generally, thermoplastic polymer materials melt when heated and return to a solid state when cooled. More specifically, the thermoplastic polymer material transitions from a solid state to a softened state or a liquid state when subjected to sufficient heat, and then the thermoplastic polymer material transitions from the softened state or the liquid state to the solid state when sufficiently cooled. Likewise, the thermoplastic polymer material may be melted, molded, cooled, remelted, remolded, and recooled through a number of cycles. Thermoplastic polymer materials may also be welded or heat bonded to textile elements such as knitted component 40, as described in more detail below. Although many thermoplastic polymer materials may be used for polymer layer 50, the benefits of utilizing thermoplastic polyurethane relate to thermal bonding and colorability. Thermoplastic polyurethanes are relatively easy to bond with other elements as compared to various other thermoplastic polymer materials (e.g., polyolefins), as discussed in more detail below, and colorants can be added to the thermoplastic polyurethane by various conventional processes. As noted above, the polymer layer 50 may be formed of a non-woven fabric. An example of a non-woven fabric having thermoplastic polymer filaments that may be incorporated onto knitted component 40 is disclosed in U.S. patent application publication No. 2010/0199406 to Dua et al, which is incorporated herein by reference.

The thermoplastic polymer material forming polymer layer 50 may be used to secure polymer layer 50 to knitted component 40. As discussed above, thermoplastic polymer materials melt when heated and return to a solid state when cooled. Based on this property of the thermoplastic polymer material, a thermal bonding process may be used to form thermal bonds that join portions of polymer layer 50 to knitted component 40. As used herein, the term "thermal bonding" or variations thereof is defined to refer to a solidification technique between two elements in which a thermoplastic polymer material within at least one element softens or melts such that the materials of the elements are secured to one another upon cooling. Similarly, the term "thermal bond" or variations thereof is defined as a bond, joint, or structure that joins two elements through a process that involves the thermoplastic polymer material within at least one of the elements softening or melting such that the materials of the elements are secured to one another upon cooling. As an example, thermal bonding may involve (a) polymer layer 50 melting or softening such that the thermoplastic polymer material mixes with the material of knitted component 40 and is secured together upon cooling, and (b) polymer layer 50 melting or softening such that the thermoplastic polymer material extends into or penetrates into the structure of knitted component 40 (e.g., extends around or bonds with filaments or fibers in knitted component 40) to secure the elements together upon cooling. Furthermore, thermal bonding does not typically involve the use of stitching or adhesives, but involves directly bonding the elements to one another with heat. However, in some cases, stitching or adhesives may be used to supplement thermal bonding or attachment of the elements by thermal bonding. A needling process may also be used to join elements or supplement thermal bonding.

Manufacturing process

Upper 30 may be manufactured using a variety of methods. In general, knitted component 40 is manufactured by the knitting process discussed above. Polymer layer 50 is then secured (e.g., bonded or heat bonded) to knitted component 40. For example, knitted component 40 and polymer layer 50 can be placed between portions of a hot press that compresses and heats the element, thereby bonding them together. In some configurations, polymer layer 50 may be a sheet or film of polymeric material that is compressed and heated with knitted component 40. In other configurations, polymer layer 50 may be a non-woven textile element that is compressed and heated along with knitted component 40. The compression and heating can melt the non-woven textile element to form a polymer film on the exterior of knitted component 40, or portions of the non-woven textile element can remain fibrous to impart breathability or breathability. Details relating to non-woven textile elements may be found in U.S. patent application publication No. 2010/0199406 to Dua et al, which is incorporated herein by reference. In further configurations, polymer layer 50 may be a polymer powder that is compressed and heated with knitted component 40, and the compression and heating may melt the powder to form a polymer film on the exterior of knitted component 40. As another example, a polymer resin may be sprayed or otherwise applied to knitted component 40 to form polymer layer 50. Accordingly, various methods may be utilized to form the combination of knitted component 40 and polymer layer 50.

Additional configuration

The features of upper 30 discussed above that include knitted component 40 and polymer layer 50 provide one example of a suitable configuration for footwear 10. Various other configurations may also be utilized. As an example, fig. 8A depicts a configuration in which knitted component 40 lacks tubes 42 and threads 43. Although polymer layer 50 may extend through substantially all of knitted component 40 and is depicted as forming a majority of the exterior surface of upper 30, polymer layer 50 may not be present in other areas to expose portions of knitted component 40. For example, fig. 8B depicts a configuration in which polymer layer 50 is primarily positioned in midfoot region 12 and knitted component 40 in both regions 11 and 13 is exposed. In other configurations, the polymer layer 50 may be absent in other areas. As an example, fig. 8C depicts a configuration in which polymer layer 50 defines various apertures throughout the area of upper 30 where knitted component 40 is exposed. Various features of knitted component 40 may also vary. Other examples of variations for knitted component 40 may be found in U.S. patent application publication No. 2010/0154256 to Dua, which is incorporated herein by reference. Further, U.S. patent application No. 13/048,514, entitled "knitting of footwearincorporation and knitting component", filed on us patent and trademark office at 15/3/2011, discloses additional configurations that may be used for knitted component 40, which application is incorporated herein by reference.

Efficiency of manufacture

For example, the upper of conventional athletic footwear may be formed from multiple material elements that each impart different properties to various regions of the footwear. To manufacture a conventional upper, the material elements are cut to the desired shape and then joined together, typically with stitching or gluing. As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, stocking, cutting, and joining the material elements may also increase. As the number and type of material elements incorporated into the upper increases, waste generated by the cutting and stitching process also accumulates to a greater extent. Moreover, footwear with a greater number of materials, material elements, and other components may be more difficult to recycle than products formed with fewer elements and materials. Accordingly, by reducing the number of elements and materials utilized in the upper, waste may be reduced while increasing production efficiency and recyclability.

Whereas a conventional upper requires various manufacturing steps involving multiple material elements, upper 30 may be formed by a combination of: (a) a flat knitting process for knitted component 40 and (b) a bonding process for securing polymer layer 50. After the flat knitting and bonding process, a relatively small number of steps are required to incorporate knitted component 40 and polymer layer 50 into footwear 10. More specifically, strobel sock 34 is attached to an edge of knitted component 40, two edges in heel region 13 are connected, lace 32 is bonded, and substantially finished upper 30 is secured with sole structure 20. The use of knitted component 40 and polymer layer 50 may reduce the overall number of manufacturing steps as compared to conventional manufacturing processes. In addition, waste is reduced while increasing recyclability.

The present invention is disclosed above and in the accompanying drawings with reference to a variety of configurations. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the configurations described above without departing from the scope of the present invention, as defined by the appended claims.

Claims (22)

1. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component defining a tubular structure formed of unitary knit construction, the tubular structure including a first knit layer and a second knit layer that overlap and are joined along opposing edges to form an unsecured central region of the tubular structure;

a wire having a configuration of one-dimensional material, the wire extending through at least a portion of a length of the unsecured central region of the tube structure; and

a polymer layer bonded to the knitted component and forming a majority of an exterior surface of the upper;

wherein the polymer layer penetrates into and bonds to the first knitted layer of the tube structure and remains unsecured to the second knitted layer of the tube structure.

2. The article of footwear recited in claim 1, wherein the knitted component and the polymer layer extend along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper.

3. The article of footwear recited in claim 2, wherein the tube structure is positioned on the lateral side of the upper and oriented to extend upward from an area proximate the sole structure, and the strand extends outward from an end of the tube structure to form a loop that receives a lace.

4. The article of footwear recited in claim 3, wherein the loops are positioned between the knitted component and the polymer layer.

5. The article of footwear recited in claim 3, wherein the knitted component defines apertures located adjacent to the loops, and the lace extends through the apertures.

6. The article of footwear recited in claim 1, wherein the polymer layer is formed from a thermoplastic polymer material.

7. The article of footwear recited in claim 1, wherein the polymer layer is a non-woven textile formed from a thermoplastic polymer material.

8. The article of footwear recited in claim 1, wherein a first area of the knitted component has a first knitting type and a second area of the knitted component has a second knitting type, the first knitting type being different than the second knitting type.

9. The article of footwear recited in claim 1, wherein a first region of the knitted component has a first thread type and a second region of the knitted component has a second thread type, the first thread type being different than the second thread type.

10. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component formed of unitary knit construction and extending along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper, the knitted component including a tube structure including a first layer of knit and a second layer of knit that overlap and are joined along opposing edges to form an unsecured central region of the tube structure; and

at least one thread positioned on the lateral side and the medial side within the unsecured central area of the tube structure of the knitted component, the thread extending upwardly from an area proximate the sole structure and the thread extending outwardly from the knitted component to form a lateral loop on the lateral side and a medial loop on the medial side;

a lace extending through the lateral loop and the medial loop; and

a polymer layer bonded to the knitted component and forming a majority of an exterior surface of the upper;

wherein the polymer layer penetrates into and bonds to the first knitted layer of the tube structure and remains unsecured to the second knitted layer of the tube structure.

11. The article of footwear recited in claim 10, wherein the lateral ring and the medial ring are positioned between the polymer layer and the knitted component.

12. The article of footwear recited in claim 10, wherein the knitted component defines apertures located adjacent to the lateral side loops and the medial side loops, and the lace extends through the apertures.

13. The article of footwear recited in claim 10, wherein the polymer layer is formed from a thermoplastic polymer material.

14. The article of footwear recited in claim 10, wherein the polymer layer is a non-woven textile formed from a thermoplastic polymer material.

15. The article of footwear recited in claim 10, wherein a first area of the knitted component has a first knitting type and a second area of the knitted component has a second knitting type, the first knitting type being different than the second knitting type.

16. The article of footwear recited in claim 10, wherein a first area of the knitted component has a first thread type and a second area of the knitted component has a second thread type, the first thread type being different than the second thread type.

17. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component formed of unitary knit construction and extending along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper, the knitted component including a tube structure including a first layer of knit and a second layer of knit that overlap and are joined along opposing edges to form an unsecured central region of the tube structure; and

a polymer layer bonded to the knitted component and forming a majority of an exterior surface of the upper, the polymer layer being formed from a thermoplastic polymer material;

wherein the polymer layer penetrates into and bonds to the first knitted layer of the tube structure and remains unsecured to the second knitted layer of the tube structure.

18. The article of footwear recited in claim 17, wherein the knitted component and the polymer layer define a plurality of apertures, and a lace extends through the apertures.

19. The article of footwear recited in claim 17, wherein the polymer layer is a non-woven textile formed from a thermoplastic polymer material.

20. The article of footwear recited in claim 17, wherein a first area of the knitted component has a first knitting type and a second area of the knitted component has a second knitting type, the first knitting type being different than the second knitting type.

21. The article of footwear recited in claim 17, wherein a first region of the knitted component has a first thread type and a second region of the knitted component has a second thread type, the first thread type being different than the second thread type.

22. A method of manufacturing an article of footwear, the method comprising:

utilizing a flat knitting process to form a knitted component having a first surface and an opposing second surface, the knitted component including a tube structure, the tube structure including a first layer of knit and a second layer of knit, the first layer of knit and the second layer of knit overlapping and joined along opposing edges to form an unsecured central region of the tube structure;

bonding a polymer layer to the first surface of the knitted component, wherein the polymer layer penetrates into and bonds to the first knitted layer of the tube structure and remains unsecured to the second knitted layer of the tube structure; and is

Incorporating the knitted component and the polymer layer into an upper of the article of footwear, the polymer layer forming a majority of an exterior surface of the upper.