Knitted tensile structure

Abstract

The present application relates to a knitted tensile structure. A knitted component may include a knitted-in tensile zone that may include an opening at least partially defined by a first intersection portion and a second intersection portion. A course of tensile material knitted integrally with the first intersection portion via knitted loops may include a float extending from the first intersection portion across the opening to the second intersection portion.

Description

[0001] This application is a divisional application of an application filed on January 18, 2019, with application number 201980007948.0 and invention name “Knitted tensile structure”. background

[0002] The present embodiments generally relate to knitted components and methods of making knitted components, such as knitted components for use in apparel and footwear applications.

[0003] Overview

[0004] The knitted component may include a knit-in tensile area, which may include an opening at least partially defined by a first intersection portion and a second intersection portion. The row of tensile material knitted integrally with the first intersection portion via a knitted loop may include a float having a float length extending from the first intersection portion across the opening to the second intersection portion. The float length may be the distance of at least three needles. The row of tensile material may have a diameter of at least 0.8 mm and a tensile strength of at least 25 kg-f, and may be knitted integrally with the second intersection portion via a second knitted loop. The knitted component may also include a second row of tensile material knitted integrally with the first intersection portion, and the second row of tensile material may include a second float, which extends from the first intersection portion across the opening to the second intersection portion. The row of tensile material may include a second float having a second float length. The opening may have a shape including a triangle, a square, a rectangle, a pentagon, an ellipse, or a circle. The first intersection portion may conceal the knitted loops of the course of tensile material from the perspective of the first surface facing the first intersection portion.

[0005] In another aspect, the upper may include a first woven-in tensile zone including a row of tensile material extending across a plurality of openings, each opening being at least partially defined by a plurality of intersection portions and a plurality of arterial portions. The row of tensile material may be knitted integrally with each of the plurality of intersection portions via one or more knitted loops and may include a plurality of floats (each having a float length), each of the floats extending across one of the plurality of openings. The row of tensile material may have an orientation in a medial-lateral direction and may extend from a lateral edge region to a medial edge region. The row of tensile material may extend in a weft direction of the woven-in tensile zone. The upper may also include a second woven-in tensile zone including a second plurality of openings and a second row of tensile material, and the second woven-in tensile zone may be located in a different region of the upper than the first woven-in tensile zone. The first woven-in tensile zone may be located in a mid-shoe region, and the second woven-in tensile zone may be located in a rear-shoe region. The second row of tensile material may have a different orientation than the row of tensile material.Each of the plurality of openings may have a first shape and a first size, and each of the second plurality of openings may have a second shape and a second size.

[0006] In another aspect, a knitting method may include knitting a first course of a multi-bed knitting structure on a first needle bed and a second needle bed, transferring a first plurality of loops of the first course of the multi-bed knitting structure to different needles to widen an opening, knitting a course of a tensile material including at least one loop interlooped with the multi-bed knitting structure and a float across the opening, knitting a second course of the multi-bed knitting structure on the first needle bed and the second needle bed, and transferring a second plurality of loops of the second course of the multi-bed knitting structure to different needles to narrow the opening. The float may have a float length of at least three needles, and the multi-bed knitting structure may have a tubular knitting structure.

[0007] This application also provides the following:

[0008] 1). A knitted component, comprising:

[0009] Woven into tensile zones, including:

[0010] an opening at least partially defined by the first intersection portion and the second intersection portion; and

[0011] A course of tensile material is knitted integrally with the first cross-point portion via knitted loops, the course of tensile material comprising a float having a float length and extending from the first cross-point portion across the opening to the second cross-point portion.

[0012] 2). The knitted component of 1), wherein the rows of tensile material have a diameter of at least 0.8 mm and a tensile strength of at least 25 kg-f.

[0013] 3) The knitted component according to 1), wherein the course of the tensile material is knitted integrally with the second intersection portion via a second knitted loop.

[0014] 4). The knitted component as described in 1) further includes a second row of tensile material, wherein the second row of tensile material is knitted integrally with the first intersection portion and includes a second float thread, and the second float thread extends from the first intersection portion across the opening to the second intersection portion.

[0015] 5). The knitted component of 1), wherein the rows of tensile material include second floats having a second float length.

[0016] 6). The knitted component as described in 1), wherein the length of the floating thread is the distance of at least three needles.

[0017] 7). The knitted component as described in 1), wherein the opening has a shape including a triangle, a square, a rectangle, a pentagon, an oval or a circle.

[0018] 8). The knitted component as described in 1),

[0019] Wherein, from the perspective of the first surface facing the first intersection portion, the first intersection portion conceals the knitted loops of the row of tensile material.

[0020] 9) A shoe upper, comprising:

[0021] The first woven-in tensile zone includes:

[0022] a row of tensile material extending across a plurality of openings, each opening being at least partially defined by a plurality of intersection portions and a plurality of roadway portions;

[0023] The course of tensile material is knitted integrally with each of the plurality of cross-point portions via one or more knitted loops and includes a plurality of floats that extend across one of the plurality of openings, respectively;

[0024] Each of the float lines has a float line length.

[0025] 10). The upper of 9), wherein the rows of tensile material have an orientation in the medial-lateral direction.

[0026] 11). The upper as described in 9), wherein the horizontal row of tensile material extends from the lateral edge area to the medial edge area.

[0027] 12). An upper as described in 9), wherein the horizontal rows of tensile material extend in the weft direction of the woven tensile zone.

[0028] 13). The upper as described in 9) further includes a second woven anti-tensile zone, which includes a second plurality of openings and a second horizontal row of tensile material, wherein the second woven anti-tensile zone is located in a different area of ​​the upper than the first woven anti-tensile zone.

[0029] 14) The shoe upper as described in 13), wherein the first woven-in tensile zone is located in the mid-shoe area, and the second woven-in tensile zone is located in the rear-shoe area.

[0030] 15). The upper of 13), wherein the second row of the tensile material has a different orientation than the row of the tensile material.

[0031] 16). The upper as described in 13),

[0032] wherein each of the plurality of openings has a first shape,

[0033] Wherein each of the second plurality of openings has a second shape.

[0034] 17). The upper as described in 13),

[0035] wherein each of the plurality of openings has a first size,

[0036] Wherein each of the second plurality of openings has a second size.

[0037] 18) A knitting method, comprising:

[0038] knitting a first row of the multi-bed knitting structure on the first needle bed and the second needle bed;

[0039] transferring a first plurality of stitches of the first course of the multi-bed knit structure to different needles to widen the opening;

[0040] a course of knitted tensile material including at least one loop interlooped with said multi-bed knit structure and a float across said opening;

[0041] knitting a second course of the multi-bed knitting structure on the first needle bed and the second needle bed; and

[0042] Transferring a second plurality of stitches of the second course of the multi-bed knit structure to a different needle to narrow the opening.

[0043] 19). The knitting method as described in 18), wherein the floating thread has a floating thread length of at least three needles.

[0044] 20). The knitting method as described in 18), wherein the multi-bed knitting structure has a tubular knitting structure.

[0045] Other systems, methods, features and advantages of the present disclosure will be or will become apparent to one skilled in the art upon review of the following drawings and detailed description. It is intended that all such additional systems, methods, features and advantages are within the scope of the present disclosure and are encompassed by the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] The present disclosure may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily to scale, but rather emphasis is placed on illustrating the principles of the present disclosure. In addition, in the drawings, like reference numerals represent corresponding parts throughout the different views.

[0047] Figure 1 is a cross-sectional view of a knitted component according to one aspect of the present disclosure.

[0048] Figure 2 It shows Figure 1 An enlarged cross-sectional view of another aspect of the knitted component.

[0049] Figure 3 It shows Figure 1 A cross-sectional view of another aspect of the knitted component.

[0050] Figure 4 is a cross-sectional view of another knitted component according to another aspect of the present disclosure.

[0051] Figure 5 is an enlarged cross-sectional view showing another knitted component according to another aspect of the present disclosure.

[0052] Figure 6 is a cross-sectional view of an upper according to one aspect of the present disclosure.

[0053] Figure 7 is a perspective view of an article of footwear according to one aspect of the present disclosure.

[0054] Figure 8 is a knitting pattern according to one aspect of the present disclosure.

[0055] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0056] refer to Figures 1 to 3The knitted component 10 is suitable for many applications, such as footwear and clothing, and the knitted component 10 can be formed as an integral one-piece element by a single knitting process such as a weft knitting process (e.g., with a knitting machine having one, two or more needle beds, or with a circular knitting machine), a warp knitting process, or any other suitable knitting process. The knitted component 10 can have an integral knitting construction because it can be formed via a knitting process without requiring significant post-knitting processes or steps. Alternatively, two or more parts of the knitted component 10 can be formed separately as separate multiple integral one-piece elements, and then these separate elements can be attached. In all of the above cases, the resulting knitted component can be formed via an integral knitting construction.

[0057] The knitted component 10 may include at least a first layer 12 and a second layer 14. The first layer 12 and the second layer 14 may be formed on one or more needle beds (e.g., a first needle bed and / or a second needle bed) of a knitting machine. When the first layer 12 is formed on a needle bed different from the second layer 14, or when any of the first layer 12 or the second layer 14 is formed on more than one needle bed, the resulting knitted component 10 has a multi-bed knitting structure. As used in the present application, the first layer 12 may form a first surface 16 including a first plurality of knitted coils, and the second layer 14 may form a second surface 18 including a second plurality of knitted coils. The first layer 12 may overlap at least a portion of the second layer 14, and the first layer 12 and the second layer 14 may be coterminous in one or more dimensions, but not necessarily connected. In some regions, the first layer 12 may be freely separable from the second layer 14. In other words, the first layer 12 and the second layer 14 may have inner surfaces facing each other. Although the first layer 12 may be freely separable from the second layer 14 in certain areas, it is not necessarily freely separable. For example, the knitted component 10 may include one or more interlayer knitting traces (e.g., loops formed between a first needle bed and a second needle bed on a weft knitting machine) connecting the first layer 12 and the second layer 14. Such interlayer knitting traces may be formed from the same yarn as the yarn forming the first layer 12 and / or the second layer 14, or from a different yarn (such as a tensile material, as discussed above). A single row of material may form both the first layer 12 and the second layer 14, for example, a knitted structure formed on both the first needle bed and the second needle bed, which includes a first plurality of knitting loops on the surface of the first layer 12 and a second plurality of loops on the surface of the second layer 14. Alternatively, different rows of material may form the first layer 12 and the second layer 14, for example, the first row forming a single jersey layer on the first needle bed and the second row forming another single jersey layer on the second needle bed.

[0058] Knitted component 10 can include additional layers, for example, to increase cushioning, protection or for obtaining other advantages. In various applications, first layer 12 or second layer 14 can correspond to the outer layer or inner layer of an article of clothing, and the outer layer or inner layer of the upper of an article of footwear, or other applications.

[0059] Depending on the application, the first layer 12 and the second layer 14 can be knitted from the same or different materials, and each layer can be knitted from one or more materials. For example, the first layer 12 can be partially or completely knitted from a material selected to have durability, such as a material having relatively high wear resistance and toughness. As another example, the second layer 14 can be knitted from a material selected to have a soft feel.

[0060] Still reference Figures 1 to 3 , the knitted component 10 may include one or more woven-in tensile zones 20, which may be located at positions where it is desired to limit stretch, improve ventilation, allow visibility through the knitted component 10, and / or provide additional technical properties. For example, the knitted component 10 may be incorporated into an article of footwear, and the woven-in tensile zones 20 may be positioned at positions where it is desired to limit movement of the wearer's foot in the medial and / or lateral directions. As another example, the knitted component 10 may be incorporated into a shirt, pants, or other clothing, and the woven-in tensile zones 20 may be positioned at positions where it is desired to improve ventilation. As yet another example, the knitted component 10 may be incorporated into an industrial textile, and the woven-in tensile zones 20 may be positioned at positions where it is desired to have relatively high strength, minimal stretch, and relatively high permeability.

[0061] The knitted-in tensile zone 20 may include portions of the first layer 12 and the second layer 14, and also include one or more rows 22 of tensile material that are integrally knitted into the first layer 12 and / or the second layer 14. Suitable tensile materials include yarns formed from low-stretch / low-elastic materials having relatively high tensile strength (e.g., at least about 25 kg-f) and high tenacity, such as cables, strands, and ropes having a diameter of at least 0.5 mm (e.g., 0.8 mm or 0.5 mm-2.0 mm). Other suitable tensile materials may include strands or fibers having a low elastic modulus and high tensile strength, such as strands of monofilament material, or SPECTRA manufactured by Honeywell International Inc. (Morristown, New Jersey). TMFibers of fibers. Other suitable tensile materials can include various filaments, fibers and yarns formed by rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramid (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene and liquid crystal polymers. As a non-limiting example, the tensile material can be a sheathed polyester cable of 1.0 mm diameter having a minimum tensile strength of 30 kg-f and a maximum elongation of less than about 50%. The selection of tensile materials can also be affected by knitting machine factors. For example, the tensile material can have a diameter small enough to allow periodic interlooping with the first layer 12 and / or the second layer 14 without damaging the knitting machine, for example, interlooping every three needles, four needles, five needles, six needles, seven needles, eight needles or more needles on the needle bed. Typically, the tensile material can have the same or different visual properties as other materials forming the knitted component. By utilizing a tensile material having at least one different visual property, such as a contrasting color or texture, the knitted component can provide an attractive appearance.

[0062] Each course 22 of tensile material may include a single yarn or strand, or may include multiple yarns or strands of tensile material. For example, a course 22 of tensile material may include a single 1.0 mm diameter sheathed polyester cable, or alternatively may include multiple smaller diameter strands of tensile material, for example, each strand having a different color for visual effect, or each strand having a different material composition.

[0063] Still reference Figures 1 to 3 , the knitted tensile zone 20 may include one or more tensile structures 24, each of which may include a plurality of intersection portions 26a-26d and a plurality of road portions 28a-28d surrounding an opening 30. Each tensile structure 24 also includes at least one row 22 of tensile material that extends across the opening 30 and is interlocked with at least one of the intersection portions 26a-26d. Each intersection portion 26a-26d is present at the junction of the road portions 28a-28d. The opening 30 may extend through the knitted component 10. The row 22 of tensile material includes a float 32 that spans the opening 30 between adjacent intersection portions 26b, 26d. In other embodiments, the float of the tensile material does not need to span the maximum dimension of the opening to span the opening, and in other embodiments, multiple rows of tensile material may span the opening.

[0064] The course 22 of tensile material is integrally knitted into the knitted component 10, for example, as a result of the knitting process, by one or more knitted loops inter-looping at least one of the cross-point portions 26a-26d. The inter-looping of the course 22 of tensile material can be contrasted with a lining process that does not inter-loop the inlaid course with the knitted component. Integrally knitting the course 22 of tensile material into the knitted component 10 advantageously secures it within the knitted component 10; otherwise, for example, due to tension, the course 22 of tensile material may translate relative to the knitted component 10 in the course direction. However, in the knitted component 10, the course 22 of tensile material can include a first loop 34 inter-looping the cross-point portion 26b, and an optional second loop 36 inter-looping the cross-point portion 26d. In other embodiments, the course 22 of tensile material can include additional loops inter-looping each cross-point portion. For example, in other embodiments, each course of tensile material can include two, three, or more numbers of loops inter-looping each cross-point portion. As another example, in other embodiments, each course of tensile material can be interlooped with every other intersection portion through which it passes. In general, the course of tensile material can be integrally knitted with any aspect of the intersection portion (e.g., portions of the first layer and / or the second layer that form the intersection portion). Depending on how the course of tensile material is integrally knitted into the knitted component, the intersection portion can hide one or more loops of the course of tensile material from one or more viewpoints. For example, in Figures 1 to 3 In an embodiment of the present invention, the first stitch 34 of the course 22 is knitted into the first layer 12; therefore, the first stitch 34 can be substantially or completely hidden from a viewpoint where the second layer 14 is visible. In contrast, the stitch 38 is knitted into the second layer 14, and therefore, the stitch 38 can be substantially hidden from another viewpoint where the first layer 12 is visible.

[0065] Still reference Figures 1 to 3 , the rows 22 of tensile material include floats 32 that span across the openings 30. Generally, each row of tensile material can include one or more floats that span across one or more openings. Advantageously, the floats 32 can contribute to the stretch resistance in the direction of the rows 22 of tensile material and can also prevent objects from passing through the openings 30 while maintaining the breathability of the knitted component 10. The floats 32 are straight across the openings 30 (e.g., taut); although in other embodiments (such as in Figure 5In the case of a knitted component, a float may not be straight (e.g., may have slack). In general, a straight float may increase the stretch resistance of the knitted component because it limits mechanical stretch (compared to a knitted loop or a float with slack, which may allow for mechanical stretch, i.e., straightening of the course due to applied tension). The distance between adjacent loops along the float may define a float length, which may be consistent with the distance between adjacent crossover portions along the float. For example, in Figure 1 to Figure 2 , the float line 32 has a float line length equal to the distance between the first coil 34 and the second coil 36 along the float line 32, which is approximately consistent with the distance between the cross-point portions 26b, 26d along the float line 32.

[0066] Due to its potentially higher stiffness and larger diameter relative to other materials that may form the knitted component, the tensile material may be relatively more difficult to knit on a knitting machine than other materials. For example, the course 22 of the tensile material may be more difficult to knit than the material used to form the first layer 12 and the second layer 14. To mitigate these challenges and facilitate knitting the tensile material, the float length of each course of the tensile material may range from a small number of floated needles (e.g., two to three needles) to a larger number of floated needles (e.g., five to ten needles). In a knitting machine such as Figures 1 to 3 In embodiments where each row of tensile material (such as row 22) includes multiple floats (i.e., the same row of tensile material extends across more than one opening), each float may have the same or different float lengths, for example, to adjust the stretch-resistance of the woven tensile zone at a particular location along the row of tensile material.

[0067] In some embodiments, a second float (e.g., a float of a non-tensile material that forms part of the first layer or the second layer, or a float of a tensile material) may also be knitted integrally with one or more crossover portions and across the opening. From some perspectives, the float of the tensile material may obscure the second float of the non-tensile material. The second float may further contribute to the stretch resistance of the knitted component. In other embodiments (e.g., Figure 4 In the embodiment of the present invention, multiple rows of tensile material can span each opening between adjacent intersection portions, and one or more of the multiple rows of tensile material can be knitted into one or two of the adjacent intersection portions. Additional rows of tensile material can contribute to greater stretch resistance.

[0068] exist Figures 1 to 3In the embodiment of the present invention, the road sections 28a-28d connect adjacent intersection sections 26a-26d. Each road section 28a-28d generally has an elongated shape, although the length of each road section 28a-28d can vary significantly between and within embodiments. For example, Figure 2 The road portions 28a-28d have a relatively short length because the intersection portions 26a-26d are relatively large. In other embodiments, and even in the same embodiment, the lengths of the road portions may be different. For example, the knitted component may include a first woven-in tensile zone that includes a road portion having a relatively short first length, and a second woven-in tensile zone that includes a road portion having a longer second length. As the length of the road portion increases, the size of the openings in the woven-in tensile zone also tends to increase, thereby facilitating better breathability and visibility through the knitted component. Other embodiments may include road portions having more than one length.

[0069] Typically, road sections can intersect each other at various angles. Figure 1 to Figure 2 In the embodiment, the road portions 28f, 28g can form an internal angle of about 100 degrees, while the road portions 28e, 28f form an internal angle of about 40 degrees. In other embodiments, the intersection portion can form an angle ranging from about 30 degrees up to about 150 degrees, such as 40 degrees, 50 degrees, 60 degrees, 70 degrees, 110 degrees, 120 degrees, or 130 degrees. Still referring to Figures 1 to 3 , each roadway portion 28a-28d may include yarns of the first layer 12 and the second layer 14 formed into knitted loops. In other embodiments, the roadway portions may appear to include no knitted loops, but rather to be taut yarns formed due to the tension applied by the knitting process. Figures 1 to 3 The roadway portions 28a-28d are free of tensile material, but in other embodiments, the roadway portions may include one or more integrally knitted rows of tensile material.

[0070] Still reference Figures 1 to 3 , each cross-point portion 26a-26d may include yarns of the first layer 12 and the second layer 14, and may have a multi-bed knit construction. In each cross-point portion 26a-26d, the first layer 12 may be primarily visible from the first viewpoint 41, and the second layer 14 may be primarily visible from the second viewpoint 42. The cross-point portions 26b, 26d generally conceal the loops 34, 36 of tensile material from the second viewpoint 42 (from which the second layer 14 is visible) because the loops 34, 36 are knitted into the first layer 12. However, the cross-point portion 26c generally conceals the loop 38 from the first viewpoint 41 (from which the first layer 12 is visible).

[0071] Each intersection section can be different in appearance, size and structure. Figures 1 to 3 In the embodiment of the present invention, each intersection portion (e.g., 26a-26d) can have an elongated mesh structure having a width w exceeding a height h, and a thickness t that approaches or exceeds the diameter of the roadway portion 28a-28d. Generally, the height h can increase with the number of rows of the first and second layers included in each intersection portion. For example, the intersection portion can include a total of four to ten rows of the first and second layers, such as eight rows. Figures 1 to 3 In the embodiment of the present invention, each intersection portion 26b, 26d includes eight rows: four double-bed rows in each of the first layer 12 and the second layer 14, although in Figure 1 to Figure 2 The rows of the first layer 12 are primarily visible. Generally, the width w may increase as the number of wales of the first layer and the second layer included in the intersection portion increases. For example, the intersection portion may include two to ten wales of the first layer and / or the second layer, such as four wales. Figure 1 to Figure 2 In the embodiment, each intersection portion 26b, 26d includes four longitudinal rows. Figure 3 As shown in , due to the mutual interlocking of at least one row of tensile material with the first layer and / or the second layer within each intersection portion, the thickness t of the intersection portion can approach or exceed the diameter of the road portion. The inherent loft of the materials and structures forming the intersection portion can also contribute to the increased thickness relative to the road portion.

[0072] Typically, the intersection portion and the road portion enclose a circular, rectangular, or elliptical opening. Figures 1 to 3 , the opening 30 has an approximately square or pentagonal shape defined by the intersection portions 26a-26d and the road portions 28a-28d. Figure 1 to Figure 2 The second opening 44 has a generally triangular shape, but in other embodiments, the opening may have a generally circular, oval, oblong, square, rectangular, hexagonal, or other shape depending on the size of the intersection portion and the road portion.

[0073] In other embodiments, the opening can have a first size (i.e., area) and can be defined by three intersection portions and three road portions. In still other embodiments, the opening can be defined by a greater number (e.g., five, six, or more) of intersection portions and road portions. In other embodiments, the plurality of openings woven into the tensile zone can have the same or different shapes and sizes.

[0074] Reference now Figure 4, another knitted component 46 is shown, which includes a woven-in tensile zone 48 formed by a plurality of first tensile structures. The exemplary first tensile structure 50 includes intersection portions 52a-52d and road portions 54a-54d, which surround a square-shaped opening 56. A row 58 of tensile material spans the opening 56 and is interlocked with the intersection portions 52b, 52d. Each intersection portion 52a-52d can have a knot-like structure having a height similar to its width, and either or both of its width and height can exceed the diameter of the road portion 50a-50d. That is, compared to the relatively slender road portions 54a-54d, the intersection portions 52a-52d can appear as a knot-like mass of yarns. The row 58 of tensile material includes a float 60 spanning the opening 56 between the intersection portions 52b, 52d. Knitted-in tensile zone 48 also includes a plurality of second tensile structures 61 that are similar to first tensile structures 50, except that at least two courses of tensile material (e.g., courses 62, 63) span each opening. In other tensile structures of knitted component 46, at least one course of non-tensile material (e.g., course 64) may span the opening, e.g., to provide the advantage of greater stretch resistance in the course-wise direction.

[0075] exist Figure 5 In FIG. 1 , an alternative woven-in tensile zone 65 is illustrated, which includes a plurality of first tensile structures (similar to Figure 4 ), further comprising a plurality of second tensile structures 66, each of which includes a non-strait float (e.g., float 67, which may have a slack or U-shaped appearance) and a cross-point portion 68a-68c having a greater height and width relative to other cross-point portions (e.g., cross-point portion 69). However, cross-point portions 68a-68c and 69 are similar in construction, and in fact, each cross-point portion may be interlooped with one or more rows of tensile material.

[0076] The aforementioned knitted components are merely exemplary and are not intended to limit the scope of the present disclosure. In contrast, other knitted components of the present disclosure may include woven-in tensile zones having different characteristics, including intersection portions and openings having different shapes and sizes, road portions having multiple and different lengths, a greater number of rows of tensile material across each opening, woven-in tensile zones having different orientations relative to other woven-in tensile zones, and the like.

[0077] A knitted component configured with a woven tensile zone according to the above structure can advantageously have the benefit of high tensile resistance in a direction parallel to the orientation of the horizontal rows of tensile material. In contrast to the horizontal rows of tensile material that are padded through the intersection portion, this tensile resistance is enhanced by knitting one or more horizontal rows of tensile material into at least one intersection portion. In addition, the floating line portion of the tensile material can further increase the tensile resistance of the knitted component by limiting the mechanical stretching woven into the tensile zone. In addition, the knitted component can also have high tensile resistance in a direction parallel to the road portion, and the road portion can generally extend straight between adjacent intersection portions (for example, it can be tightened between adjacent intersection portions). In addition, due to the intersection portion that can fix the relative position of the intersecting road portions, the knitted component can have relatively high strength and tear resistance. As another advantage, due to the formation of one or more openings in the woven tensile zone, the knitted component can advantageously provide relatively high visibility and permeability. Additional advantages will be obvious to those skilled in the art.

[0078] Reference now Figure 6, an upper 70 for an article of footwear may include a knitted component 72 having one or more woven-in tensile zones, particularly where it is desired to limit stretch, improve ventilation, or improve visibility through the knitted component 72. Each woven-in tensile zone may include one or more tensile structures as described above. The upper 70 is similar to a U-shape, however, it should be understood that the "horseshoe-shape" or "U-shape" shape is merely exemplary, and other uppers embodying the disclosure of the present application may have the edges knitted in different positions, such as a "C-shaped" upper or a multiple-piece upper. The knitted component 72 includes a first layer 74 and a second layer (not shown). For reference purposes, the upper 70 can generally be divided into three approximate regions along the longitudinal direction (heel to toe): a forefoot region 78 having a forefoot edge region 79, a midfoot region 80, and a rearfoot region 82. The forefoot region 78 may generally include a portion of the upper 70 that may ultimately cover the toe and the joint connecting the metatarsal bones to the phalanges (when incorporated into an article of footwear). The midfoot region 80 may generally include a portion corresponding to the arch area of ​​the foot and may include a throat area 81. The rearfoot region 82 may generally correspond to the rear portion of the foot, including a region covering the calcaneus (which includes a portion of the wearer's heel). In addition, the rearfoot region 82 may cover some or all of the wearer's ankle and talus (which includes a portion of the ankle). The rearfoot region 82 may overlap with the collar region 83. The upper 70 may also include a medial side 84 having an inner side edge 86 and an inner side edge region 88 and a lateral side 90 having an outer side edge 92 and an outer side edge region 94. Each of the medial side 84 and the lateral side 90 may extend through each of the forefoot region 78, the midfoot region 80, and the rearfoot region 82, and may correspond to the opposite side. More specifically, lateral side 90 may correspond to the lateral area of ​​the foot (i.e., the surface facing away from the other foot), and medial side 84 may correspond to the medial area of ​​the foot (i.e., the surface facing the other foot). Forefoot region 78, midfoot region 80, rearfoot region 82, medial side 84, and lateral side 90 are not intended to demarcate precise areas of upper 70 or knitted component 72, but are intended to represent approximate areas to facilitate the following discussion.

[0079] Still reference Figure 6 , the first layer 74 may ultimately correspond to the outer layer, and the second layer may ultimately correspond to the inner layer. The upper 70 also includes a first woven-in tensile zone 96 located in the rear region 82, a second woven-in tensile zone 100 located in the mid-shoe region 80, and a third woven-in tensile zone 102 located in the forefoot region 78. It should be understood that the knitted structure present in any area of ​​the upper 70 may also be applicable to any other area of ​​any upper.

[0080] The first woven-in tensile zone 96 is located on the medial side 84 of the knitted component 72 and extends from the collar area 83 to the medial edge area 88. The rows of tensile material (e.g., row 106) extend from the rear edge area to the midfoot area 80. The rows of the first woven-in tensile zone 96 can have a different orientation than the rows of other woven-in tensile zones due to the use of inserts or wedges (e.g., wedge 108) in the knitted component 72. In general, the orientation of any woven-in tensile zone can be adjusted using an insert or wedge.

[0081] The first woven-in tensile zone 96 may have a similar knit structure (e.g., tensile structures 104) constructed as described above, wherein each tensile structure 104 includes at least a portion of a course (e.g., course 106) of tensile material oriented in a lengthwise direction (which may correspond to a weft direction and a forefoot-hindfoot orientation) having a float across an opening (e.g., opening 107 having a first float length). Road portions (such as road portions 109) extend diagonally downward from collar region 83 toward medial edge region 88. Other road portions extend diagonally upward. When incorporated into an article of footwear, the first woven-in tensile zone 96 may secure upper 70 around the rear of a wearer's foot by preventing lengthwise stretching. Because the first woven-in tensile zone 96 may experience relatively low tension compared to other woven-in tensile zones, the materials selected for these areas may be different from those of the other woven-in tensile zones. For example, the first woven-in tensile zone 96 may include a tensile material having a lower maximum tensile strength than the tensile material utilized in the other woven-in tensile zones. Similarly, due to the relatively high wear forces that may be experienced in the rear region 82 of the shoe, the material used for the first layer 74 may be different from other materials utilized elsewhere in the knitted component 72.

[0082] The second woven-in tensile zone 100 located in the midfoot region 80 includes a plurality of first tensile structures (e.g., structures 110 having floats having a second float length) and second tensile structures (e.g., structures 112 having tensioned floats having a third float length), both of which are constructed as described above. The second woven-in tensile zone 100 includes one or more rows (e.g., rows 113) of tensile material extending from the medial edge region 88 (including the medial edge 86) to the lateral edge region 94 (including the lateral edge 92), and may also include one or more partial rows (e.g., rows 114) of tensile material extending from the throat region 81 to the lateral edge region 94 (including the lateral edge 92) or the medial edge region 88 (including the medial edge 86). This orientation in the medial-lateral direction may correspond to the weft direction. The rows of tensile material may extend beyond the medial edge 86 and the lateral edge 92, for example, to facilitate securing the rows to other structures such as the sole structure, for the purpose of increasing stretch resistance and strength advantages. When the upper 70 is incorporated into an article of footwear, this configuration of the tensile material in the mid-shoe area 80 in the medial-lateral direction can advantageously promote a high degree of "lock down" or stability in the medial-lateral direction. In other embodiments, the rows of tensile material in the mid-shoe area 80 need not have a strict medial-lateral orientation, but may extend diagonally (e.g., upward and forward) or may have another orientation. Given that the mid-shoe area 80 may experience relatively high tensions, the material utilized in the third woven-in tensile zone 100 may be different from other materials used in the knitted component 72. For example, the tensile material utilized in the third woven-in tensile zone 100 may have a greater maximum tensile strength than the tensile material utilized in other woven-in tensile zones.

[0083] The third woven-in tensile zone 102 located in the forefoot region 78 includes a plurality of first tensile structures 116 and a plurality of second tensile structures 118. The first tensile structures 116 may be spaced apart by one or more openings 120 without tensile material. The spaced-apart tensile structures may advantageously save weight and material costs while increasing breathability and visibility through the knitted component 72. The second tensile structures 118 may each include more than one float of tensile material across each opening, for example, for increased stretch resistance. Each row of tensile material extends from the medial edge region 88 (including the medial edge 86) to the lateral edge region 94 (including the lateral edge 92), while the third woven-in tensile zone 102 extends from the forefoot edge region 79 to the midfoot region 80.

[0084] The aforementioned woven-in tensile structures are exemplary and are not intended to limit the scope of the present disclosure. In contrast, other woven-in tensile structures in other embodiments may utilize one or more features of any of the aforementioned examples and may have additional differences. For example, a knitted component may include a first woven-in tensile zone and a second woven-in tensile zone. The floats in the first woven-in tensile zone may have a first float length, and the opening may have a first shape (e.g., square, circular, oval, triangular, etc.) and a first size, while the floats in the second woven-in tensile zone may have a second float length that is the same or different from the first float length. Similarly, the opening in the second woven-in tensile zone may have an opening that has the same or different shape and size as compared to the first woven-in tensile zone. In the same or other embodiments, the float lengths of different floats may be different along each horizontal row of the tensile material.

[0085] exist Figure 7 , an article of footwear 122 is shown, comprising an upper 124 at least partially formed with a knitted component 126. Item 122 has an overall construction suitable for walking or running. The concepts associated with footwear (including upper 124 and knitted component 126) may also be applied to a variety of other athletic footwear types, including, but not limited to, baseball shoes, basketball shoes, cross-training shoes, cycling shoes, rugby shoes, soccer shoes, sprinting shoes, tennis shoes, and hiking boots. The concepts may also be applied to types of footwear that are generally considered non-athletic, including dress shoes, loafers, sandals, and work boots. Thus, the concepts disclosed herein apply to a variety of footwear types. In Figure 7 In the embodiment of the present invention, upper 124 can generally provide a comfortable and secure covering for the wearer's foot. As such, upper 124 can define void 128 to effectively receive and secure the foot within article 122. In addition, optional sole structure 130 can be secured to a lower area of ​​upper 124 and can extend between the wearer's foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, increase stability, and influence the movement of the foot.

[0086] Article 122 may include one or more woven-in tensile zones, utilizing aspects from any of the knitted component and upper examples described above. For example, the knitted component 126 of article 122 includes a first woven-in tensile zone 132 positioned on the lateral side 134, and may also include a second woven-in tensile zone positioned on the medial side (not shown). Rows of tensile material (e.g., row 135) may extend across an upper portion 136 of article 122, for example, from an outer edge region 138 (including the outer edge 140) to an inner edge region (including the inner edge). Additionally or alternatively, rows of tensile material (e.g., row 142) may extend partially over article 122, for example, from an outer edge region 138 to a throat region 144. One or more rows of tensile material may be fixed to sole structure 130, for example, at the outer edge region 138, such as by an adhesive or other attachment method. Securing one or more rows of tensile material to sole structure 130 can advantageously improve stability of article 122 in the medial-lateral direction by preventing movement of the wearer's foot within void 128. The rows of tensile material can also cooperate with fastening system 146. For example, laces can be threaded through openings in the tensile structure, i.e., using the openings as lace loops. Alternatively, fastening system 146 can be attached to woven-in tensile zone 132, for example, to facilitate providing a secure anchor point.

[0087] Reference now Figure 8 , illustrates a knitting sequence that can be used to form an integrally knitted component as described above, such as by a weft knitting process (e.g., using a flat knitting machine having one, two or more needle beds). Figure 8 A non-limiting sequence of is illustrated on a weft knitting machine having a first needle bed 150 and a second needle bed 152. The knitting sequence illustrates the formation of knitted-in tensile zones using courses of tensile material 154 and courses of first material 156 and second material 158 to form the first and second layers.

[0088] At a first step 160, the knitting machine forms a row 162 of tensile material 154 by periodically knitting loops separated by floats on the second needle bed 152. Each loop can be knitted into a crossover portion, and each float can span an opening (not shown) formed in a previous knitting step. Each float jumps over a plurality of needles, such as two to ten needles, between the knitted loops. In other words, the float can have a float length of at least two needles. For example, in Figure 8In a first step 160, each float formed during course 162 skips five needles. In other embodiments, the float lengths may be longer or shorter, for example, depending on properties of the tensile material that affect how easily it is knitted on the knitting machine (e.g., diameter and hardness), or depending on whether the float is straight (e.g., whether it is taut or slack), or depending on the size of the opening in the knitted component. In still other embodiments, a single course of tensile material may include floats having more than one float length. In a first step 160, the knitting machine secures the position of course 162 within the knitted component by interlooping with one or more previously knitted courses, and prepares course 162 to interloop with a crossover portion of the knitted component in a subsequent step. In the first step 160, all of the loops of course 162 (of tensile material 154) are formed on the second needle bed 152, where they will interloop with the loops of the second layer in a subsequent step. Alternatively, the loops of the course of tensile material may be formed in whole or in part on the first needle bed 150 in preparation for subsequent interlooping with the loops of the first layer. By forming all of the loops of the course 162 on a single needle bed, the loops may be hidden from at least one viewpoint of the finished knitted component. For example, by knitting the loops of the course 162 on the second needle bed 152, where they will be interlooped with one or more courses of the second layer, those loops of the course 162 may be hidden from a first viewpoint where the first layer is visible.

[0089] At a second step 164, the knitting machine closes the rows 162 of tensile material 154 knitted at the first step 160 by knitting rows of first material 156 and second material 158, respectively. Figure 8 In the step, the courses 166, 168 form an interlocking knitted structure of the first material 156 and the second material 158. The courses 166, 168 both include loops formed on both the first needle bed 150 and the second needle bed 152. In this step, at least one of the courses 166, 168 is interlooped with the loops of the course 162 of the tensile material 154 knitted during the first step 160. For example, in Figure 8 In the embodiment, the rows 168 of the second material 158 are interlooped with each loop of the rows 162 of the tensile material 154. However, in other embodiments, the first layer and / or the second layer need not be interlooped with all loops of the tensile material.

[0090] After the first step 162 and the second step 164, the knitting machine has knitted one or more crossover portions at each location where the interlocking courses of the first material 156 and the second material 158 interloop the knitted loops of the tensile material 154. In addition, the knitting machine has knitted one or more floats of the tensile material 154 across the opening formed by the previous knitting step (not shown).

[0091] At a third step 170, the knitting machine begins to form the intersection portions, openings and road portions in the knitted component by alternating between knitting additional courses of the first material 156 and the second material 158 and by performing inter-needle transfers of the stitches of these courses. Figure 8 , the rows 172 of the first material 156 and the rows 174 of the second material 158 form a multi-bed knitted structure that does not initially form a portion of an opening. For example, the rows 172, 174 may form a tubular knitted structure. However, subsequently, the knitting machine performs transfer steps 176, 178, which move the knitted loops of the rows 172, 174 to other needles. The locations of these transfers coincide with the floats of the tensile material 154 that will be knitted in subsequent steps. More specifically, the transfer steps 176, 178 pull the loops of the rows 172, 174 away from each other, thereby creating an opening and forming a road portion of the knitted component around the opening. After the transfer steps 176, 178, the knitting machine knits optional rows 180-186 and performs additional transfer steps 188, 190 to further widen the opening and lengthen the road portion. In other embodiments with smaller openings and shorter road portions, the courses 180-186 and transfers 188, 190 may not be necessary. Likewise, in other embodiments with larger openings and longer road portions, the third step 170 may include additional courses and transfers. After the first to third steps 160, 164, 170, the knitting machine has knitted one or more crossover portions and one or more partial openings in the knitted component.

[0092] At a fourth step 192, the knitting machine knits another row 194 of the tensile material 154 by periodically knitting loops on the second needle bed 152, the loops being separated by floats across the incomplete opening formed during the third step 170. Where the row 194 of tensile material 154 forms loops on the second needle bed 152, it forms part of an additional crossover portion of the knitted component.

[0093] At a fifth step 196, the knitting machine completes the opening started in the third step 170 by alternating between knitting additional courses of the first material 156 and the second material 158 and performing additional needle-to-needle transfers. Figure 8In the fifth step 196, similar to the third step 170, the rows 198, 202 of the first material 156 and the rows 200, 204 of the second material 158 form a multi-bed knit structure (e.g., tubular knit). Subsequently, the knitting machine performs transfer steps 206, 208 to move the knitted loops of the rows 198-204 to other needles. Unlike the third step 170, the transfer steps 206, 208 of the fifth step 196 pull the loops together (make the opening smaller) when transferring the loops that are pulled apart (making the opening larger). In other words, the third step 170 forms a widened portion of the opening, while the fifth step 196 forms a narrowed portion of the opening. More specifically, the transfer steps 206, 208 pull the spaced-apart loops of the rows 198-204 toward each other, thereby narrowing the opening. In addition, the third step 170 can form a road portion oriented in a first direction, while the fifth step 196 can form a road portion oriented in a second direction. After the transfer steps 206, 208, the knitting machine knits optional courses 210-216 and performs additional transfer steps 218, 220 to further narrow the opening. In other embodiments with smaller openings, the courses 210-216 and transfers 218, 220 may not be necessary. Likewise, in other embodiments with larger openings, the fifth step 196 may include additional courses and transfers. After the first through fifth steps 160, 164, 170, 192, and 196, the knitting machine has knitted the knitted component into a crossover portion with interlooped tensile material, one or more complete openings spanned by floats of tensile material, and one or more road portions.

[0094] Although the foregoing knitting sequence describes five steps for the sake of comprehensive description, fewer steps may be required to form the tensile structure. For example, the first step may include forming a widened portion of the opening, a road portion, and a crossover portion (as in the third step 170 discussed above). The second step may include knitting a row of tensile material, including at least one loop and a float across the opening, and continuing to form a crossover portion on either side of the float that can be knitted integrally with the tensile material (as described above in the fourth step 192). The third step may include forming a narrowed portion of the opening and an additional road portion (as in the fifth step 196 discussed above).

[0095] Although various embodiments of the present disclosure have been described, the present disclosure is not limited except in accordance with the attached claims and their equivalents. Instead, the embodiments discussed are selected and described to provide the best illustration of the principles of the present disclosure and its practical application, so that those of ordinary skill in the art can utilize the present disclosure in various forms and utilize the present disclosure using various modifications suitable for the intended specific use. It is intended and will be understood that the embodiments can be combined or separated differently without departing from the present disclosure, and all exemplary features described herein are applicable to all aspects of the present disclosure described herein. In addition, the advantages described herein are not necessarily the only advantages of the present disclosure, and it is not necessarily expected that each embodiment of the present disclosure will achieve all the advantages described.

Claims

1. A knitted component, comprising: Woven into tensile zones, including: an opening at least partially defined by the first intersection portion and the second intersection portion; and a course of tensile material knitted integrally with the first cross-point portion via knitted loops, the course of tensile material comprising a float having a float length and extending from the first cross-point portion across the opening to the second cross-point portion, wherein the first intersection portion conceals the knitted loops of the row of tensile material from the perspective of the first surface facing the first intersection portion, and wherein the tensile material comprises a higher stiffness and a larger diameter than other materials forming the knitted component, wherein each opening is at least partially defined by a plurality of intersection portions and a plurality of road portions, the road portions connecting adjacent intersection portions, where each intersection portion has a width that exceeds its height, wherein the height of the intersection portion increases as the number of rows within the corresponding intersection portion increases, and The width of the intersection portion increases as the number of vertical rows in the corresponding intersection portion increases.

2. The knitted component of claim 1, wherein the rows of tensile material have a diameter of 0.5 mm to 2.0 mm and a tensile strength of 25 kg-f to 30 kg-f.

3. The knitted component according to claim 1, wherein the row of tensile material is knitted integrally with the second cross-point portion via a second knitted loop.

4. The knitted component according to claim 1 further includes a second row of tensile material, which is knitted integrally with the first intersection portion and includes a second float thread, which extends from the first intersection portion across the opening to the second intersection portion.

5. The knitted component of claim 1, wherein the course of tensile material includes a second float having a second float length. The knitted component according to claim 1 , wherein the float length is a distance of at least three needles.

7. The knitted component according to claim 1, wherein the opening has a shape including a triangle, a square, a rectangle, a pentagon, an oval or a circle.

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