Article of footwear incorporating a woven component

Abstract

The present application relates to articles of footwear incorporating a knitted component. An article of footwear can have an upper and a knitted component. Separately or in combination, the knitted component can include regions having different degrees of stretch resistance; the knitted component forms a collar having half-gauge knitting; the upper includes a thread having segments embedded into the knitted component, and the segments are positioned directly adjacent to one another; the thread forms a plurality of loops, pairs of loops are positioned directly adjacent to one another and configured to receive a lace; and the knitted component includes a thermoplastic polymer material, and the thread is not bonded to the thermoplastic polymer material.

Description

[0001] This application is a divisional application of the application filed on December 2, 2013, with application number 202010575928.8 and invention title "Footwear Article Combining Knitted Components".

[0002] The application filed on December 2, 2013, with application number 202010575928.8 and invention title "Footwear Article with Knitted Components" is a divisional application of the application filed on December 2, 2013, with application number 201710434256.7 and invention title "Footwear Article with Knitted Components".

[0003] The application filed on December 2, 2013, with application number 201710434256.7 and entitled "Footwear Article with Knitted Components", is a divisional application of the application filed on December 2, 2013, with application number 201310636770.0 and entitled "Footwear Article with Knitted Components". background

[0004] Conventional footwear generally comprises two main components: the upper and the sole structure. The upper is attached to the sole structure and forms a cavity within the footwear to comfortably and securely accommodate the foot. The sole structure is attached to the underside of the upper to position it between the upper and the ground. In some athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed of a polymer foam material that dampens ground reaction forces during walking, running, and other walking activities to reduce stress on the feet and legs. The outsole is attached to the underside of the midsole and forms the ground contact portion of the sole structure, which is made of a durable and abrasion-resistant material. The sole structure may also include an insole positioned within the cavity and close to the underside of the foot to enhance comfort.

[0005] The upper generally extends above the instep and toe areas of the foot, along the inner and outer sides of the foot, and around the heel area. In some footwear, such as basketball shoes and boots, the upper may extend upwards and around the ankle to provide support or protection. Access to the cavities within the upper is typically provided by an ankle opening in the heel area. Lacing systems are often incorporated into the upper to adjust the fit, allowing the foot to enter and exit the cavities within the upper. Lacing systems also allow the wearer to alter certain dimensions of the upper, particularly the girth, to accommodate different foot sizes. Additionally, the upper may include a tongue extending below the lacing system to enhance adjustability, and may incorporate a heel stabilizer to restrict heel movement.

[0006] Shoe uppers are typically made from a variety of materials. For example, the uppers of athletic shoes can be formed from multiple material elements. Materials can be selected based on various properties, including, for example, tensile strength, abrasion resistance, flexibility, breathability, compressibility, and moisture wicking. Regarding the outer areas of the upper, the toe and heel areas can be formed from leather, synthetic leather, or rubber to provide relatively high abrasion resistance. For other outer areas, leather, synthetic leather, and rubber may not exhibit the desired level of flexibility and breathability. Therefore, other outer areas can be formed from, for example, synthetic fabrics. Thus, the outer surface of the upper can be formed from multiple material elements, each imparting different properties to the upper. The middle or core layer of the upper can be formed from a lightweight polymer foam material, which provides cushioning and enhances comfort. Similarly, the inner surface of the upper can be formed from a comfortable and moisture-wicking fabric that removes sweat from the area directly surrounding the foot. Various material elements and other components can be joined using adhesives or stitching. Therefore, a typical upper is formed from multiple material elements, each imparting different properties to different areas of the footwear.

[0007] Overview

[0008] Footwear items may have uppers with woven components. In some configurations, the woven components may include areas with varying degrees of tensile resistance. In some configurations, the woven components form a collar with a half-gauge knit. In some configurations, the upper includes yarn with segments embedded in the woven components, the segments positioned directly adjacent to each other. In some configurations, the yarn forms multiple loops, the loop pairs positioned directly adjacent to each other, and the laces extend through the loop pairs. Furthermore, in some configurations, the woven components comprise a thermoplastic polymer material, and the yarn is not bonded to the thermoplastic polymer material.

[0009] This invention provides a footwear article having an upper and a sole structure fixed to the upper, the upper including a woven component formed of an integral woven structure, the woven component comprising:

[0010] A first region, which forms the collar of the shoe upper and has a first tensile resistance, the collar defining an opening into a cavity within the shoe upper for receiving a foot;

[0011] A second region, extending outward from the first region and having a second tensile resistance; and

[0012] A third region, which at least partially extends around the second region and has a third tensile resistance,

[0013] The first tensile resistance is less than the second tensile resistance, and the second tensile resistance is less than the third tensile resistance.

[0014] In the aforementioned footwear, the first region may be formed as a half-gauge knit. The second and third regions may be formed as a full-gauge knit. The second region may be located in the throat region of the upper. The yarn in the third region may comprise a thermoplastic polymer material. The thermoplastic polymer material may be substantially absent from the first and second regions. Embedded threads may extend through the third region. The embedded threads may form lace loops configured to receive shoelaces. The embedded threads may form lace loops, and pairs of lace loops may overlap each other and be configured to receive shoelaces. The knitting component may be a flat knitting component.

[0015] The present invention also provides a footwear article having an upper and a sole structure attached to the upper, the upper including a knitted component forming a collar defining an opening into a cavity within the upper for receiving a foot, the collar being formed as a half-gauge knit.

[0016] In the aforementioned footwear, the collar may have a ribbed structure. Other areas of the knitted component may be formed as a full-gauge knit. The collar may have a lower tensile strength than other areas of the knitted component. The knitted component may have (a) a central region extending outward from the collar and (b) a peripheral region extending at least partially around the central region, the collar, the central region, and the peripheral region may be formed from an integral knitted structure, and the collar may have a lower tensile strength than the central region and the peripheral region. The central region may have a lower tensile strength than the peripheral region. The central region and the peripheral region may be formed as a full-gauge knit. The yarns in the peripheral region may include a thermoplastic polymer material. The thermoplastic polymer material may be substantially absent from the collar and the central region. The knitted component may be a flat knitted component.

[0017] The present invention further provides a footwear article having an upper and a sole structure fixed to the upper, the upper including a woven component and a thread having a first segment embedded in the woven component, a second segment positioned outside the woven component and forming a lace loop configured to receive a lace, and a third segment embedded in the woven component, the first segment and the third segment being positioned directly adjacent to each other.

[0018] In the aforementioned footwear, the first segment and the third segment may be positioned within 2 mm of each other. The first segment and the second segment may extend between the throat region and the lower region of the upper. The yarn may form a plurality of additional lace loops positioned on opposite sides of the upper. The lace loops and additional lace loops may overlap each other and may form a pair of lace loops configured to receive the laces. The yarn may have a greater tensile strength than the braided component. The braided component may include a thermoplastic polymer material, and the yarn may not be bonded to the thermoplastic polymer material. The braided component may have (a) a collar region forming a collar, (b) a central region extending outward from the collar region, and (c) a peripheral region extending at least partially around the central region, the collar region, the central region, and the peripheral region may be formed by an integral braided structure, and the first segment and the third segment of the yarn may be embedded in the peripheral region. The yarn in the peripheral region may include a thermoplastic polymer material, and the thermoplastic polymer material may be substantially absent from the collar region and the central region. The woven component can be a flat woven component.

[0019] The present invention also provides a footwear article having an upper and a sole structure attached to the upper, the upper including a woven component and threads embedded in the woven component, portions of the threads being positioned outside the woven component and forming a plurality of loops, pairs of the loops being positioned directly adjacent to each other and configured to receive shoelaces.

[0020] In the aforementioned footwear, the pairs of coils can be in an overlapping configuration. Each of the pairs of coils can be aligned to form a hole. A first pair of coils can be positioned on one side of the upper, and a second pair of coils can be positioned on the other side of the upper. The laces can extend through the upper and through each of the first and second pairs of coils. The yarn can have a greater tensile strength than the braided component. The braided component can include a thermoplastic polymer material, and the yarn may not be bonded to the thermoplastic polymer material. The braided component can have (a) a collar area forming a shoe collar, (b) a central area extending outward from the collar area, and (c) a peripheral area extending at least partially around the central area, the collar area, the central area, and the peripheral area being formed by an integral braided structure. The yarn in the peripheral area can include a thermoplastic polymer material, and the thermoplastic polymer material may be substantially absent from the collar area and the central area. The collar area can be formed as a half-gauge knit, and the central area and the peripheral area can be formed as a full-gauge knit. The knitting component can be a flat knit component.

[0021] The present invention also provides a footwear article having an upper and a sole structure fixed to the upper, the upper comprising:

[0022] A braided component comprising a thermoplastic polymer material, the braided component having at least one fusion region in which the thermoplastic polymer material bonds to yarns within the braided component; and

[0023] The thread is embedded within the braided component and is not bonded to the thermoplastic polymer material.

[0024] In the aforementioned footwear articles, the yarn within the woven component may include yarn that does not contain the thermoplastic polymer material and is positioned directly adjacent to the yarn. The yarn may include a material that does not bond with the thermoplastic polymer material. The material of the yarn may be nylon. The material of the yarn may be polytetrafluoroethylene. The yarn may include a first segment embedded within the woven component, a second segment positioned outside the woven component and forming a loop, and a third segment embedded within the woven component, the first segment and the third segment being positioned directly adjacent to each other. A portion of the yarn may be positioned outside the woven component and forming a plurality of loops, pairs of loops being positioned directly adjacent to each other, and shoelaces may extend through the pairs of loops. The woven component may have (a) a collar area forming a shoe collar, (b) a central area extending outward from the collar area, and (c) a peripheral area extending at least partially around the central area, the collar area, the central area, and the peripheral area being formed by an integral woven structure. The thermoplastic polymer material may be positioned in the peripheral area and may not be present in the collar area and the central area. The collar area can be formed as a half-gauge knit, and the central area and the peripheral area can be formed as a full-gauge knit.

[0025] The appended claims specifically point out the advantages and features of the invention in terms of its novelty. However, for a better understanding of the novel advantages and features, reference may be made to the following description and accompanying drawings, which illustrate and explain various configurations and concepts related to the invention.

[0026] Attached Figure Description

[0027] The foregoing overview and the following detailed description will be better understood when read in conjunction with the accompanying drawings.

[0028] Figure 1 This is a front view of the outer side of the first configuration of footwear.

[0029] Figure 2This is a front view of the inner side of the first configuration of footwear.

[0030] Figure 3 It is a top-down plan view of the first configuration of footwear.

[0031] Figures 4A-4C It is the first configuration of footwear items, such as Figure 3 Cross-sectional views defined by mid-section lines 4A-4C.

[0032] Figure 5 It is a top plan view of the woven components of the upper from the first configuration of footwear.

[0033] Figures 6A-6C It is a coil diagram depicting the structure of a braid from the braided components.

[0034] Figure 7 This is a front view of the outer side of the second configuration of footwear.

[0035] Figure 8 This is a front view of the inner side of the second configuration of footwear.

[0036] Figure 9 This is a top-down plan view of the second configuration of footwear.

[0037] Figures 10A-10C It is the second configuration of footwear items, such as Figure 9 Cross-sectional views defined by mid-section lines 10A-10C.

[0038] Figure 11 This is a top plan view of the woven component of the upper, which is a second configuration of footwear.

[0039] Figure 12 yes Figure 11 The woven components depicted in the text are as follows Figure 11 Cross-sectional view defined by section line 12.

[0040] Figure 13 It is a description of the source Figure 11 The diagram shows the coil of the braided structure of the braided component depicted in the figure.

[0041] Figure 14 This is a perspective view of a portion of the upper in the second configuration of footwear.

[0042] Figure 15 It is a top plan view of an additional woven component configuration that can be used with footwear.

[0043] Detailed Explanation

[0044] The following discussion and accompanying figures disclose footwear articles having uppers including woven components. The footwear articles are disclosed as having a general configuration suitable for walking or running. The concepts associated with footwear including uppers can also be applied to a variety of other athletic footwear types, including, for example, baseball shoes, basketball shoes, cross-training shoes, cycling shoes, soccer shoes, football boots, running shoes, tennis shoes, and hiking boots. The concepts can also be applied to footwear types generally considered non-athletic, including dress shoes, casual shoes, sandals, and work boots. Therefore, the concepts disclosed herein are applicable to a wide range of footwear types.

[0045] Typical footwear structure

[0046] As a first example, footwear item 100 Figure 1-4C The shoe is depicted as including a sole structure 110 and an upper 120. While the sole structure 110 is positioned under the wearer's foot and supports the foot, the upper 120 provides a comfortable and secure cover for the foot. Therefore, the foot can be positioned within the cavity of the upper 120 to effectively secure the foot within the shoe 100 or otherwise bind the foot to the shoe 100. Furthermore, the sole structure 110 is attached to the lower region of the upper 120 and extends between the foot and the ground, for example, to reduce ground reaction forces (i.e., cushion the foot), provide traction friction, enhance stability, and influence foot movement.

[0047] For reference purposes, footwear 100 can be divided into three general regions: a forefoot region 101, a midfoot region 102, and a heel region 103. The forefoot region 101 generally includes the portion of footwear 100 corresponding to the forefoot portion of the foot, including the toes and the joints connecting the metatarsals and phalanges. The midfoot region 102 generally includes the portion of footwear 100 corresponding to the middle portion of the foot, including the arch region. The heel region 103 generally includes the portion of footwear 100 corresponding to the rearfoot portion of the foot, including the heel and calcaneus. Footwear 100 also includes a lateral side 104 and a medial side 105, which extend through each of regions 101-103 and correspond to opposite sides of footwear 100. More specifically, the lateral side 104 corresponds to the outer region of the foot (i.e., the surface facing away from the other foot), and the medial side 105 corresponds to the inner region of the foot (i.e., the surface facing towards the other foot). Regions 101-103 and sides 104-105 are not intended to precisely delineate the areas of footwear 100. Rather, regions 101-103 and sides 104-105 are intended to represent the general areas of footwear 100 to aid the discussion below. In addition to footwear 100, regions 101-103 and sides 104-105 may also be applied to the sole structure 110, the upper 120, and their individual components.

[0048] The main components of the sole structure 110 are the midsole 111, the outsole 112, and the insole 113. The midsole 111 is attached to the lower surface of the upper 120 and may be formed of a compressible polymer foam element (e.g., polyurethane or ethyl vinyl acetate foam) that reduces ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other walking activities. In other configurations, the midsole 111 may incorporate plates, adjusters, fluid-filled chambers, durable elements, or motion control components that further reduce force, enhance stability, or influence foot movement, or the midsole 111 may be primarily formed of fluid-filled chambers. The outsole 112 is attached to the lower surface of the midsole 111 and may be formed of a textured, abrasion-resistant rubber material to impart adhesion friction. The insole 113 is located within a cavity in the upper 120 and is positioned to extend below the lower surface of the foot to enhance the comfort of the footwear 100. As another example, the sole structure 110 may have the configuration disclosed in U.S. Patent No. 6,990,755 to Hatfield et al., issued January 31, 2006, and incorporated herein by reference in its entirety. While these configurations for the sole structure 110 provide examples of sole structures that can be used in conjunction with the upper 120, a variety of other conventional or unconventional configurations for the sole structure 110 may also be used. Therefore, the characteristics of the sole structure 110, or any sole structure, used with the upper 120 can vary significantly.

[0049] The upper 120 extends through each of regions 101-103, along both the outer side 104 and the inner side 105, over the forefoot region 101, around the heel region 103, and on the upper surface of the sole structure 110. When the foot is positioned within a cavity formed to accommodate the foot, the upper 120 extends along the outer side of the foot, along the inner side of the foot, above the foot, around the heel, and below the foot. The upper 120 includes an outer surface 121 and an opposing inner surface 122. The outer surface 121 faces outward and away from the footwear 100, while the inner surface 122 faces inward and defines a large portion or a relatively large part of the cavity in the upper 120. Furthermore, the inner surface 121 can rest against the foot or cover a sock. The upper 120 also includes a collar 123, primarily located in the heel region 103, defining an opening into the cavity in the upper 120, thereby providing an entrance for the foot into the cavity. In other words, the foot can be inserted into and removed from the upper 120 through the opening formed by the collar 123.

[0050] The majority of the upper 120 is formed by a woven component 130, which will be discussed in more detail below. Although the woven component 130 is depicted as essentially forming the entire upper 120, including both surfaces 121 and 122 and the collar 123, various additional elements can be incorporated into the upper 120. For example, a strobel sock 124 is attached to the woven component 130 and forms a large portion of the underfoot extension of the upper 120, such as... Figures 4A-4C As depicted. In this configuration, insole 113 extends over shoe lining 124 and forms the surface on which the foot rests. Alternatively, woven component 130 may extend under the foot, thereby replacing some or all of shoe lining 124. Furthermore, seam 125 extends over the inner side 105 through heel region 103 to connect the edges of woven component 130. Although woven component 130 forms part of both surfaces 121 and 122, a polymer layer or surface layer may be bonded to areas of woven component 130, as disclosed in U.S. Patent Application Publication 2012 / 0246973 of Dua, which is incorporated herein by reference in its entirety. In another configuration, the upper 120 may also include one or more of the following: (a) laces to help tighten the upper 120 around the foot; (b) a heel stabilizer in the heel region 103 for enhanced stability; (c) a toe guard made of abrasion-resistant material in the forefoot region 101; and (d) logos, trademarks, and posters with instructions and material information. Therefore, in addition to the features and elements discussed herein and shown in the accompanying drawings, the upper 120 may incorporate a variety of other features and elements.

[0051] Configuration of woven components

[0052] The woven component 130 is formed using a weaving process, such as cross weaving, and extends throughout the upper 120. Although seams may exist in areas of the woven component 130, the majority of the woven component 130 has a substantially seamless configuration. Furthermore, the woven component 130 can be formed from a monolithic woven structure. As used herein, when a woven component (e.g., woven component 130) is formed as a one-piece element by a weaving process, it is defined as being formed from a “monolithic woven structure.” That is, the weaving process substantially forms the various features and structures of the woven component 130 without requiring significant additional manufacturing steps or processes. Although portions of the woven component 130 may be joined together after the weaving process (e.g., the edges of the woven component 130 are joined together, as at seam 125), the woven component 130 is still formed from a monolithic woven structure because it is formed as a one-piece woven element. Moreover, when other elements (such as shoe lining 124, shoelaces, logos, trademarks, posters) are added after the weaving process, the woven component 130 is still formed by the overall woven structure.

[0053] The knitted component 130 is formed as a knitted element and can incorporate various types and combinations of stitches and yarns. Regarding the stitches, the yarns forming the knitted component 130 can have one type of stitch in one area of ​​the knitted component 130 and another type of stitch in another area. Depending on the type and combination of stitches used, the areas of the knitted component 130 can have, for example, a plain knit structure, a mesh knit structure, or a rib knit structure. Different types of stitches can affect the physical properties of the knitted component 131, including aesthetics, tensile strength, thickness, breathability, and abrasion resistance. That is, different types of stitches can impart different properties to different areas of the knitted component 130. Regarding the yarns, the knitted component 130 can have one type of yarn in one area of ​​the knitted component 130 and another type of yarn in another area. Depending on various design criteria, the knitted component 130 can incorporate yarns with, for example, different deniers, materials (e.g., cotton, elastic fibers, polyester, rayon, wool, and nylon), and twists. Different types of yarn can affect the physical properties of the woven component 131, including aesthetics, tensile strength, thickness, breathability, and abrasion resistance. In other words, different types of yarn can impart different properties to different areas of the woven component 130. By combining various types and combinations of stitches and yarns, each area of ​​the woven component 130 can have specific properties that enhance the comfort, durability, and performance of the footwear 100.

[0054] Separate from footwear 100 and with Figure 5The knitted component 130 is depicted in a planar or flat configuration. As discussed above, each region of the knitted component 130 may have specific properties depending on the type and combination of stitches and yarns used during the knitting process. Although the properties of the regions of the knitted component 130 can vary significantly, the knitted component is depicted as including a first or collar region 131, a second or central region 132, and a third or peripheral region 133, each of which has different properties and is formed by the overall knitted structure. Generally, for example, the collar region 131 has a greater tensile strength than the central region 132, and the central region 132 has a greater tensile strength than the peripheral region 133. That is, a tension acting on the collar region 131 will cause greater elongation or stretching in the knitted component 130 compared to the same tension acting on the central region 132. Similarly, a tension acting on the central region 132 will cause greater elongation or stretching in the knitted component 130 compared to the same tension acting on the peripheral region 133. In other words, the collar area 131 has less tensile strength than the central area 132, and the central area 132 has less tensile strength than the peripheral area 133. It should be noted that although the areas 131-133 are distinguished and defined by dashed lines, the dashed lines may be invisible in some configurations of the woven component 130 for reference.

[0055] The collar area 131 corresponds to the collar 123 in the upper 120 and forms a ring-shaped or tubular structure. When the footwear 100 is worn, the collar area 131 extends around or surrounds the wearer's ankle and can rest against the ankle. As described above, the collar area 131 exhibits greater tensile strength than both areas 132 and 133. The advantage of giving the collar area 131 relatively low tensile resistance is that this area of ​​the woven component 130 will elongate or otherwise stretch when the foot is inserted into and removed from the upper 120 through the opening formed by the collar 123. Furthermore, when the footwear 100 is worn, the collar area 131 can remain partially stretched and rest against the ankle, thereby preventing dirt, pebbles, and other debris from entering the footwear 100 through the collar 123.

[0056] For the collar area 131, various types of stitches and yarns can be used. As an example, Figure 6AA loop diagram depicts the knitted structure representing the collar area 131, formed by a first yarn 134 and a second yarn 135. To impart stretch to the collar area 131, the loop diagram shows that the collar area 131 is formed as a half-gauge knit. That is, loops and tuck stitches formed by yarns 134 and 135 are knitted at every other stitch to create gaps or ribs in the knitted structure, thereby promoting expansion or stretching. In some configurations, forming the collar area 131 as a half-gauge knit creates a rib-like structure in the knitted component 130. To impart additional stretch to the collar area 131, the first yarn 134 can be an elastic yarn, such as a 210-denier elastic fiber (e.g., spandex) covering the two ends of a 150-denier polyester yarn. Furthermore, the second yarn 135 can be the two ends of a 150-denier textured polyester yarn.

[0057] The central region 132 extends outward from the collar region 131 and toward a portion of the woven component 130 positioned in the forefoot region 101, corresponding to the throat region of the upper 120. When the footwear 100 is worn, the central region 132 extends over and rests against the upper surface of the foot. As described above, the central region 132 exhibits greater tensile resistance than the collar region 131, but less tensile resistance than the peripheral region 133. The advantage of giving the central region 132 an appropriate degree of tensile resistance is that this area of ​​the woven component 130 will expand or otherwise stretch when the foot is inserted into the upper 120, thus accommodating feet of different sizes, such as girth and width. Furthermore, when the footwear 100 is worn, the central region 132 can remain partially stretched and rest against the upper surface of the foot, ensuring a reliable fit during running or walking.

[0058] For the central area 132, various types of stitches and yarns can be used. As an example, Figure 6B A loop diagram representing the knitted structure for the central region 132 is depicted, the knitted structure being formed by a first yarn 134. Although the loop diagram indicates that the central region 132 is formed as a full-gauge knit, the first yarn 134 may be an elastic yarn that imparts an appropriate degree of tensile resistance to the central region 132. As described above, the first yarn 134 may be a 210-denier elastic fiber covered at both ends of a 150-denier polyester.

[0059] The peripheral region 133 forms the remainder of the woven component 130 and extends at least partially around the central region 132, thus being positioned around the periphery of the woven component 130. When incorporated into footwear 100, the peripheral region 133 extends through each of regions 101-103, along both the outer and inner sides 104 and 105, over the forefoot region 101, and around the heel region 103. Furthermore, when wearing footwear 100, the peripheral region 133 extends along the outer side of the foot, along the inner side of the foot, over the foot, and around the heel. As described above, the peripheral region 133 exhibits greater tensile resistance than both regions 131 and 132. Moreover, when tension is applied, the peripheral region 133 may exhibit relatively little or no tension. The advantage of giving the peripheral region 133 a relatively small degree of tension is that this area of ​​the woven component 130 resists tension in the upper 120 and ensures a reliable fit during running or walking.

[0060] For the surrounding area 133, various types of stitches and yarns can be used. As an example, Figure 6C A loop diagram representing the woven structure for the collar area 133 is depicted, the woven structure being formed by a first yarn 134 and a third yarn 136. Although the first yarn 134 can be an elastic yarn, the greater tensile resistance in the peripheral area 133 may be a result of (a) the full-gauge woven fabric depicted in the loop diagram and (b) the thermoplastic characteristics of the third yarn 136. In other words, the third yarn 136 may incorporate a fusible or thermoplastic polymer material that softens or melts when heated and returns to a solid state upon cooling. More specifically, thermoplastic polymer materials transition from a solid state to a softened or liquid state when subjected to sufficient heat, and then transition from a softened or liquid state to a solid state upon sufficient cooling. Thus, thermoplastic polymer materials are often used to join two objects or components together. In this configuration, the thermoplastic polymer material in the third yarn 136 can be used to (a) connect portions of the third yarn 136 to portions of the first yarn 134 and (b) connect portions of the third yarn 136 to other portions of the third yarn 136. Therefore, the thermoplastic polymer material, which can be thermoplastic polyurethane, can be fused or bonded to the woven structure and stabilize the peripheral region 133, thereby minimizing tension in the peripheral region 133. As an example, the third yarn 136 can be the two ends of a 20-denier elastic fiber covered with 150-denier elastic polyester and a fusible or thermoplastic polymer material. It should be noted that in many configurations of footwear 100, the thermoplastic polymer material is substantially absent in the collar region 131 and the center region 132.

[0061] Although the braided component 130 can be formed using a variety of different braiding processes and with a variety of different braiding machines, cross braiding (i.e., the use of a cross braiding machine) has the ability to form the braided component 130 with the various features discussed above. Cross braiding is a method for producing a braided material that rotates periodically (i.e., a material woven from alternating sides). The two sides of the material (in other words, the two surfaces) are conventionally designated as the front side (i.e., the side facing outwards and toward the observer) and the back side (i.e., the side facing inwards and away from the observer). Additional information regarding cross braiding and processes that can be used to form the braided component 130 can be found in U.S. Patent Application Publication 2012 / 0233882 by Huffa et al., which is incorporated herein by reference in its entirety. While cross braiding provides a suitable means for forming the braided component 130, a variety of other braiding processes can also be utilized, depending on the features incorporated into the braided component 130. Examples of other knitting techniques that can be used include wide tube circular knitting, narrow tube circular knit jacquard, single knit circular knit jacquard, double knit circular knit jacquard, warp knit tricot, warp raschel, and double needle bar raschel.

[0062] Configuration with embedded shoelace loops

[0063] Another configuration of footwear 100 is in Figure 7-10CThe woven component 130 is described as having many or all of the features discussed above. Therefore, the woven component 130 (a) is formed by a weaving process such as cross weaving and extends throughout the upper 120, (b) can be formed from an integral woven structure, and (c) is formed as a woven element and can incorporate various types and combinations of stitches and yarns. Furthermore, the woven component 130 may include each of the collar region 131, the central region 132, and the peripheral region 133, and the relative stretching discussed above. As an additional feature, this configuration of the footwear 100 includes insert lines 140 forming various lace loops 141 configured to receive laces 126, which are depicted passing through the various lace loops 141. As with some conventional footwear items, the laces 126 pass through the upper 120 and between the lace loops 141, which are positioned along opposite sides of the upper 120. When using footwear 100, shoelaces 126 allow the wearer to change the size of the upper 120 to fit the size of the foot. More specifically, shoelaces 126 can be manipulated in a conventional manner, allowing the wearer to (a) tighten the upper 120 around the foot and (b) loosen the upper 120 to facilitate insertion of the foot into and removal of the foot from the cavity in the upper 120 (i.e., through the opening formed by the collar 123).

[0064] A portion of the insert thread 140 is positioned within the braided component 130 and can be embedded into the structure of the braided component 130 during the braiding process. U.S. Patent Application Publication 2012 / 0233882 by Huffa et al., which is referenced above and incorporated herein, provides a discussion of ways in which the braided component 130 can be formed, including processes for embedding or otherwise positioning the insert thread 140 within the braided component 130. Assuming that the insert thread 140 is incorporated into the braided component 130 during the braiding process, the braided component 130 and the insert thread 140 can be formed from a single braided structure. In other words, the braided component 130 and the insert thread 140 are formed as a one-piece element by the braiding process.

[0065] Embedded thread 140 repeatedly passes between (a) the throat region of upper 120 and (b) the lower region of upper 120, the throat region corresponding to the position of laces 126 and the upper surface of the foot, and the lower region of upper 120 adjacent to the position where it is secured to the upper 120 by sole structure 110. Although a portion of embedded thread 140 is positioned within the braided component 130 between the throat and lower regions, other portions of embedded thread 140 are exposed or positioned outside the braided component 130 in the throat region to form lace loops 141. In this configuration, embedded thread 140 is tensioned when laces 126 are pulled, and embedded thread 140 resists stretching within upper 120. Furthermore, embedded thread 140 helps secure upper 120 around the foot and engages with laces 126 to enhance the fit of footwear 100.

[0066] Separate from footwear 100 and with Figure 11 The woven component 130 and the insert 140 are depicted in a planar or flat configuration. Although the specific location of the insert 140 can vary significantly, it is depicted as primarily positioned within the peripheral region 133. As discussed above, the peripheral region 133 exhibits greater tensile resistance than both regions 132 and 133, and may exhibit relatively little or no stretch when placed under tension. The insert 140 may exhibit even greater tensile resistance than the peripheral region 133. That is, the insert 140 may stretch less than the peripheral region 133 when subjected to the same tensile force. Assuming that multiple segments of the insert 140 extend from the throat region of the upper 120 to the lower region of the upper 120, the insert 140 imparts tensile resistance to a portion of the upper 120 between the throat region and the lower region. Moreover, applying tension to the laces 126 imparts tension to the insert 140, thereby causing a portion of the upper 120 between the throat region and the lower region to rest against the foot. Therefore, the embedded thread 140 is combined with the shoelace 126 to enhance the fit of the footwear 100.

[0067] Reference Figure 12 The insert thread 140 is depicted as being positioned within the braided component 130 and between opposing surfaces of the braided component 130. Assuming that the surfaces of the braided component 130 may also form surfaces 121 and 122 when incorporated into the footwear 100, the insert thread 140 will also be positioned between surfaces 121 and 122. Although each segment of the insert thread 140 positioned within the braided component 130 may be spaced apart from each other, the segments of the insert thread 140 forming individual lace loops 141 are depicted as being positioned directly adjacent to each other. As defined herein, segments of the insert thread 140 are “directly adjacent” to each other when positioned within 2 mm of each other. In this configuration, segments of the insert thread extending downward from each lace loop 141 and toward the sole structure 110 are directly adjacent to each other. In some configurations, the directly adjacent segments of the insert thread 140 may touch each other or may be separated from each other by, for example, one or two yarns. Furthermore, the structural braided component 130 can define channels or pathways within the upper 120, and segments of the embedded thread extending downward from each shoelace loop 141 can be positioned in the same channel.

[0068] As discussed above, portions of the insert thread 140 are positioned within the braided component 130, while other portions of the insert thread 140 are exposed or positioned outside the braided component to form shoelace loops 141. For each shoelace loop 141, a first segment of the insert thread 140 is positioned or embedded within the braided component 130, a second segment of the insert thread 140 forms one of the shoelace loops 141, and a third segment of the insert thread 140 is also positioned or embedded within the braided component 130. Furthermore, the first and third segments are positioned directly adjacent to each other and extend between the throat and lower regions of the upper 120. In some configurations, the first and third segments may be positioned within the same channel or passageway within the braided component 130.

[0069] Figure 13 A loop diagram representing the braided structure for the region including the insert yarn 140 is depicted. In addition to the insert yarn 140, a fourth yarn 137 can be positioned in this region and has two ends covered with 120-denier elastic fibers of 150-denier elastic polyester. The fourth yarn 137 has a structure similar to the third yarn 136, but without a fusible or thermoplastic polymer material. The advantage of this configuration is that the insert yarn 140 will remain unbonded to the braided component 130 or otherwise spaced apart from the braided component 130 in the surrounding region 133. Furthermore, the insert yarn 140 can slide or move within the braided component 130, thereby allowing adjustment of (a) the size of each shoelace loop 141 and (b) the tension in portions of the insert yarn 140 during the manufacturing process of the footwear 100.

[0070] Another method to ensure that the insert yarn 140 remains unbonded to or otherwise spaced apart from the braided component 130 involves the selection of materials for the insert yarn 140. As an example, the insert yarn 140 may be formed of nylon material that is not bonded or connected to some thermoplastic polymer material, such as thermoplastic polyurethane. Therefore, when the insert yarn 140 is formed of nylon, the fourth yarn 137 can be replaced by a third yarn 136, which comprises a fusible or thermoplastic polymer material, and the insert yarn 140 will not be bonded to the third yarn 136. The advantage of this method is that it can minimize the number of different types of yarns used in the braided component 130, thereby improving manufacturing efficiency. Various coatings, such as polytetrafluoroethylene (PTFE), can also be used to inhibit bonding between the insert yarn 140 and the fusible or thermoplastic polymer material. Therefore, selecting the insert yarn 140 to have a material incompatible with the thermoplastic polymer material can ensure that the insert yarn 140 remains unbonded to the braided component 130.

[0071] Generally, portions of the braided component 130 may include yarns at least partially formed of a thermoplastic polymer material. The braided component 130 can be heated such that the thermoplastic polymer material bonds or fuses regions of the braided component 130, such as in peripheral region 133. More specifically, the thermoplastic polymer material can bond portions of the yarns together to form bonded or fused regions. In some configurations, yarns having the thermoplastic polymer material may bond to themselves in the fused region. In other configurations, yarns having the thermoplastic polymer material may bond to other yarns in the fused region, the other yarns may or may not include the thermoplastic polymer material. However, in either case, various methods can be used to ensure that the insert yarn 140 remains unbonded to the thermoplastic polymer material. In one example, the braided structure of the braided component 130 places yarns without thermoplastic polymer material directly adjacent to the insert yarn 140, thereby forming a buffer zone between the insert yarn 140 and the thermoplastic polymer material. In another example, the insert yarn 140 may include a material that does not bond with the thermoplastic polymer material. Therefore, a variety of configurations and methods can be used to ensure that the embedded line 140 remains separate from or unbonded to the thermoplastic polymer material.

[0072] Similar to the yarn forming the braided component 130, the configuration of the insert yarn 140 can also vary significantly. Besides yarn, the insert yarn 140 can have a configuration such as filament (e.g., monofilament), thread, rope, band, cable, or chain. The insert yarn 140 can be thicker than the yarn forming the braided component 130. In some configurations, the insert yarn 140 can have a much greater thickness than the yarn forming the braided component 130. Although the cross-sectional shape of the insert yarn 140 can be circular, it can also be triangular, square, rectangular, elliptical, or irregular. Furthermore, the material forming the insert yarn 140 can include any of the materials used for the yarn within the braided component 130, such as cotton, elastic fibers, polyester, rayon, wool, and nylon. As mentioned above, the insert yarn 140 can exhibit greater tensile strength than the braided component 130. Therefore, suitable materials for the embedded wire 140 may include a variety of engineering filaments for high tensile strength applications, including glass, aramids (e.g., para-aramids and meta-aramids), ultra-high molecular weight polyethylene, and liquid crystal polymers. As another example, braided polyester wire or cable with a diameter of 0.8 mm may also be used as the embedded wire 140.

[0073] As described above, shoelaces 126 pass through the upper 120 and between shoelace loops 141, which are positioned along opposite sides of the upper 120. In fact, shoelaces 126 follow an alternating path passing through the upper 120 and between opposite sides of the upper 120. At different locations on opposite sides of the upper 120, two shoelace loops 141 are positioned overlapping each other and directly adjacent to each other, as... Figure 14 As shown, the shoelace 126 passes through two shoelace loops 141 simultaneously. That is, at each location where the shoelace 126 changes direction as it repeatedly passes through the upper 120, a pair of shoelace loops 141 is used as a shoelace receiving element. Since the pairs of shoelace loops 141 are in an overlapping configuration, each pair of shoelace loops 141 can be aligned to form a hole, and the shoelace 126 extends through the hole. Although the shoelace 126 can pass through a single shoelace loop 141 at each location, the advantage of using a pair of shoelace loops 141 is that the impact of breakage of the insert wire 140 can be minimized. That is, when the portion of the insert wire 140 associated with one shoelace loop 141 breaks or otherwise fails, the other shoelace loop 141 can form a shoelace receiving element at each location.

[0074] Another configuration of the braided component 130 is in Figure 15 The upper 120 is depicted as including (a) multiple sub-regions 138 within a peripheral region 133 and (b) multiple holes 139 extending through the knitted component 130 in the regions of the central region 132 and the peripheral region 133. Sub-regions 138 may be areas where the knitted component 130 contains stitches and yarns of different types and combinations. Therefore, each sub-region 138 can have different properties, such as tensile strength, thickness, breathability, and abrasion resistance. Alternatively, the aesthetics of the upper 120 can be altered simply by changing the color of the yarn used in the sub-regions 138. In addition to enhancing the breathability of the upper 120, the holes 139 can also impart tensile strength to the knitted component 130. That is, the holes 139 can reduce the tensile strength of the knitted component 130 in a specific region. Therefore, various features and structures within the knitted component 130 can be significantly varied to provide specific properties to regions of the knitted component 130.

[0075] The invention has been disclosed with reference to various configurations in the foregoing and accompanying drawings. However, the purpose of this disclosure is to provide examples of various features and concepts of the invention, rather than to limit the scope of the invention. Those skilled in the art will recognize that many changes and modifications can be made to the configurations described above without departing from the scope of the invention as defined by the appended claims.

Claims

1. A footwear article comprising an upper, the upper including a flat-knit component formed of an integral knit structure, the flat-knit component comprising: A first region forming the collar of the shoe upper, wherein at least the collar of the first region has a first tensile resistance, the collar defining an opening into a cavity within the shoe upper for receiving a foot; A second region extends outward from the first region and is at least partially located in the throat region of the upper, the second region having a second tensile resistance; as well as A third region defines the peripheral area of ​​the shoe upper, extends at least partially around the second region, including at least partially around the throat region, and has a third tensile resistance, wherein the first tensile resistance is less than the second tensile resistance, and the second tensile resistance is less than the third tensile resistance. The flat-knit component includes a heel seam that joins the edges of the flat-knit component together. The heel seam extends at least partially in the heel region of the upper, and the heel seam deviates from the centerline of the heel region and extends toward at least one of the inner and outer sides of the upper. The offset heel seam includes a first segment and a second segment extending between the collar and the interlocking line, wherein the first segment extends on the upper in a first direction and the second segment extends on the upper in a second direction different from the first direction, wherein the interlocking line is the boundary line where the upper and the sole structure of the footwear article meet.

2. The footwear article according to claim 1, wherein the first region is formed as a half-gauge knit.

3. The footwear article according to claim 2, wherein the second region and the third region are formed as a full-gauge knit.

4. The footwear article of claim 1, wherein the embedded thread extends through the third region.

5. The footwear article of claim 4, wherein the embedded thread forms a lace loop, the lace loop being configured to receive a lace.

6. The footwear article of claim 5, wherein the pairs of shoelace loops overlap each other.

7. The footwear article of claim 1, wherein the heel seam extends in the third region along a first direction from the interlocking line to the bottom of the collar, forming an acute angle toward the heel region, and extends in the first region along a second direction from the bottom of the collar to the top of the collar.

8. An upper for footwear articles, the upper including a flat-knitted portion forming a collar defining an opening into the upper for receiving a foot, the collar being formed as a half-gauge knit, wherein other areas of the flat-knitted portion are formed as full-gauge knit, and wherein the flat-knitted portion includes a heel seam to join the edges of the flat-knitted portion together, wherein the heel seam is offset from a centerline of a heel region of the upper and extends toward at least one of an inner and outer side of the upper, wherein the offset heel seam includes a first segment and a second segment extending between the collar and a seam line, wherein the first segment extends on the upper in a first direction, and the second segment extends on the upper in a second direction different from the first direction, wherein the seam line is a boundary line where the upper and the sole structure of the footwear article meet.

9. The upper according to claim 8, wherein the collar has a ribbed structure.

10. The upper of claim 8, wherein the collar has a smaller tensile resistance than other areas of the flat-knit component.

11. The upper of claim 8, wherein the flat knit component has (a) a central region extending outward from the collar and (b) a peripheral region extending at least partially around the central region; the collar, the central region, and the peripheral region are formed of an integral knit structure, and the collar has a smaller tensile resistance than the central region and the peripheral region.

12. The upper according to claim 11, wherein the central region has a smaller tensile resistance than the peripheral region.

13. The upper according to claim 11, wherein the central region and the peripheral region are formed as a full-gauge knit.

14. The upper of claim 11, wherein the yarn in the peripheral region comprises a thermoplastic polymer material.

15. The upper of claim 14, wherein the thermoplastic polymer material is substantially absent from the collar and the central region.

16. The upper of claim 8, wherein the heel seam extends at least in a first direction toward the heel region and in a second direction toward the inner or outer side.

17. The upper of claim 8, wherein the heel seam extends along a first direction from the interlocking line to the bottom of the collar, forming an acute angle toward the heel region, and extends along a second direction from the bottom of the collar to the top of the collar.

18. A footwear article comprising a flat-knit component formed of an integral knitted structure, the flat-knit component comprising: A first region, which forms the collar of the shoe upper, wherein at least the collar of the first region has a first tensile resistance, the collar defining an opening into a cavity within the shoe upper for receiving a foot; The second region extends outward from the first region and has a second tensile resistance; as well as A third region, extending at least partially around the second region and having a third tensile resistance, wherein the first tensile resistance is less than the second tensile resistance and the second tensile resistance is less than the third tensile resistance, wherein the third region comprises a thermoplastic polymer material, wherein the flat-knit component includes a heel seam to join the edges of the flat-knit component together, the heel seam extending at least partially in the heel region of the upper, wherein the heel seam deviates from the centerline of the heel region and extends toward at least one of the inner and outer sides of the upper, wherein the deviated heel seam includes a first segment and a second segment extending between the collar and the interlocking line, wherein the first segment extends on the upper in a first direction and the second segment extends on the upper in a second direction different from the first direction, wherein the interlocking line is the boundary line where the upper and the sole structure of the footwear article meet.

19. The footwear article of claim 18, wherein the thermoplastic polymer material is substantially absent in the first region and the second region.

20. The footwear article of claim 18, wherein the thermoplastic polymer material is bonded to the yarns within the flat-knit component to define at least one fusion region.

21. The footwear article of claim 18, wherein the thread is disposed within the flat knitting member, between opposing substantially parallel surfaces of the flat knitting member defining a single layer of the flat knitting member, the thread extending at least partially through the fusion region and not bonded to the thermoplastic polymer material.

22. The footwear article of claim 19, wherein the yarn includes a first segment disposed within the flat knitting member, a second segment positioned outside the flat knitting member and forming a loop, and a third segment disposed within the flat knitting member, the first segment and the third segment being positioned directly adjacent to each other between opposing substantially parallel surfaces of the flat knitting member defining a single layer of the flat knitting member.

23. The footwear article of claim 19, wherein portions of the thread are positioned outside the flat-knitted component and form a plurality of loops, pairs of the loops being positioned directly adjacent to each other, and the laces extending through the pairs of the loops.

24. The footwear article of claim 21, wherein the upper further comprises a channel, and segments of the thread extending downward from each coil are positioned within the channel.

25. The footwear article of claim 23, wherein the pairs of coils overlap each other.

26. The footwear article of claim 18, wherein the heel seam extends in the third region along a first direction from the interlocking line to the bottom of the collar, forming an acute angle toward the heel region, and extends in the first region along a second direction from the bottom of the collar to the top of the collar.

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