Upper for an article of footwear having first and second knitted portions and method of making the same

Abstract

The present application relates to an upper for an article of footwear having first and second knitted portions and a method of manufacturing the same. The upper (102) may include: a first knitted portion (132) configured to form an outer surface (136) of the upper; a second knitted portion (134) configured to form an inner surface (138) of the upper, wherein the second knitted portion is at least partially coextensive with the first knitted portion; a gap space between the first knitted portion and the second knitted portion; and a knitted connection structure (140) connecting the first knitted portion to the second knitted portion. The knitted connection structure may extend at least partially along at least one of a tongue (126) and a collar (118) of the upper, and the second knitted portion may include at least one double-sided plain knit structure coextensive with the first knitted portion.

Description

[0001] This application is a divisional application of an application with an application date of May 3, 2018, application number 201880038961.8, and invention name “Upper for footwear having a first knitted part and a second knitted part and a method for manufacturing an upper”.

[0002] Related Applications

[0003] This application claims the benefit of U.S. Provisional Application Serial No. 62 / 502,264, filed May 5, 2017, which is hereby incorporated by reference in its entirety. background

[0004] Conventional footwear generally includes two main elements: an upper and a sole structure. The upper is fixed to the sole structure and forms a cavity within the footwear for comfortably and securely receiving the foot. The sole structure is fixed to the lower surface of the upper so as to be positioned between the upper and the ground. In some footwear articles, the sole structure may include a midsole and an outsole. The midsole may be formed of a polymer foam material that attenuates ground reaction forces to relieve stress on the foot and leg during walking, running, and other ambulatory activities. The outsole may be fixed to the lower surface of the midsole and form a portion of the sole structure that engages the ground, which is formed of a durable and wear-resistant material.

[0005] The upper of an article of footwear generally extends over the instep and toe regions of the foot, along the medial and lateral sides of the foot, and around the heel region of the foot. An ankle opening in the heel region generally provides access to a cavity within the upper. A lacing system is generally incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the cavity within the upper. The upper may include a tongue that extends below the lacing system to enhance the adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.

[0006] Brief Overview

[0007] One general aspect of the present disclosure includes an upper having: a first knitted portion configured to form an exterior surface of the upper; a second knitted portion configured to form an interior surface of the upper, wherein the second knitted portion is at least partially coextensive with the first knitted portion; a gap space between the first knitted portion and the second knitted portion; and a knitted connection structure connecting the first knitted portion to the second knitted portion. The knitted connection structure may extend at least partially along at least one of a tongue and a collar of the upper, and the second knitted portion may include at least one double jersey knit structure coextensive with the first knitted portion.

[0008] Another general aspect of the present disclosure includes an upper for an article of footwear having a first knitted portion forming an exterior surface of the upper, a second knitted portion forming an interior surface of the upper, and a connecting structure securing the first knitted portion to the second knitted portion. The connecting structure may include at least one loop incorporated into a course of the first knitted portion and at least one loop incorporated into a course of the second knitted portion, wherein the second knitted portion may include at least one double jersey knit structure coextensive with the first knitted portion.

[0009] Another general aspect of the present disclosure relates to a method of forming an upper, the method comprising the steps of knitting a first knitted portion, the first knitted portion being configured to form an outer surface of the upper; knitting a second knitted portion, the second knitted portion being configured to form an inner surface facing a cavity formed by the upper; and knitting a connecting structure connecting the first knitted portion to the second knitted portion. The connecting structure may extend at least partially along at least one of a tongue and a collar of the upper, and the second knitted portion may include at least one double-sided plain knit structure coextensive with the first knitted portion.

[0010] Specifically, this application provides the following:

[0011] 1). A shoe upper, comprising:

[0012] a first knitted portion configured to form an outer surface of the upper;

[0013] a second knitted portion configured to form an interior surface of the upper, wherein the second knitted portion is at least partially coextensive with the first knitted portion;

[0014] a gap space between the first knitted portion and the second knitted portion; and

[0015] a knitted connecting structure connecting the first knitted portion to the second knitted portion,

[0016] wherein the knitted connection structure extends at least partially along at least one of a tongue and a collar of the upper, and

[0017] The second knitted portion includes at least one double-sided plain knitted structure coextensive with the first knitted portion.

[0018] 2) An upper as described in 1), wherein the first knitted portion includes a first plurality of horizontal rows, wherein the second knitted portion includes a second plurality of horizontal rows, and wherein the knitted connecting structure is located between the first plurality of horizontal rows and the second plurality of horizontal rows relative to the knitting direction.

[0019] 3) The upper as described in 2), wherein at least one of the first plurality of rows and at least one of the second plurality of rows each comprise a double-sided plain knit structure.

[0020] 4). The shoe upper as described in 1), wherein the first knitted portion is fixed to the second knitted portion at least partially along a bite line of the shoe upper.

[0021] 5). The shoe upper as described in 1), wherein the first knitted portion includes a window, and wherein an area of ​​the second knitted portion is visible through the window.

[0022] 6). The upper as described in 1), wherein at least one of the first knitted portion and the second knitted portion includes an inlaid bulked yarn, and the inlaid bulked yarn is configured to provide cushioning to the upper.

[0023] 7). The shoe upper as described in 1), wherein the shoe upper comprises a lateral heel area and a medial heel area connected at a seam.

[0024] 8). The upper as described in 1), wherein at least one of the first knitted portion and the second knitted portion includes at least one inlaid stretch line.

[0025] 9). The shoe upper as described in 1), wherein at least one of the first knitted portion and the second knitted portion includes a tubular knitted structure forming a bag.

[0026] 10) A shoe upper for a footwear article, the shoe upper comprising:

[0027] a first knitted portion, the first knitted portion forming an outer surface of the upper;

[0028] a second knitted portion, the second knitted portion forming an inner surface of the upper; and

[0029] a connecting structure that fixes the first knitted portion to the second knitted portion,

[0030] wherein the connecting structure comprises at least one stitch incorporated into a row of the first knitted portion and at least one stitch incorporated into a row of the second knitted portion, and

[0031] The second knitted portion includes at least one double-sided plain knitted structure coextensive with the first knitted portion.

[0032] 11). An upper as described in 10), wherein the first knitted portion includes a first plurality of horizontal rows, wherein the second knitted portion includes a second plurality of horizontal rows, and wherein the connecting structure is located between the first plurality of horizontal rows and the second plurality of horizontal rows relative to the knitting direction.

[0033] 12) The upper of 11), wherein at least one of the first plurality of rows and at least one of the second plurality of rows comprise a double-sided plain knit structure.

[0034] 13) The shoe upper as described in 10), wherein the connecting structure extends at least partially around the collar of the shoe upper.

[0035] 14). The upper as described in 10), further comprising a seam, at which the lateral heel area and the medial heel area are connected, wherein the lateral heel area and the medial heel area are each at least partially formed by the first knitted part and the second knitted part.

[0036] 15) A method for forming a shoe upper, the method comprising:

[0037] knitting a first knitted portion, the first knitted portion being configured to form an outer surface of the upper;

[0038] knitting a second knitted portion, the second knitted portion being configured to form an inner surface facing a cavity formed by the upper; and

[0039] a knitted connecting structure connecting the first knitted portion to the second knitted portion,

[0040] wherein the connecting structure extends at least partially along at least one of a tongue and a collar of the upper, and

[0041] The second knitted portion includes at least one double-sided plain knitted structure coextensive with the first knitted portion.

[0042] 16) The method as described in 15), further comprising flipping at least one of the first knitted part and the second knitted part during the folding step.

[0043] 17) A method as described in 16), wherein when folded, the upper includes a lateral heel area and a medial heel area, and wherein the method further comprises fixing the lateral heel area to the medial heel area at a seam.

[0044] 18) The method of 15), wherein the connecting structure extends along the tongue of the upper and along the collar of the upper.

[0045] 19). The method as described in 15), further comprising inlaying a stretch line in at least one of the first knitted part and the second knitted part.

[0046] 20). The method of 15), wherein at least one of the first knitted portion and the second knitted portion comprises a tubular knitted structure forming a pocket for receiving an insert. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 is a diagram showing an article of footwear formed with an upper including a knitted component according to an embodiment of the present disclosure.

[0048] Figure 2 It is shown for Figure 1 An illustration of a knitted component of an upper depicted in FIG, as the knitted component may appear after being formed on a knitting machine.

[0049] Figure 3 is a diagram used to form Figure 1 A diagram of an implementation scheme of a knitting process for a knitted component is depicted in FIG.

[0050] Figure 4 It is shown Figure 2 Illustration of a top view of a knitted component when folded or otherwise manipulated into a folded state.

[0051] Figure 5 It is shown Figure 2 Illustration of a bottom view of a knitted component when folded or otherwise manipulated into a folded state.

[0052] Figure 6 It is shown Figure 2 Illustration of an upper being folded or otherwise manipulated into a wearable shape.

[0053] Figure 7 It is shown in Figure 6 Illustration of the upper being secured to the sole structure after the folding process.

[0054] Figure 8 It is shown Figure 2 Illustration of an upper of when incorporated into an article of footwear having hidden elements shown in dotted lines.

[0055] Fig. 9 It is shown Figure 2 Illustration of the upper when incorporated into an article of footwear with no hidden lines. Detailed Description

[0056] Various aspects are described below with reference to the accompanying drawings, in which like elements are generally identified by like numbers. The relationships and functions of the various elements of the various aspects may be better understood by reference to the following detailed description. However, the various aspects are not limited to those aspects illustrated in the accompanying drawings or explicitly described below. It should also be understood that the drawings are not necessarily to scale, and in some cases, details that are not necessary for understanding the aspects disclosed herein, such as conventional manufacturing and assembly, may have been omitted.

[0057] Certain aspects of the present disclosure relate to articles formed at least in part by textile materials. An example of an article is an article of clothing (e.g., shirts, pants, socks, footwear, jackets and other coats, underpants and other underwear, hats and other headwear or the like). A specific article is a shoe upper configured for use in an article of footwear. The shoe upper can be used in combination with any type of footwear. Illustrative, non-limiting examples of articles of footwear include basketball shoes, cycling shoes, cross-training shoes, international football (global football) (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski boots or snowboard boots, tennis shoes, running shoes, or walking shoes. The shoe upper can also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, or a sandal.

[0058] Figure 1 1 is a diagram showing a footwear article 100 formed with an upper 102, wherein the upper 102 is generally formed as a textile component, such as a knitted component 130. As shown, the upper 102 can be fixed to a sole structure 104. The upper 102 may include a lateral side 106 and a medial side 108. The area where the sole structure 104 connects the upper 102 may be referred to as a biteline 110. The upper 102 may be connected to the sole structure 104 in a fixed manner using any suitable technology (such as by using an adhesive, by sewing, etc.). The upper 102 may extend partially or completely around the wearer's foot, and / or may be integral with the sole structure 104, and may or may not use a sockliner. In some embodiments, the sole structure 104 may include a midsole (not shown) and an outsole.

[0059] The upper 102 may additionally include a throat area 112 extending from an ankle opening 114 leading to a cavity 116, and a collar 118 may at least partially surround the ankle opening 114. The cavity 116 of the article of footwear 100 may be configured (e.g., sized and shaped) to receive and accommodate a person's foot. The throat area 112 may generally be disposed in a mid-shoe area 120 of the upper 102. The mid-shoe area 120 of the upper 102 may be located between the heel area 122 and the toe area 124. In some embodiments, an optional tongue, such as the depicted tongue 126, may be disposed in the throat area 112. The tongue 126 may be any type of tongue, such as a gusseted tongue or a burrito tongue. If the tongue is not included (or not combined with the tongue), the lateral side and medial side of the throat area 112 may be connected together.

[0060] The article of footwear 100 may include fastening elements (not shown). Any suitable type of fastening elements may be used, such as shoelaces, cable-tensioning systems, and / or any other suitable means. The upper 102 may be configured to be fixed to and communicate with the fastening elements so that the fastening elements may adjust and / or tighten the upper 102 around the wearer's foot. For example, the upper 102 may include a set of holes 128 for receiving the fastening elements, but other suitable elements may alternatively be used.

[0061] At least a portion of the upper 102 and potentially the entire upper 102 can be formed by a knitted component 130 (or another suitable textile component). The knitted component 130 can be formed as an integrated one-piece element during a knitting process such as a weft knitting process (e.g., with a flat knitting machine or a circular knitting machine), a warp knitting process, or any other suitable knitting process. In other words, the knitting process on the knitting machine can generally form the knitted structure of the knitted component 130 without requiring a large number of post-knitting processes or steps. Optionally, two or more parts of the knitted component 130 can be individually formed into different integrated one-piece elements, and then the corresponding elements are attached.

[0062] Forming the upper 102 with a knitted component 130 can provide the upper 102 with advantageous features, including but not limited to a specific elasticity (e.g., expressed as Young's modulus), breathability, bendability, strength, hygroscopicity, weight, wear resistance, and / or a combination thereof. These features can be achieved by selecting a specific single-layer knitted structure or a multi-layer knitted structure (e.g., a ribbed knit structure, a single-sided plain knitted structure, etc.), by changing the size and tension of the knitted structure, by using one or more yarns formed by a specific material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting a yarn of a specific size (e.g., denier), and / or a combination thereof. The knitted component 130 can also provide desirable aesthetic features by incorporating yarns of different colors, textures arranged in a specific pattern, or other visual characteristics. The yarns of the knitted component 130 themselves and / or the knitted structure formed by one or more of the yarns of the knitted component 130 can vary at different locations, so that the knitted component 130 has two or more portions with different properties (e.g., a portion forming the throat area 112 of the upper 102 can be relatively elastic, while another portion can be relatively inelastic). In some embodiments, the knitted component 130 can incorporate one or more materials having properties that change in response to a stimulus (e.g., temperature, humidity, electric current, magnetic field, or light). For example, the knitted component 130 can include yarns formed from a thermoplastic polymer material (e.g., polyurethane, polyamide, polyolefin, and / or nylon) that transitions from a solid state to a softened state or liquid state when subjected to certain temperatures at or above its melting point, and then transitions back to a solid state when cooled. Thermoplastic polymer materials can provide the ability to heat and then cool a portion of the knitted component 130 to form an area of ​​bonded or continuous material (referred to herein as a "fused area") that exhibits certain advantageous properties, including, for example, relatively high stiffness, strength, and water resistance.

[0063] Figure 2A knitted component 130 of an upper 102 is shown as the knitted component 130 may appear after a knitting process (e.g., after exiting a flat-bed knitting machine) but before being manipulated into its wearable shape. The knitted component 130 may include a first portion 132 and a second portion 134, wherein an outer surface 136 of the upper 102 is at least partially formed by the first portion 132, and wherein an inner surface 138 of the upper 102 is at least partially formed by the second portion 134. The first portion 132 and the second portion 134 may be formed during a single knitting process (e.g., such that the first portion 132 and the second portion 134 are attached when the knitted component 130 exits the knitting machine). Thus, in some embodiments, the first portion 132 and the second portion 134 may share a common yarn, a common row, a common knit stitch or other knit structure, etc. In addition, the first portion 132 and the second portion 134 may be secured via at least one knitted structure (e.g., a knitted loop) of the knitted component 130. As described below (reference Figure 3 ), the unique shape of upper 102 can advantageously allow first portion 132 and / or second portion 134 to each utilize more than one needle bed (e.g., two needle beds of a flat knitting machine) during the formation of knitted component 130. Thus, after knitted component 130 is in its wearable shape, second portion 134 can have a double jersey knit structure. In this document, a "double jersey knit structure" is generally defined as any knit structure formed on two needle beds and utilizing at least one needle from each bed, including (but not limited to) full rib knit structure, 1x1, 2x1, and 3x1 rib structures, interlock knit structures, half cardigan knit structures and full cardigan knit structures, half milano structures and full milano structures, etc. Since the second portion 134 and the first portion 132 can each use two needle beds of the knitting machine separately, the double-sided plain structure of the second portion 134 and the double-sided plain structure of the first portion 132 can be coextensive in the upper 102. Advantageously, since the two portions can have a double-sided plain structure (which can be coextensive), the upper 102 has an enhanced ability to provide knit-in visual features and / or functional features for the first portion 132 and / or the second portion 134.

[0064] In some embodiments, a connecting structure 140 can connect and secure the first portion 132 to the second portion 134, and the connecting structure 140 can include one or more rows of at least one loop or other knitted structure formed by one or more passes of a feeder of a knitting machine. The connecting structure 140 can extend along the tongue 126 and generally around the collar 118, as shown (see also Figure 6 ), but in other embodiments, the connecting structure 140 can be limited to the tongue 126 (or a portion of the tongue 126), the collar 118 (or a portion of the collar 118), or any combination thereof. It is also contemplated that the connecting structure 140 can be included in locations other than the tongue 126 and the collar 118 (e.g., Figure 1 14). The first portion 132 can extend from the connecting structure 140 to a first midfoot region 146 of the first portion 132 and to a first toe region 142 of the first portion 132. In some embodiments, the first portion 132 can terminate at an end 148 of the first toe region 142. Similarly, the second portion 134 can extend from the connecting structure 140 in the opposite direction to a second midfoot region 150 and to a second toe region 144. In some embodiments, the second portion 134 can terminate at an end 152 of the second toe region 144.

[0065] After the knitting process, first portion 132 and / or second portion 134 may be folded or otherwise manipulated so that first portion 132 forms exterior surface 136 of upper 102 and second portion 134 forms interior surface 138 of upper 102 (or vice versa), respectively. Figure 4-Figure 5 Still refer to Figure 2 , when upper 102 is folded or otherwise manipulated into its wearable shape, second toe region 144 of second portion 134 may be manipulated so that it is adjacent to and / or coextensive with first toe region 142 of first portion 132. Thus, when upper 102 is in its wearable shape, both first toe region 142 and second toe region 144 may be located in toe region 124 ( Figure 1 ). Additionally, when upper 102 is folded or otherwise manipulated into its wearable shape, one of first portion 132 and second portion 134 can be substantially flipped relative to the other such that first clearance surface 154 of first portion 132 (which can relatively face exterior surface 136) and second clearance surface 156 of second portion 134 (which can relatively face interior surface 138) face each other and become adjacent to each other.

[0066] Optionally, before or during the folding step, an adhesive or other attachment means may be applied to at least one of the first gap surface 154 and the second gap surface 156 so that the first gap surface 154 and the second gap surface 156 are substantially secured (e.g., fixed) together along at least a portion of their coextensive region, but without the need for an adhesive. In some embodiments, the first portion 132 and the second portion 134 may remain partially unsecured relative to each other at least in some locations (e.g., not attached along their coextensive portion in a particular region). Thus, the first portion 132 and the second portion 134 may remain movable (e.g., slidable) relative to each other, and a gap space may be located between the first portion 132 and the second portion 134. In addition to being secured via the knitted connection structure 140 (or as an alternative to being secured via the knitted connection structure 140), the first portion 132 and the second portion 134 may be secured (e.g., sewn or otherwise secured) along the bite line 110. In other embodiments, the first portion 132 and the second portion 134 may be indirectly secured via the sole structure (e.g., each independently secured to the sole structure). Figure 1 ) as shown in the sole structure 104 .

[0067] Optionally (and as described in more detail below), an insert or other object may be positioned between first portion 132 and second portion 134 to provide certain functional or visual features to upper 102. Advantageously, the insert may be substantially permanently located between portions of upper 102 such that the insert is substantially inaccessible to a user during typical use. Thus, the interstitial space may be useful for retaining certain components that are not intended for user access (e.g., electronic sensors or other electronic components, moisture-sensitive components (particularly when at least one of first portion 132 and second portion 134 is waterproof), foam or materials that may be harmful to humans or pets, etc.).

[0068] Figure 3 is a diagram used to form Figure 2 A diagram (“knitting diagram”) of an implementation scheme of a knitting process (e.g., a knitting sequence on a flat knitting machine) for a knitted component 130. Figure 3 The marker position corresponds to Figure 2 160. Each horizontal line 160 may represent a course, a number of courses, and / or other types of structures (e.g., inlays) formed on the knitting machine during a passage of the feeder. The knitting sequence may be performed in the direction depicted by arrow 162 such that the knitted component moves relative to the needle bed in a direction opposite to that depicted by arrow 162. The first portion 132 of the knitted component 130 may be knitted first, followed by the second portion 134, as shown (or vice versa).

[0069] The first toe region 142 of the first portion 132 may include a first course formed on the knitting machine (e.g., a course at the distal end 148 of the first toe region 142). Figure 3 146 of the first portion 132 and then approaching the connecting structure 140. As shown, the courses 160 that form the knitted component 130 may extend in both the medial-to-lateral and lateral-to-medial directions. At least a portion of the courses 160 may utilize two needle beds of the knitting machine (e.g., for forming a double jersey knit structure or another suitable structure utilizing two beds), but the knitted component may have certain areas where the courses are formed on only one bed. Figure 3 A particular knitting direction is not necessarily required, and it is contemplated that the course 160 may extend in another direction (e.g., a direction perpendicular to the depicted direction, a direction diagonal to the depicted direction, etc.). However, Figure 3 The knit direction may provide the ability to form the connecting structure 140 along a shaped, non-linear contour (eg, along the collar 118 and / or the tongue 126).

[0070] For example, the connecting structure 140 can be formed using a technique in which, when the pattern narrows, the knitting machine holds the outer loops on the needles of the needle bed for a certain number of rows until the pattern widens again. Figure 3 In a specific example, when the knitting machine reaches the heel area 122 of the collar 118 (on at least one of the medial side 108 and the lateral side 106), the needles used to form the loops of the collar 118 can continue to hold these loops during the knitting of the first tongue area 166 of the first portion 132 (e.g., without knitting other yarns). Similarly, as the first tongue area 166 narrows, the outer loops of the first tongue area 166 can be held as the knitting machine continues along the first tongue area 166 in the knitting direction. When the knitting machine reaches the second portion 134, the held loops can be reincorporated into a new row 160 as the second tongue area 168 widens. Similarly, when the collar 118 of the second portion 134 is formed, the held loops of the collar 118 of the first portion 132 can be reincorporated into a new row. The holding and reincorporation technique can form a connecting structure 140 that is not knitted together in the knitting direction. Figure 3 This is represented by small arrows indicating the retained and reincorporated coils.

[0071] The knitting machine may then continue knitting the second portion 134 by knitting the second midsole region 150 of the second portion 134 and then knitting the second toe region 144 of the second portion 134. The terminal end 174 of the second toe region 144 may be the last course formed on the knitting machine. Figure 3 It is depicted starting with a first portion 132 and ending with a second portion 134 .

[0072] Figure 4 1 is a diagram showing the knitted component 130 forming the upper 102 when folded or otherwise manipulated into a folded state. The second portion 134 ( Figure 2 ) may be coextensive with the first portion 132 and extend from Figure 4 134 is obscured from view by the first portion 132, as depicted. Advantageously, the second portion 134 can include one or more knitted or non-knitted functional features (as described in more detail below) that provide functional advantages to the upper 102 without sacrificing aesthetic appeal, particularly when the first portion 132 is configured to provide a pleasing aesthetic. However, it is contemplated that in other embodiments, the second portion 134 can have portions that extend beyond the coverage of the first portion 132 (e.g., when the first portion 132 and the second portion 134 have different shapes and / or when the upper 102 has certain portions formed by only one of the first portion 132 and the second portion 134). After folding, the upper can include a heel region 122 having a lateral heel region 176 and a medial heel region 178 that are configured to be secured together, and the collar 118 can be configured to wrap around the ankle opening 114.

[0073] As described above, first portion 132 may form outer surface 136 of upper 102. Therefore, it may be desirable to provide outer surface 136 with a specific knit structure and / or a specific material (e.g., yarn type) for suitable wear resistance to improve the durability of upper 102. Optionally, first portion 132 may have a relatively low elasticity when compared to second portion 134 to provide a shell-like structure for upper 102, to provide suitable strength, rigidity, and durability for upper 102, and / or to provide protection for the wearer's foot.

[0074] In addition, when the upper 102 is used in a footwear article, the outer surface 136 may be visible. Therefore, it may be desirable that the outer surface 136 includes one or more decorative elements 192. In some embodiments, the decorative element 192 may be formed by incorporating yarns of different colors or other visual effects in a specific pattern during the knitting process. The first portion 132 may advantageously be formed by rows utilizing two needle beds (e.g., two needle beds of a flat knitting machine), which may enhance the ability to include certain knitting features, which may include desirable visual effects. In addition, certain areas of the first portion 132, such as the first throat area 164, may include at least two separable layers, with a bag between the two separable layers, which may be formed by, for example, a tubular knitting structure or another suitable technology (which may be more easily implemented when using two needle beds). Advantageously, an insert may be placed in the bag. Additionally or alternatively, certain areas of the first portion 132 may have mechanical features different from other areas, which may also be easier and / or better implemented when two needle beds are available when forming the first portion 132. For example, in some embodiments, the throat area 112 of the first portion 132 can be more elastic than other areas of the first portion 132 (e.g., the medial side 108, the lateral side 106, the heel area 122, and / or the toe area 124), which can help to accommodate the foot within the cavity of the upper 102, provide a snug and comfortable fit of the upper 102, and / or provide proper connectivity with the fastening system while still providing the desired rigidity, durability, and support areas in the desired areas.

[0075] Optionally, the first portion 132 may include a window 180 to allow an observer to view the Figure 4 180. Window 180 may be visually pleasing by allowing an observer to see a color contrast or other visual contrast between the window-exposed areas of first portion 132 and second portion 134. It is contemplated that if first portion 132 moves relative to second portion 134 when the article of footwear is in use (e.g., when the wearer walks or otherwise performs an activity that displaces first portion 132 relative to second portion 134 at window 180), then window 180 may provide a dynamic visual effect. Window 180 may have any suitable structure, and in some specific embodiments, window 180 may incorporate a monofilament line, as described in U.S. Patent Application 14 / 026,531, filed on September 13, 2013 and published as US2015 / 0075031, which is incorporated herein by reference in its entirety.

[0076] The first portion 132 may additionally or alternatively incorporate functional elements (including reference Figure 5Any functional elements described with respect to the second portion 134). For example, the first portion 132 may incorporate cushioning elements in the first throat area 164, the collar 118, and / or the tongue 126, as shown. In some embodiments, the cushioning element may be provided by a bulking yarn, which may be inlaid and / or floated within the first portion 132, particularly when two needle beds are used when forming the first portion 132 (which may facilitate the inlay process). Bulking yarns are described in U.S. Provisional Patent Application No. 62 / 355,153 filed on June 27, 2016, which is incorporated herein by reference in its entirety. Bulking yarns may additionally or alternatively be included in the second portion 134.

[0077] Figure 5 It is shown Figure 2 A bottom view of a knitted component when folded or otherwise manipulated into a folded state. The first portion 132 (at Figure 2 and Figure 4 ) may be coextensive with the second portion 134 and extend from Figure 4 134 is blocked from view by the second portion 134 from the bottom view, as depicted. However, it is contemplated that in other embodiments, the first portion 132 may have an area that extends beyond the coverage of the second portion 134 (e.g., when the first portion 132 and the second portion 134 have different shapes and / or when the upper 102 has certain portions formed by only one of the first portion 132 and the second portion 134). As described above, after folding, the upper may include the heel region 122 having the lateral heel region 176 and the medial heel region 178 that are configured to be secured together, and the collar 118 may be configured to wrap around the ankle opening 114 to form the collar 118 (as shown in reference Figure 6 described).

[0078] The second portion 134 can form an inner surface 138, which can face and / or define a cavity when the upper 102 is incorporated into an article of footwear. Therefore, although the second portion 134 may include any or all of the features described above with respect to the first portion 132, it may be particularly desirable that the second portion 134 includes a material and / or knitted structure suitable for contacting the wearer's foot (or socks). For example, the second portion 134 can be generally formed by polyester yarn, which can impart to the second portion 134 features that are particularly suitable for contacting the foot and are related to comfort. In addition, the second portion 134 can be formed by a specific material and / or knitted structure, making it more elastic than the first portion, thereby providing the wearer with a desirable retention and snug-feeling fit. Like the first portion 132, the second portion 134 can include different regions with different mechanical properties (e.g., different elasticities).

[0079] The second portion 134 may additionally or optionally incorporate other functional elements, such as a stretch line 182. The stretch line 182 may be embedded in the knitted structure of the knitted component 130 and may be configured (e.g., with suitable rigidity and tensile strength) to provide additional support and stability in the medial to lateral direction, particularly when connected to a fastening system (e.g., shoelaces). The stretch line 182 may form a coil 184 (which may surround and / or form a shoelace eyelet) in the shoe throat region, which is configured to receive a fastening system, as shown. Some embodiments of the stretch line 182 that may be used are described in U.S. Patent Application Publication No. 2015 / 0359290, U.S. Patent Application Publication No. 2014 / 0237861, and U.S. Patent No. 9,145,629, which are incorporated herein by reference in their entirety.

[0080] In addition, the second portion 134 may optionally include at least one pocket 186 for receiving an insert 188. The pocket 186 may be formed by utilizing a tubular knit structure or another suitable knit structure to provide two separable layers when forming the second portion 134. The insert 188 may then be permanently or temporarily placed within the pocket 186 to provide cushioning, rigidity, protection, durability, etc. The first portion 132 described above may also (or alternatively) include a pocket and an insert.

[0081] Advantageously, because second portion 134 may be hidden from typical view by first portion 132 when upper 102 is in use, second portion 134 may incorporate one or more functional characteristics or features without regard to their impact on the visual appeal of upper 102. For example, if a particular insert / pocket combination or other element is generally negatively received from an aesthetic standpoint, that element may be at least partially hidden from view by first portion 132 of knitted component.

[0082] Figure 6 is a diagram showing knitted component 130 of upper 102 being folded or otherwise manipulated into a wearable shape, and Figure 7 The manipulated upper 102 is shown secured to the sole structure 104. Figure 6-Figure 7 134. As shown in FIG. 13 , an outer surface 136 formed by the first portion 132 can face outward, and an inner surface 138 formed by the second portion 134 can face inward. A connecting structure 140 connecting the first portion 132 to the second portion 134 can extend at least partially around the collar 118 and / or along the tongue 126. The lateral heel region 176 and the medial heel region 178 can be joined at this step to form a seam 190 in the heel region 122. Connecting the lateral heel region 176 to the medial heel region 178 at the seam 190 can include sewing, adhesive bonding, heat bonding, welding, using a mechanical clamp, or any other suitable device or method, and it is contemplated that another device can be placed between the medial heel region 178 and the lateral heel region 176. The folding / manipulating step and / or the step of forming the seam 190 can be performed at least partially while the upper 102 is on the last. Examples of shoe lasts and related lasting processes are described in US Patent Application Serial No. 12 / 848,352, filed on August 2, 2010, and issued as US Patent No. 8,595,878, which is incorporated herein by reference in its entirety. Figure 7 The manufacturing process is depicted in which upper 102 is secured to sole structure 104 to complete (or substantially complete) article of footwear 100 .

[0083] Figure 8 It is shown Figure 2 1 and 10. An illustration of upper 102 of FIG. 1 when incorporated into article of footwear 100 with hidden elements shown in phantom. As depicted, upper 102 may include certain functional elements, such as stretch lines 182, pockets 186 with inserts 188, fused areas of thermoplastic polymer material, and / or any other suitable functional elements. However, as shown in FIG. Fig. 9As shown in , the functional element can be hidden from view when needed. The article of footwear may include decorative element 192 for enhancing the visual appearance of the article of footwear. This embodiment is particularly advantageous because at least one and potentially both of the first portion 132 and the second portion 134 of the knitted component 130 can be formed with the full capability of the two needle beds of the knitting machine to provide such functional and decorative features, which can be achieved due to the unique shape of the knitted component as described herein.

[0084] like Figure 8-Figure 9 , it is contemplated that the stretch cord 182, if included, may extend from the outer surface 136 so that they are visible when the article of footwear 100 is in use. Advantageously, the coil 184 may be accessible by a user and / or communicate with a fastening system positioned adjacent the outer surface 136. A slot 196 may be included in the first portion 132 for receiving the coil 184 of the stretch cord 182, as shown. The coil 184 may communicate with (e.g., surround) the optional aperture 128.

[0085] In the present disclosure, the scope given in absolute terms or approximate terms is intended to cover both, and any definition used herein is intended to be illustrative and not restrictive. Although the numerical range and parameter setting forth the wide range of the present embodiment are approximate values, the numerical value set forth in the specific examples is reported as accurately as possible. However, any numerical value inherently contains certain errors that are inevitably caused by the standard deviation present in its corresponding test measurement. In addition, the full range disclosed herein should be understood to cover any and all subranges (including all fractional values ​​and integer values) included herein.

[0086] In addition, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present disclosure and without reducing its expected advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims

1. A shoe upper, comprising: a first knitted portion configured to form an outer surface of the upper; a second knitted portion configured to form an inner surface of the upper; a gap space between the first knitted portion and the second knitted portion; as well as a knitted connection structure connecting the first knitted portion to the second knitted portion, wherein the knitted connection structure is configured so that one of the first knitted portion and the second knitted portion is flipped relative to the other about the knitted connection structure to place the upper in a folded state in which the second knitted portion is at least partially coextensive with the first knitted portion; and The upper further includes a lateral heel area and a medial heel area connected at a heel seam.

2. The upper according to claim 1, wherein the first knitted portion includes a first plurality of rows, wherein the second knitted portion includes a second plurality of rows, and wherein the knitted connecting structure is located between the first plurality of rows and the second plurality of rows relative to the knitting direction.

3. The upper of claim 2, wherein at least one course of the first plurality of courses and at least one course of the second plurality of courses each comprise a double jersey knit structure. 4 . The upper of claim 1 , wherein the first knitted portion is secured to the second knitted portion at least partially along a bite line of the upper.

5. The upper of claim 1, wherein the first knitted portion includes a window, and wherein an area of ​​the second knitted portion is visible through the window.

6. The upper of claim 1, wherein at least one of the first knitted portion and the second knitted portion includes an inlaid bulked yarn configured to provide cushioning to the upper.

7. The upper of claim 1, wherein at least one of the first knitted portion and the second knitted portion includes at least one inlaid stretch strand.

8. The upper of claim 1, wherein at least one of the first knitted portion and the second knitted portion comprises a tubular knitted structure forming a pocket.

9. An upper for an article of footwear, the upper comprising: a first knitted portion, the first knitted portion forming an outer surface of the upper; a second knitted portion, the second knitted portion forming an inner surface of the upper; as well as a connecting structure that secures the first knitted portion to the second knitted portion, wherein the connecting structure is configured so that one of the first knitted portion and the second knitted portion is flipped relative to the other about the connecting structure to place the upper in a folded state in which the second knitted portion is at least partially coextensive with the first knitted portion; and The upper further includes a lateral heel area and a medial heel area connected at a heel seam.

10. The upper according to claim 9, wherein the first knitted portion includes a first plurality of courses, wherein the second knitted portion includes a second plurality of courses, and wherein the connecting structure is located between the first plurality of courses and the second plurality of courses relative to the knitting direction.

11. The upper of claim 10, wherein at least one course of the first plurality of courses and at least one course of the second plurality of courses comprises a double jersey knit structure.

12. The upper of claim 9, wherein the connecting structure extends at least partially around a collar of the upper.

13. A method of forming a shoe upper, the method comprising: knitting a first knitted portion, the first knitted portion being configured to form an outer surface of the upper; knitting a second knitted portion, the second knitted portion being configured to form an inner surface facing a cavity formed by the upper; a knitted connecting structure connecting the first knitted portion to the second knitted portion; as well as flipping at least one of the first knitted portion and the second knitted portion during the folding step; Wherein when folded, the upper further comprises a lateral heel region and a medial heel region, and wherein the method further comprises securing the lateral heel region to the medial heel region at a seam.

14. The method of claim 13, wherein the connecting structure extends along a tongue of the upper and along a collar of the upper.

15. The method of claim 13, further comprising inlaying a stretch thread in at least one of the first knitted portion and the second knitted portion.

16. The method of claim 13, wherein at least one of the first knitted portion and the second knitted portion comprises a tubular knitted structure forming a pocket for receiving an insert.

17. A knitted component for use in a heel region of an upper of an article of footwear, comprising: a first knitted portion, the first knitted portion forming part of an outer surface of the upper, The first knitted portion comprises a double jersey knit structure, and The first knitted portion includes an inlaid bulked yarn; a second knitted portion, the second knitted portion forming a portion of an inner surface of the upper; a gap space between the first knitted portion and the second knitted portion; as well as a knitted connection structure connecting the first knitted portion to the second knitted portion, wherein the knitted connection structure is configured so that one of the first knitted portion and the second knitted portion is flipped relative to the other about the knitted connection structure to place the upper in a folded state in which the second knitted portion is at least partially coextensive with the first knitted portion; and The upper further includes a lateral heel area and a medial heel area connected at a heel seam.

18. A knitted component according to claim 17, wherein the first knitted portion includes a first plurality of rows, wherein the second knitted portion includes a second plurality of rows, and wherein the knitted connecting structure is located between the first plurality of rows and the second plurality of rows relative to the knitting direction.

19. The knitted component of claim 18, wherein at least one course of the first plurality of courses and at least one course of the second plurality of courses comprises a double jersey knit construction.

20. The knitted component according to claim 17, wherein the knitted component forms a lateral side and a medial side of the upper.

21. The knitted component of claim 17, wherein the knitted component is formed as an integral, one-piece element.

22. The knitted component according to claim 18, wherein the knit connecting structure extends along an ankle collar of the upper.

23. The knitted component of claim 17, wherein at least one of the first knitted portion and the second knitted portion comprises an inlaid stretch strand.

24. An upper for an article of footwear, the upper comprising a knitted component forming a heel area of ​​the upper, the upper comprising: a first knitted portion, the first knitted portion forming an outer surface of the upper, the first knitted portion comprising a double-sided plain knitted structure, a second knitted portion, the second knitted portion forming an inner surface of the upper, wherein the first knitted portion and / or the second knitted portion comprises an inlaid bulked yarn; a gap space between the first knitted portion and the second knitted portion, and a knitted connection structure connecting the first knitted portion to the second knitted portion, wherein the knitted connection structure is configured so that one of the first knitted portion and the second knitted portion is flipped relative to the other about the knitted connection structure to place the upper in a folded state in which the second knitted portion is at least partially coextensive with the first knitted portion; and The upper further includes a lateral heel area and a medial heel area connected at a heel seam.

25. The upper according to claim 24, wherein the first knitted portion includes a first plurality of courses, wherein the second knitted portion includes a second plurality of courses, and wherein the knitted connecting structure is located between the first plurality of courses and the second plurality of courses relative to the knitting direction.

26. The upper of claim 25, wherein at least one course of the first plurality of courses and at least one course of the second plurality of courses comprises a double jersey knit construction.

27. The upper of claim 24, wherein the knitted component forms a lateral side and a medial side of the upper.

28. The upper of claim 24, wherein the knitted component is formed as a unitary, one-piece element.

29. The upper of claim 25, wherein the knit connection structure extends along an ankle collar of the upper.

30. The upper of claim 24, wherein at least one of the first knitted portion and the second knitted portion includes an inlaid stretch strand.

31. An article of footwear having an upper formed from a knitted component, the knitted component extending into a heel region of the upper, the article of footwear comprising: a first knitted portion, the first knitted portion forming an outer surface of the upper, The first knitted portion comprises a double jersey knit structure, and The first knitted portion includes an inlaid bulked yarn; a second knitted portion, the second knitted portion forming an inner surface of the upper; a gap space between the first knitted portion and the second knitted portion; as well as a knitted connection structure connecting the first knitted portion to the second knitted portion, wherein the knitted connection structure is configured so that one of the first knitted portion and the second knitted portion is flipped relative to the other about the knitted connection structure to place the upper in a folded state in which the second knitted portion is at least partially coextensive with the first knitted portion; and The upper further includes a lateral heel area and a medial heel area connected at a heel seam.

32. The article of footwear according to claim 31, wherein the knitted component is formed as an integral, one-piece element.

33. The article of footwear according to claim 32, wherein the knit connection structure extends along an ankle collar of the upper.

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