The shoe upper, including the knitted cushioning area, and footwear items incorporating the knitted cushioning area.

Abstract

This application relates to an upper for a shoe including a knitted cushioning area and footwear articles incorporating the upper. The upper may include a knitted component (100) having a first surface (108) and a second surface (114). The knitted component (100) may include at least one integrally knitted cushioning area (112) located on the second surface (114). The cushioning area (112) may include a plurality of non-planar structures (122) protruding at least 1 mm away from the second surface (114) of the knitted component (100), and the cushioning area (112) may be located in the rear part of the upper (100).

Description

[0001] This application is a divisional application of the application filed on April 1, 2019, with application number 201980026109.3 and invention title "An upper for a shoe including a knitted cushioning area and a footwear article incorporating the upper".

[0002] Related applications

[0003] This application claims the benefit of pending U.S. Provisional Application No. 62 / 658,232, filed April 16, 2018, which is incorporated herein by reference. background

[0004] This disclosure generally relates to knitted components and methods of manufacturing knitted components (e.g., knitted components for use in footwear applications).

[0005] Overview

[0006] In one aspect, this disclosure provides an upper that may include a knitted component having a first surface and a second surface. The knitted component may have at least one integrally knitted cushioning region located on the second surface. The cushioning region may include a plurality of non-planar structures that protrude at least 1 mm (e.g., 2 mm, 3 mm, 4 mm, 5 mm, 10 mm, 15 mm or greater) away from the second surface of the knitted upper, and the cushioning region may be located in the rear portion of the upper. The cushioning region may be at least partially located in the calcaneal region and / or at least partially located in the Achilles tendon region. The cushioning region may have a depth of at least 1000 mm. 2 Area (e.g., 1200mm²) 2 1400mm 2 1500mm 2 2000mm 2 5000mm 2The cushioning area can have a shape (or a larger area). It can have geometric shapes such as rectangles, squares, trapezoids, rhombuses, ellipses, circles, conic sections (e.g., hyperbolic shapes), and other geometric shapes. Alternatively, the cushioning area can have non-geometric shapes. Multiple non-planar structures can be separated by multiple base portions, which can be formed at least partially by one or more elastic yarns. Multiple non-planar structures can include one or more tubular knitted structures, loft portions, or other non-planar structures. Multiple non-planar structures can have multiple orientations, such as orientations parallel or perpendicular to the heel centerline of the upper. Multiple non-planar structures can include at least 5, 10, 15, 20, 25, 30, or more non-planar structures. The knitted components can be formed from a variety of different materials. For example, the knitted components can include thermoplastic polymers (e.g., thermoplastic polyurethane) constituting at least 90%, 93.5%, or a higher percentage by weight of the knitted components. The upper can include a second plurality of knitted elements projecting from a first surface.

[0007] In another aspect, this disclosure provides footwear articles that may include an upper associated with a sole structure. The upper may form a void and may include an inner surface facing the void and an outer surface facing the void. The upper may include a cushioning region knitted integrally with the knitted components of the upper. The cushioning region may include a plurality of non-planar structures that protrude into the void and are configured to contact the wearer's heel. The cushioning region may begin at the bite line where the upper meets the sole structure or at a distance of 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, or greater from the bite line. The knitted upper may include one or more tension zones configured to pull the cushioning region against the wearer's heel. In such embodiments, the tension zones may be located adjacent to the collar area of ​​the upper, for example, in the sub-ankle region of the upper.

[0008] Other systems, methods, features, and advantages of this disclosure will be apparent or will become apparent to those skilled in the art after reviewing the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages are within the scope of this disclosure and are covered by the appended claims. Attached Figure Description

[0009] The present disclosure can be better understood by referring to the following figures and description. The components in the figures are not necessarily to scale, but are intended to illustrate the principles of the present disclosure. Furthermore, throughout the figures, the same reference numerals denote corresponding parts.

[0010] Figure 1A An upper for footwear articles is shown according to one aspect. Figure 1B An upper for footwear items is shown according to another aspect. Figure 1C An upper for footwear items is shown according to another aspect. Figure 1D An upper for footwear items is shown according to another aspect.

[0011] Figure 1E An upper for footwear items is shown according to another aspect.

[0012] Figure 2A It shows Figure 1A A perspective view of the shoe upper.

[0013] Figure 2B It shows Figure 1B A perspective view of the shoe upper.

[0014] Figure 2C It shows Figure 1C A perspective view of the shoe upper.

[0015] Figure 2D It shows Figure 1D A perspective view of the shoe upper.

[0016] Figure 2E It shows Figure 1E A perspective view of the shoe upper.

[0017] Figure 3 A schematic diagram of the anatomical structure of the human foot is shown.

[0018] Figure 4A A cross-sectional view of a knitted component according to one aspect is shown.

[0019] Figure 4B A cross-sectional view of the knitted component is shown according to another aspect.

[0020] Figure 4C A cross-sectional view of the knitted component is shown according to another aspect.

[0021] Figure 5A An exterior perspective view of a footwear item is shown, based on one aspect.

[0022] Figure 5B It shows Figure 5A An inside perspective view of footwear.

[0023] Figure 5C It shows Figure 5A Rear view of footwear.

[0024] Figure 5D It shows Figure 5AA front cross-sectional view of footwear.

[0025] Figure 6A A rear view of the footwear item is shown, according to another perspective.

[0026] Figure 6B It shows Figure 6A A front cross-sectional view of footwear.

[0027] Figure 7A A rear view of the footwear item is shown, according to another perspective.

[0028] Figure 7B It shows Figure 7A A front cross-sectional view of footwear.

[0029] Figure 8 The knitting sequence is shown according to one aspect.

[0030] Figure 9 The knitting sequence is shown according to another aspect.

[0031] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0032] Detailed description of the preferred implementation scheme

[0033] Figure 1A The illustration shows an upper 10 for footwear. When incorporated into footwear, the upper 10 typically provides comfortable and secure coverage for the wearer's foot. The upper 10 can be divided into a forefoot region 14, a midfoot region 18, and a heel region 22. Figure 3 refer to Figure 1AWhen the upper 10 is incorporated into a footwear article, the forefoot region 14 typically includes portions corresponding to the toes and the joints connecting the metatarsals and phalanges. The midfoot region 18 typically includes portions of the upper 10 corresponding to the arch region of the foot. The heel region 22 includes portions of the upper 10 corresponding to the rear portion of the foot, including an area covering the calcaneus (which forms part of the wearer's heel). Furthermore, the heel region 22 may cover some or all of the wearer's ankle and talus (which forms part of the ankle) and may extend anteriorly to these areas. The upper 10 also includes a lateral surface 26 and a medial surface 30 extending through each of the forefoot region 14, the midfoot region 18, and the heel region 22. More specifically, the lateral surface 26 corresponds to the lateral region of the foot (i.e., the surface facing away from the other foot), and the medial surface 30 corresponds to the medial region of the foot (i.e., the surface facing the other foot). The forefoot region 14, midfoot region 18, and heel region 22, as well as the outer side 26 and inner side 30, are not intended to define precise areas of the footwear 10. Rather, they are intended to represent general areas of the footwear 10 to facilitate the discussion below.

[0034] Still referencing Figure 1A At least a portion, and possibly substantially the entirety, of the upper 10 may be formed of a knitted component 34. The knitted component 34 may be formed as a single, integral element during a knitting process such as weft knitting (e.g., using a flat knitting machine with one, two, or more needle beds, or a circular knitting machine), warp knitting, or any other suitable knitting process. That is, the knitting process on a knitting machine can substantially form the knitted structure of the knitted component 34 without requiring significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component 34 may be formed separately as two or more distinct knitted components (each knitted integrally) and may be joined together after the knitting process. The knitted component 34 may include an inner surface 38 that, when the knitted component is incorporated into the footwear article, may ultimately face the internal cavity or the wearer's foot. The knitted component 34 may also include an outer surface 42 that may face away from the cavity of the footwear article. In some implementations (e.g., implementations with separable layers), the knitted component 34 may include one or more inner surfaces.

[0035] In general, forming the upper with at least part of knitted components can provide advantageous properties, including but not limited to specific degrees of stretch (e.g., expressed in Young's modulus), breathability, flexibility, strength, moisture absorption, weight, abrasion resistance, and / or combinations thereof. These properties can be achieved by selecting specific single-layer or multi-layer knitted structures (e.g., ribbed knit structure, interlock structure, single-jersey knit structure, double-jersey knit structure, additional knitted structures, or any combination thereof), by varying the size and tension of the knitted structure, by using one or more yarns formed from specific materials (e.g., polyester, relatively inelastic materials, or relatively elastic materials such as elastane), by selecting yarns of specific dimensions (e.g., denier), and / or combinations thereof. Knitted components can also provide desired aesthetic properties by incorporating yarns of different colors, textures, or other visual properties arranged in specific patterns. The yarn itself and / or the knitted structure formed by one or more yarns of a knitted component can vary at different locations, such that the knitted component has two or more parts with different properties (e.g., the portion forming the throat area of ​​a shoe upper can be relatively elastic, while another portion can be relatively inelastic). In some embodiments, the knitted component can comprise one or more materials that have properties that change in response to stimuli (e.g., temperature, humidity, electric current, magnetic field, or light). For example, the knitted component can comprise yarns formed of at least one thermoplastic polymer material or material composition (e.g., at least one polyurethane, polyamide, polyolefin, and / or nylon) that transitions from a solid to a softened or liquid state when subjected to certain temperatures at or above its melting point, and then transitions back to a solid state upon cooling. For example, at least a portion of the knitted component can comprise a first thermoplastic polymer. Alternatively, at least half of the knitted component can comprise a first thermoplastic polymer. Alternatively, most or substantially all of the knitted component can comprise a first thermoplastic polymer. As a non-limiting example, the knitted part may include a higher weight (mass) percentage of resin constituting the first thermoplastic polymer type. Therefore, at least 90% (e.g., 93.5%, 95%, etc.) of the weight (mass) of the knitted part is the resin constituting the first thermoplastic polymer. It should be understood that the first thermoplastic polymer may be present in a higher or lower amount (%) as needed or desired.

[0036] like Figure 1AAs shown, the knitted component 34 can be knitted into a two-dimensional configuration (e.g., by a flat knitting process), which can then be shaped into the shape of the wearer's foot by post-knitting methods (e.g., lasting). In other embodiments, the knitted component can be knitted into a three-dimensional configuration, by which a knitting process (e.g., a flat knitting process or a circular knitting process) knits the upper substantially into the shape of the wearer's foot. Such a three-dimensional knitted component may include an opening for receiving the wearer's foot within the overfoot portion. As a result of the knitting process, the overfoot portion may be connected to the underfoot portion, for example, around the perimeter of the underfoot portion. Such a three-dimensional knitted component can resemble a shoe insole or shoe lining after the knitting process. However, it should be understood that the shapes of the knitted components shown in the figures are merely exemplary, as other knitted components embodying the construction disclosed herein can be knitted into different configurations. For example, a knitted component can be generally knitted into a two-dimensional U-shape, C-shape, another one-piece shape having one or more edges in different locations, or a multi-piece configuration. Therefore, as used herein, the term "knitted component" is not intended to limit the knitted component to a particular shape, manufacturing process, or particular edge configuration.

[0037] In any of the embodiments discussed herein, the knitted component may include any number of integral knitted features on its outer surface. For example, Figure 1A The knitted component 34 includes a non-planar structure 46 that is integrally knitted with the knitted component 34 and extends away from the outer surface 42, for example, to enhance durability and / or to provide an attractive aesthetic. Such a non-planar structure 46 can together resemble a separate component (e.g., a cage) surrounding the upper 34; however, the non-planar structure 46 can be integrally knitted with the upper 34 and can form part of the outer surface 42. Additionally or alternatively, and as... Figure 1B As shown, the knitted component 100 may include one or more channels 104 comprising two freely separable textile layers in a specific location, wherein the channels 104 may extend away from the outer surface 108 to provide passage for shoelaces or other materials. Additionally or alternatively, and as... Figure 1C As shown, the knitted component 150 may include knitting marks 154 on the outer surface 158. Additionally or alternatively, and as... Figure 1DAs shown, the knitted component 200 may include one or more pillow-shaped, cloud-shaped, or quilt-shaped fluffy portions 204 on the outer surface 208, providing cushioning and an attractive aesthetic, such as those described in U.S. Provisional Patent Application No. 62 / 574,989, the entire contents of which are expressly incorporated herein by reference. Additionally or alternatively, and as... Figure 1E As shown, the knitted component 250 may include one or more knitted recesses 254 on the outer surface 258, at least one of which may expose or conceal one or more loose yarns 262, such as those described in U.S. Patent Application No. 15 / 875,821, the entire contents of which are expressly incorporated herein by reference. Additionally or alternatively, the knitted component may include one or more knitted structures, such as those described in U.S. Provisional Patent Application No. 62 / 541,500, the entire contents of which are expressly incorporated by reference. The foregoing overall knitted features are merely exemplary and intended to illustrate a subset of the many potential knitted features that may be found on the outer surface of the knitted component described herein.

[0038] refer to Figure 1A and Figure 2A The rear portion 22 of the upper 10 may include one or more cushioning regions 54, which are integrally knitted with the knitted component 34 and protrude away from the inner surface 38 (i.e., the surface that may ultimately face the wearer's foot and / or the interior of the footwear). Generally, the structure, shape, size, and other properties of the cushioning regions can vary between embodiments; however, the cushioning regions are typically integrally knitted with the knitted component (i.e., formed largely by the same knitting process that forms the knitted component, without significant post-processing steps), protrude away from the inner surface of the knitted component, and are configured to face towards the rear portion of the wearer's foot (e.g., the heel (including the calcaneus) and / or the Achilles tendon (see...)). Figure 3 It provides cushioning and support. Although the area of ​​the cushioning zones disclosed herein can vary, each cushioning zone can typically have at least approximately 1000 mm². 2 The area; in some implementations, each buffer zone may have a minimum area of ​​1200 mm. 2 1400mm 2 1500mm 2 2000mm 2 5000mm 2 The area or larger. It is explicitly envisioned in this application that knitted parts may have a single buffer area or multiple buffer areas. While the following disclosure generally discusses buffer areas in the singular, it should be understood that this does not in any way limit the number of buffer areas that can be knitted integrally with the knitted part.

[0039] In conventional footwear construction, for maximum comfort, the inner surface of the upper (and any knitted components forming part of the upper) is relatively smooth, with no elements that could protrude away from the inner surface and toward the wearer's foot. In contrast to this conventional construction, the cushioning areas described herein protrude away from the inner surface of the knitted components, but due to their knitted construction, shape, size, location, and material, they will not cause discomfort to the wearer when the knitted components are incorporated into the footwear; instead, they will advantageously cushion the wearer's foot. By protruding away from the inner surface of the knitted components in a location corresponding to the rear portion of the wearer's foot, the cushioning areas advantageously prevent the wearer's foot from sliding up and down the footwear. Additionally, in some embodiments, when the knitted components are incorporated into the footwear, the cushioning areas can eliminate the need for conventional heel counters and other components, thereby reducing weight and cost. Furthermore, in some embodiments, the cushioning areas can be formed from one or more materials similar to or the same as other materials used in the knitted components, thereby improving the recyclability of the knitted components.

[0040] Refer again Figure 1A , Figure 2A and Figure 3 In some embodiments, the cushioning region 54 may be at least partially located in the calcaneal region 56 of the knitted component 34, that is, when the knitted component 34 is incorporated into the footwear article, it may ultimately correspond to at least a portion of the wearer's calcaneus. This application envisions that the calcaneal region 56 of the knitted component 34 may ultimately correspond to any aspect of the wearer's calcaneus, such as the upper, lower, rear, medial, and lateral portions of the calcaneus. Typically, when the upper is incorporated into the footwear article, the calcaneal region may begin approximately at the cleavage line where the upper meets the sole structure and may terminate approximately 25mm-50mm above the cleavage line. Similarly, the calcaneal region may begin approximately 25mm-50mm above the lower or outer edge of the knitted component and may terminate approximately 50mm-100mm above the lower or outer edge. The calcaneal region 56 may coincide with the heel centerline 58 of the knitted component 34; however, its precise boundary may not be apparent within the knitted component 34 itself. The calcaneal region 56 may extend up to approximately 30 mm, 40 mm, 50 mm or more away from the heel centerline 58 in both the medial and lateral directions. In another dimension, the calcaneal region 56 may extend toward and / or reach towards the outer edge 60 of the knitted component and / or the collar edge 62.

[0041] In various implementations, the cushioning area may not cover the calcaneal region, a portion of the calcaneal region, or substantially the entire calcaneal region. In this application, the cushioning area covers at least approximately 400 mm within approximately 20 mm on either side of the heel centerline. 2 In areas where the buffer zone covers "largely" the calcaneal region, the buffer zone can cover the entire calcaneal region. For example, in... Figure 1A and Figure 2A In this design, the knitted cushioning area 54 covers substantially the entire calcaneal region 56 by extending approximately 30mm-45mm from either side of the heel centerline 58 and approximately 20mm-40mm in a direction parallel to the heel centerline 58. In other similar embodiments, the horizontal and vertical dimensions can each vary from approximately 20mm to approximately 100mm or greater. Figure 1B and Figure 2B In an alternative embodiment, the cushioning region 112 on the inner surface 114 covers a portion of the calcaneal region 116, since the curved edge 120 only covers the upper portion of the calcaneal region 116; however, the cushioning region 112 extends approximately 20mm-30mm in both the medial and lateral directions on either side of the heel centerline 124. Figure 1C and Figure 2C In an alternative implementation, a first buffer region 162 on the inner surface 164 covers a portion of the calcaneal region 166. Figure 1D and Figure 2D In an alternative implementation, the trapezoidal buffer region 212 on the inner surface 214 substantially covers the calcaneal region 216. Figure 1E and Figure 2E In an alternative implementation, the buffer region 266 on the inner surface 268 does not cover any part of the calcaneal region 270.

[0042] Additionally or alternatively, in some embodiments, the cushioning area may be at least partially located in the Achilles tendon region of the knitted component; that is, when the knitted component is incorporated into the footwear article, it may ultimately correspond to at least a portion of the wearer's Achilles tendon. This can provide additional cushioning and protection for the wearer's Achilles tendon. (Reference) Figure 1A The Achilles tendon region 64 of the knitted component 34 can be positioned along the heel centerline 58 and closer to the collar edge 62 than the calcaneal region 56. Not all knitted components can have an Achilles tendon region. In those knitted components that do have an Achilles tendon region, the extent to which the cushioning area may be located within the Achilles tendon region (if any) can vary between implementations. For example, in Figure 1B and Figure 2BIn one embodiment, the knitted component 100 includes a high collar region 128 covering the Achilles tendon region 132. In this embodiment, a cushioning region 112 extends along the inner surface 114 from the calcaneal region 116 to the collar edge 134, thereby occupying at least a portion of the Achilles tendon region 132. In other embodiments, such as in Figure 1C and Figure 2C In this embodiment, the second buffer region 168 may extend only partially into the Achilles tendon region 170, while the buffer region 162 covers at least a portion of the calcaneal region 166. In other embodiments, such as... Figure 1E and Figure 2E In this context, the cushioning area 266 may extend along the outer and / or inner side of the inner surface of the knitted component away from the heel centerline 272 in the Achilles tendon region, for example, to provide increased Achilles tendon support.

[0043] As described above, the size and shape of the buffer zone can vary between embodiments. The shape defining the boundary of the buffer zone can be geometric or non-geometric, and can be symmetrical or asymmetrical. Exemplary geometric shapes include rectangles, squares, trapezoids, rhombuses, ellipses, circles, conic sections (e.g., hyperbolic shapes), and other geometric shapes. Non-geometric shapes can include organic shapes, such as kidney shapes, and other contour shapes, such as shapes that can correspond to the anatomical structure of the wearer's foot. The area of ​​the two-dimensional shape defining the boundary of the buffer zone can vary between embodiments, for example from approximately 400 mm². 2 Approximately 5000mm 2 Or even larger. In contrast, as described below, due to the presence of non-planar structures, the buffer region can have a surface area exceeding the area of ​​a two-dimensional shape that defines the boundaries of the buffer region. For example, Figure 1A and Figure 2A The buffer area 54 has a rectangular shape with a width (w) 66 of approximately 60mm-90mm and a vertical height (h) 68 of approximately 20mm-40mm in a direction parallel to the heel centerline 58. In similar embodiments, the horizontal and vertical dimensions can each vary from approximately 20mm to approximately 100mm or greater. Figure 1B and Figure 2B In an alternative embodiment, the cushioning region 112 has a non-geometric shape that extends from the upper portion of the calcaneal region 116 into the Achilles tendon region 132, thereby extending to the collar edge 134. The cushioning region 112 also extends approximately 20mm-30mm on either side of the heel centerline 124 in both medial and lateral directions. Figure 1C and Figure 2CIn an alternative implementation, the first cushioning area 162 has an organic non-geometric shape having a first height (h1) 172 along the heel centerline 174. The height of the first cushioning area 162 increases to a second height (h2) 176 at other locations spaced away from the heel centerline 174, for example, to better conform to the shape of the wearer's foot. Figure 1D and Figure 2D In an alternative implementation, the buffer area 212 has a trapezoidal shape having a wider first width (w1) 218 ​​and a narrower second width (w2) 220. The shapes and dimensions described above are merely exemplary and are not intended to limit the number of potential shapes and sizes that the buffer area can reflect, but rather to represent the width of potential shapes, sizes, and locations of the buffer area.

[0044] In any implementation, the buffer area may include one or more non-planar structures that enhance cushioning and provide volume to the buffer area by extending away from the inner surface of the knitted part. For example, Figure 1A and Figure 2A The buffer region 54 includes approximately twenty non-planar structures 70; however, other embodiments may include more or fewer non-planar structures, for example, two, four, five, ten, twenty-five, thirty, or more non-planar structures. Figure 1B and Figure 2B In an alternative implementation, the buffer region 112 includes a plurality of non-planar structures 122, each having a different height. Figure 1C and Figure 2C In an alternative implementation, the first buffer region 162 and the second buffer region 168 each include a plurality of non-planar structures 163 and 169. Figure 1D and Figure 2D In the implementation scheme, the buffer region 212 includes multiple horizontal non-planar structures 213. Figure 1E and Figure 2E In one embodiment, the buffer region 266 includes a plurality of non-planar structures 276 formed as a fluffy portion. (See reference...) Figure 4A In a cross-sectional view, the knitted component 300 includes an integrally knitted cushioning region 302 having a plurality of non-planar structures 304 protruding away from a surface 308. Each non-planar structure 304 may extend away from the surface 308 to a depth (d) 312, which may be at least about 1 mm, for example, 2 mm, 3 mm, 4 mm, 5 mm, 10 mm, 15 mm or greater. When the knitted component 300 is incorporated into a footwear article, the non-planar structures 304 extend into the cavity formed by the knitted component 304, i.e., towards the wearer's foot. Figure 4AIn one implementation, each non-planar structure 304 extends the same depth (d) 312 away from the surface 308. However, as Figure 4B As shown in the alternative cross-sectional view, the knitted component 350 may include a buffer region 354 having a non-planar structure 358 that extends away from the surface 362 by different distances d1 (366) and d2 (370), for example, to form a more ergonomic profile.

[0045] Refer again Figure 4A The nonplanar structures can be spaced apart by base portions 332, which can be formed of a material similar to or different from the nonplanar structures 304. In such embodiments, each base portion 332 has a width (w1) 336 that affects the spacing between the nonplanar structures 304. In some embodiments, each base portion can have a very small width, for example, 1-2 mm, which can correspond to a single row or a few rows of yarn. In such embodiments, the nonplanar structures can be spaced so closely that adjacent nonplanar structures are almost in contact with each other or actually in contact with each other. In other embodiments, such as Figure 4B As shown in the cross-sectional view and possibly in embodiments where the non-planar structure has an orientation not parallel to the heel centerline, the base portion 374 may have a larger width (w2) 378, allowing the non-planar structures to be spaced further apart. In all embodiments, the buffer area may include a base portion having one or more widths.

[0046] Typically, suitable non-planar structures can include solid rib structures, tubular rib structures, and loose sections. Rib structures can be linear or non-linear. (See again...) Figure 4A Typically, the non-planar structure 304 can be a tubular rib structure, which can be a region of a knitted component consisting of two or more integrally knitted and overlapping knitted portions 316, 320 (forming tubes or tunnels). Although the sides or edges of the knitted portions 316, 320 may be secured to other layers, the central area is typically not secured to form a hollow tube or tunnel. An exemplary type of tubular rib structure is an ottoman structure. For example, Figure 1A The cushioning region 54 of the knitted component 34 includes a plurality of elongated tubular non-planar structures 70 extending away from the inner surface 38. Hollow rib structures generally provide improved cushioning than solid rib structures because each hollow tubular rib structure can compress in response to forces (such as the force of a wearer's heel). In some cases, the tubular rib structure may include one or more additional components, such as one or more yarns or strands, disposed within the tube, for example, to increase cushioning or loft.

[0047] In other embodiments, the buffer area may include other suitable non-planar structures, as described in U.S. Provisional Patent Application No. 62 / 574,989, the entire contents of which are expressly incorporated herein by reference. Such non-planar structures may include one or more integrally knitted cloud-like, quilt-like, or pillow-like fluffy portions formed by knitting into cavities between freely separable knitted layers and also by knitting material (e.g., monofilament yarn) into the cavities to impart cushioning or fluffiness to the knitted structure. Such alternative non-planar structures in… Figure 1E and Figure 2E The implementation shows that the buffer region 266 includes a plurality of non-planar structures 276 as a fluffy portion. (See reference...) Figure 4C In a cross-sectional view, the fluffy portion 400 may include a portion of a first knitted layer 404 (which extends away from a portion of the underlying second knitted layer 408) and material 412 knitted between the first layer 404 and the second layer 408. Typically, within each fluffy portion, the first layer may extend away from the second layer by a distance of approximately 1 mm–2 mm, approximately 2 mm–3 mm, approximately 3 mm–4 mm, approximately 4 mm–5 mm, or greater. In other words, the cushioning area may protrude away from the inner surface of the knitted part by a distance of 2 mm–3 mm, approximately 3 mm–4 mm, approximately 4 mm–5 mm, or greater. Such fluffy portions may have approximate geometries such as circles, triangles, squares, rectangles, rhombuses, pentagons, hexagons, curves (e.g., sine curves or other curves), etc. In other embodiments, the cushioning area may include one or more pods, as described in U.S. Provisional Patent Application No. 62 / 541,500, the entire contents of which are expressly incorporated by reference.

[0048] Typically, non-planar structures can be knitted into arrays, patterns, mosaics, checks, or other arrangements to enhance cushioning, improve the interface between the upper and the wearer's heel area, enhance aesthetics, or provide other advantages. For example, Figure 1A and Figure 2A Multiple tubular non-planar structures 70 are knitted into a closely spaced parallel array, wherein each tubular non-planar structure 70 is oriented parallel to the heel centerline 58 of the knitted part (“vertical” orientation). Figure 1A The vertical orientation of the tubular non-planar structure 70 may correspond to the direction of the transverse direction of the knitted part 34, but in other embodiments it may alternatively correspond to the direction of the longitudinal direction. Figure 1AThe vertical orientation of the tubular non-planar structure 70 also corresponds to the orientation of the wearer's Achilles tendon, which advantageously allows each tubular non-planar structure 70 to independently conform to the wearer's heel and / or Achilles tendon. However, in other embodiments, the non-planar structure may have one or more non-vertical orientations. For example, in Figure 1E and Figure 2E In an alternative implementation, the non-planar structure 276 is a fluffy portion knitted into a quilt-like pattern.

[0049] The cushioning area of ​​the knitted component can be knitted from a variety of materials. Assuming the cushioning area is located where it may come into contact with the wearer's foot when the knitted component is integrated into footwear, it may be desirable to knit at least a portion of the non-planar structure from one or more materials with a relatively soft hand feel. It may also be desirable to knit at least a portion of the non-planar structure from a relatively durable yarn that will withstand repeated entry and exit of the wearer's foot into the footwear and constant friction without degradation. Such a yarn may exhibit a minimum tensile strength, for example, about 0.2 kgf, 0.3 kgf, 0.4 kgf, 0.5 kgf, or greater. The yarn may also have a minimum toughness, for example, about 2 g / denier, 3 g / denier, 4 g / denier, 5 g / denier, 6 g / denier, or greater. For example, the non-planar structure may be knitted from one or more synthetic yarns at least partially formed of polyester (e.g., yarns with at least 70%, 75%, 80%, 85%, 90%, 95%, or higher polyester content). Because a better fit to the wearer's foot results in improved performance of the cushioning area, it may be desirable to knit at least a portion of the cushioning area with one or more elastic yarns, which imparts resilience to the knitted structure. For example, at least some non-planar structures and / or the base portion may be knitted from yarns containing elastic fibers, comprising at least 2%, 3%, 5%, 10%, or more of the yarn, allowing the yarn to achieve an elongation of at least about 15%, 20%, 25%, or greater without breaking. For instance, the base portion positioned near the heel centerline may include yarns containing elastic fibers to improve the fit of the cushioning area to the wearer's foot.

[0050] In any of the embodiments described herein, it may be desirable to knit part or substantially all of the knitted component (including any cushioning areas) from recyclable materials (e.g., thermoplastic polymers that can be melted and reshaped). With this in mind, the cushioning areas can be formed with alternative yarns that substantially comprise recyclable materials exhibiting similar physical properties as described above. For example, the knitted component may comprise yarns formed from at least one thermoplastic polymer material or material composition (e.g., at least one polyurethane, polyamide, polyolefin, and / or nylon) that transitions from a solid to a softened or liquid state when subjected to certain temperatures at or above its melting point, and then transitions back to a solid state upon cooling. For example, at least a portion, at least half, most, or substantially all of the knitted component may comprise a first thermoplastic polymer. As a non-limiting example, at least 90%, 93.5%, or greater percentage by weight of the knitted component may comprise a resin constituting the first thermoplastic polymer.

[0051] The forefoot upper may include one or more optional tension zones that help the cushioning area hold the wearer's foot in place when the knitted component is incorporated into the footwear. More specifically, the tension zone may form part of a single, integrally knitted component with the cushioning area and may therefore be connected to the cushioning area via one or more rows of yarn. The tension zone may include one or more elastic yarns as described above, which facilitate the entry and exit of the wearer's foot when the knitted component is incorporated into the footwear by slightly elongating under tensile load. The tension zone may be located near the cushioning area on the outer or inner side of the knitted component. For example, Figure 1A The knitted component 34 includes a first tension zone 72 and a second tension zone 74, respectively, in the outer collar area 76 and the inner collar area 78. In other embodiments, the tension zones may additionally or alternatively be located in the outer ankle area, the inner ankle area, or the sub-ankle area. For example, Figure 1B The knitted component 100 includes a first tension zone 136 and a second tension zone 138 located in the lateral sub-ankle region 140 and the medial sub-ankle region 142, respectively. In other embodiments, the tension zones may extend toward or to the outer edge of the knitted component, and may also extend toward or to the collar edge.

[0052] When knitted components are incorporated into footwear and the wearer inserts their foot into the garment, the yarns in the tension zone experience tension. Because the interlooped rows of yarn connect the cushioning and tension zones, the tension experienced in the tension zone pulls the cushioning zone forward, causing it to conform to the wearer's heel. This anatomical fit helps secure the wearer's foot during activities such as walking, running, and sports.

[0053] The knitted components and uppers described in this article can be incorporated into footwear items. Figures 5A-5D The illustration depicts a footwear article 500, which includes an upper 504 formed at least partially by a knitted component 508. As shown, the upper 504 may be attached to at least one sole structure 512. Article 500 is disclosed to have an overall configuration suitable for walking, running, sports, and other movement activities. The concepts associated with footwear (including the upper 504 and the knitted component 508) can 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, sprint shoes, tennis shoes, and hiking boots. The concepts can also be applied to footwear types generally considered non-athletic, including fashion shoes, loafers, sandals, and work boots. Therefore, the concepts disclosed herein are applicable to a wide variety of footwear types. Furthermore, the concepts disclosed herein can be applied to items other than footwear, such as accessories or clothing.

[0054] like Figures 5A-5D As shown, the upper 504 typically provides a comfortable and secure cover for the wearer's foot. This allows the wearer to insert their foot through an opening 516 formed in the upper 504 and into a cavity to effectively secure the foot within the article 500 or otherwise bind the foot to the article 500. The opening 516 is defined by a collar 524. Furthermore, the sole structure 512 can be attached to the lower region of the upper 504 and extends between the foot and the ground to cushion the foot, provide traction friction, enhance stability, and influence foot movement.

[0055] Similar to the uppers and knitted components described above, footwear can generally be divided into three main areas: the forefoot, midfoot, and heel. (See also...) Figures 5A-5DThe heel region 528 of the shoe secures the wearer's heel within the article 500 and protects it from abrasion and impact. The heel region 528 of the article 500 may include components of the upper 504 (including knitted components 508) and the sole structure 512, and may further interact with other systems within the article 500 (e.g., tension systems and / or closure systems) to enhance function and performance. It is noteworthy that the heel region 528 need not be visually distinct from the midfoot region 532 (e.g., distinguished by edges, seams, or other structures). Instead, the two regions 528 and 532 can transition continuously, such as through a common and continuous knitted structure formed during a single knitting process.

[0056] Still referencing Figures 5A-5D The heel region 528 can extend from the inner boundary region 536 around the heel region 540 to the outer boundary region 544. Furthermore, the heel region 528 can extend upwards to the opening 516 and the collar 524, and downwards to the ground, encompassing all structures present in that space, including portions of the upper 504 and the sole structure 512. Additionally, the heel region 528 of the article 500 can include more than one layer of material, such as an inner knitted layer of knitted component 508 configured to face the wearer's foot, and an outer knitted layer of knitted component 508 facing outwards from the cavity. In such cases, the layers may, but are not necessarily, physically separable. The heel region 528 may also include other components, such as components positioned between the knitted layers of the upper 504 to provide cushioning.

[0057] Still referencing Figures 5A-5C Together with Figure 5D In a cross-sectional view, the rear shoe region 528 of article 500 includes a rectangular cushioning region 548 with a plurality of non-planar structures 550, which are integrally knitted with the knitted component 508 and protrude away from the inner surface 552 of the knitted component 508 into a cavity. The knitted component 508 also includes knitted non-planar structures 556 on its outer surface 560. In this embodiment, the knitted non-planar structures 556 are similar to cages; however, this is merely exemplary, and the outer surfaces of other knitted components may have different structures and appearances. Figures 5A-5D The embodiment illustrates that the knitted component 508 may include a non-planar structure with an integral knit on both the inner surface 552 and the outer surface 560. A cushioning region 548 is located in the calcaneal region 564 and wraps forward along the inner side 568 and outer side 572 of the upper 504. (Reference) Figure 5DA cross-sectional view shows multiple non-planar structures 550 knitted in a vertical orientation (i.e., parallel to the heel centerline 576 of the article 500). In this embodiment, the cushioning area 548 begins at the bite line 546; however, in other embodiments, the cushioning area may begin at a distance of 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, or greater from the bite line. The cushioning area 548 has a vertical height of approximately 20 mm to 40 mm (i.e., in the direction of the heel centerline 576) and a width of approximately 60 mm to 90 mm; however, alternative embodiments may have different dimensions, as discussed above with reference to the knitted component. The article 500 also includes a first tension zone 580 located in the outer collar area 584 and a second tension zone 588 located in the inner collar area 592, both tension zones 580 and 592 being at least partially formed of elastic yarn to give the knitted component 508 stretch and also to allow the cushioning area 548 to be pulled against the wearer's heel.

[0058] exist Figures 6A-6B In the alternative footwear article 600, the upper 604 includes a knitted component 608 having an ergonomically designed, non-geometrically shaped cushioning region 612 extending away from the inner surface 616 of the knitted component 608 within a cavity 620 formed by the upper 604. The cushioning region 612 includes a plurality of non-planar structures 624 comprising a coarse cross-ribbed fabric. In this embodiment, the upper 604 extends high into an Achilles tendon region 628. The cushioning region 612 is located in a calcaneal region 632 and extends toward the collar edge 636 into the Achilles tendon region 628. Reference Figure 6B The cross-sectional view shows that the non-planar structure 624 is knitted in a horizontal orientation (i.e., perpendicular to the center line 640 of the heel).

[0059] exist Figures 7A-7B In an alternative embodiment, footwear article 700 includes an upper 704 formed at least partially by a knitted component 708. The knitted component 708 includes an ergonomically designed, non-geometric cushioning region 712, which includes a plurality of non-planar structures 716 formed as a fluffy portion. The cushioning region 712 is located in a calcaneal region 720 but does not extend into the Achilles tendon region 724. The non-planar structures 716 are knitted in a quilt pattern to improve fit to the wearer's heel.

[0060] Figure 8 The illustration shows a non-limiting knitting sequence that can be used to form a knitted component (such as an upper for footwear articles) having a first surface and a second surface facing opposite each other, as well as a buffer area of ​​integral knitting as described above. The knitted component can be formed by a weft knitting process (e.g., using a flat knitting machine with one, two, or more needle beds). Figure 8The sequence is illustrated on a weft knitting machine having a first needle bed 800 and a second needle bed 804.

[0061] In the first step 808, the knitting machine knits the base portion of the buffer area. More specifically, the knitting machine knits rows of the first yarn 812 and the second yarn 816 on the first needle bed 800 and the second needle bed 804 to form a relatively firm knitted area. The number of rows knitted in the first step 808 is generally related to the width of the base portion of the buffer area. In other words, knitting more rows in the first step 808 will produce a base portion with a wider width, and vice versa. Although some rows of the first yarn 812 utilize... Figure 8 The first step 808 involves the knitting of a tuck stitch, but other embodiments may utilize different knitting structures in this step, such as double-knit or rib knit structures. The first step 808 includes the knitting of a row of second yarns 816 on a second needle bed 804 to prepare for the next step, in which the knitting machine knits a non-planar structure. Then, the knitting machine knits a row of first yarns 812 on a first needle bed 800. The first yarns 812 and second yarns 816 may be the same or different. For example, the first yarns 812 and second yarns 816 may comprise one or more inelastic yarns having a tensile strength of at least about 0.2 kgf, 0.3 kgf, 0.4 kgf, 0.5 kgf, or greater, and may comprise at least 70%, 75%, 80%, 85%, 90%, 95%, or a higher percentage (by weight) of a specific base chemical substance. Alternatively, the first yarn 812 and / or the second yarn 816 may include elastic yarns to impart stretch and resilience to the knitted component.

[0062] In the second step 820, the knitting machine knits a portion of the non-planar structure of the cushioning area, which extends away from the second surface of the knitted part. More specifically, the knitting machine knits multiple partial rows of the third yarn 824 on the second needle bed 804. The knitting length of the partial rows can typically correspond to a dimension of the resulting non-planar structure, such as height (if the rows are ultimately oriented parallel to the heel centerline of the shoe upper). For example, the partial rows in the second step 820 have a knitting length of approximately twenty-two stitches. In other embodiments, knitting partial rows with shorter knitting lengths (e.g., less than twenty-two stitches) will produce a non-planar structure with a shorter height. The number of partial rows knitted in the second step 820 can correspond to the depth to which the resulting non-planar structure extends away from the second surface of the knitted part. In other words, a larger number of rows knitted in the second step 820 can produce a non-planar structure with greater depth (i.e., extending further away from the inner surface of the knitted part). For example, Figure 8The second step 820 includes eight rows of the second yarn, which can produce a non-planar structure that, depending on the choice of yarn, extends approximately 2mm-5mm away from the base portion. Conversely, knitting a smaller number of rows in the second step 820 will produce a non-planar structure with a shallower depth, all others being equal. The third yarn 824 can be formed from the same or different material as the first yarn 812 and the second yarn 816.

[0063] In the third step 828, the knitting machine knits multiple additional rows of the first yarn 812 on the first needle bed 800 and the second needle bed 804; however, the number of rows can vary in different embodiments. More specifically, in the third step 828, the knitting machine closes the non-planar structure knitted during the second step 820 and knits another base portion by utilizing a combination of single-bed and double-bed knitting structures to knit additional rows of the first yarn 812 and the second yarn 816. Additionally, the knitting machine knits at least one row of the second yarn 816 on the second needle bed to prepare for knitting the next non-planar structure.

[0064] After steps 808, 820, and 828 (first to third steps), the preceding sequence can be repeated as needed to form additional non-planar structures and base portions, i.e., extended buffer areas. For example, in step 832, the knitting machine forms another non-planar structure from the third yarn 824, as described above with reference to step 820. In step 836, the knitting machine completes the non-planar structure knitted in step 832, similar to step 828 described above.

[0065] Figure 9 The illustration shows another non-limiting knitting sequence that can be used to form knitted parts (such as uppers for footwear) with integrally knitted cushioning areas. The resulting knitted part can have the same characteristics as those made by... Figure 8 The knitting sequence produces knitted parts with different visual appearances and physical properties (e.g., different stretch levels).

[0066] In the first step 900, the knitting machine forms a base portion comprising fifteen rows by knitting multiple rows of the first yarn 904 on the first needle bed 908. Using these fifteen rows, the base portion is formed by… Figure 9 The first step, 900 knitting, has a base portion that is more than that made by Figure 8In the third step 828, the base portions of the twelve rows of knitted yarn have a larger width, while all others are equal. The first yarn 904 may include an elastic yarn as described above, such as a yarn with elastic fibers constituting at least 2%, 3%, 5%, 10%, or a greater portion of the yarn, such that the yarn can achieve an elongation of at least about 15%, 20%, 25%, or a greater without breaking. The rows of the first yarn 904 may include multiple interlocking rows knitted on the first needle bed 908 and the second needle bed 912, which can help impart stretchability to the knitted portion.

[0067] In the second step 916, the knitting machine knits a portion of the non-planar structure of the buffer area, which extends away from the second surface of the knitting component. More specifically, the knitting machine knits eleven partial rows of the second yarn 920 on the second needle bed 912. Utilizing these eleven rows, in conjunction with the... Figure 8 Compared to the non-planar structure knitted in the second step 820, it is composed of... Figure 9 The second step 916, knitting a non-planar structure, will protrude further away from the surface of the knitted part, all others being equal. Furthermore, each local row of the second yarn 920 has a knit length of seventeen stitches. The result is that... Figure 9 The second step, 916, will result in a non-planar structure that is more complex than that created by knitting. Figure 8 The second step, 820, knits a 22-gauge non-planar structure with a shorter height, all others being equal. The second yarn 920 can be formed from the same or a different material as the first yarn 904.

[0068] In the third step 924, similar to the first step 900, the knitting machine closes the non-planar structure knitted during the second step 916 and forms a second base portion by the first yarn 904. After the third step 924, the preceding sequence can be repeated as needed to form additional non-planar structures and base portions, i.e., to extend the knitted buffer area.

[0069] In use, uppers for footwear articles incorporating knitted components with an integrally knitted cushioning area in the heel region as described above can offer numerous advantages. For example, such knitted components improve the fit of the footwear article by ensuring a close and conforming fit to the wearer's heel. The cushioning area also prevents the wearer's foot from slipping out of the footwear article. Additionally, in some embodiments, when the knitted component is incorporated into the footwear article, the cushioning area can eliminate the need for conventional heel stabilizers and other components, thereby reducing weight and cost. In some embodiments, the cushioning area can be formed from one or more materials similar to or the same as those used in the knitted component, thereby improving the recyclability of the knitted component.

[0070] While various embodiments of this disclosure have been described, this disclosure is not limited except as provided in the appended claims and their equivalents. Rather, the embodiments discussed have been chosen and described to provide the best illustration of the principles of this disclosure and its practical application, thereby enabling those skilled in the art to utilize this disclosure in various forms and with various modifications suitable for the intended particular purpose. It is intended and will be understood that embodiments may be combined or separated differently without departing from this disclosure, and all exemplary features described herein are applicable to all aspects of this disclosure described herein. Furthermore, the advantages described herein are not necessarily the only advantages of this disclosure, and it is not necessarily expected that every embodiment of this disclosure will achieve all the described advantages.

Claims

1. A shoe upper, the shoe upper forming a cavity, the shoe upper comprising: A knitted component having an inner surface facing the cavity and an outer surface opposite to the inner surface, wherein the knitted component includes a cushioning region that is integrally knitted with the knitted component and located in the rear region of the shoe upper; The buffer area includes a plurality of tubular rib structures, each of which protrudes away from the inner surface of the knitted component; and In the rear region of the shoe, the plurality of tubular ribbed structures extend vertically and parallel to the heel centerline of the shoe upper.

2. The upper according to claim 1, wherein the cushioning area is at least partially located in the calcaneal region.

3. The upper according to claim 1, wherein the cushioning area has a width of at least 1000 mm. 2 The shape of the area.

4. The upper according to claim 1, wherein the cushioning area has a geometric shape.

5. The upper according to claim 1, wherein the cushioning area has a non-geometric shape.

6. The upper of claim 1, wherein the plurality of tubular rib structures are separated from each other by a plurality of base portions.

7. The upper of claim 6, wherein the plurality of base portions are at least partially formed of elastic yarn.

8. The upper according to claim 1, wherein the plurality of tubular rib structures comprises at least five tubular rib structures.

9. The upper according to claim 1, wherein the thermoplastic polymer material constitutes at least 93.5% of the weight of the knitted component.

10. The upper according to claim 9, wherein the thermoplastic polymer material is thermoplastic polyurethane.

11. The upper of claim 1, further comprising a second plurality of tubular rib structures, each of the second plurality of tubular rib structures protruding from the outer surface of the knitted component.

12. A type of footwear, comprising: An upper, the upper being fixed to a sole structure, the upper forming a cavity, the upper including a knitted component having an inner surface facing the cavity and an outer surface facing oppositely, wherein the knitted component includes a cushioning region knitted integrally with the knitted component and located in the rear region of the upper. The cushioning area comprises a plurality of tubular rib structures, each of which has its inner surface, distal from the knitted component, protruding into the cavity and configured to contact the wearer's heel. In the rear region of the shoe, the plurality of tubular ribbed structures extend vertically and parallel to the center line of the heel.

13. The footwear article of claim 12, wherein the plurality of tubular rib structures begin at the seam where the upper and the sole structures meet or within 5 mm of the seam.

14. The footwear article of claim 12, wherein the knitted component includes a tension zone configured to pull the cushioning area against the wearer's heel.

15. The footwear article of claim 14, wherein the tension zone is located in the sub-ankle region of the upper.

16. The footwear article of claim 12, wherein the plurality of tubular rib structures are separated from each other by a plurality of base portions formed at least partially of elastic yarn.

17. The footwear article of claim 12, wherein the plurality of tubular rib structures comprises at least five tubular rib structures.

18. The footwear article of claim 12, wherein the knitted component is at least partially formed of a thermoplastic polymer material.

19. A shoe upper, the shoe upper forming a cavity, the shoe upper comprising: A knitted component having an inner surface facing the cavity and an outer surface facing the opposite direction, the knitted component comprising: Forefoot area Mid-shoe area The rear area of ​​the shoe; and At least one integrally knitted cushioning area is located on the inner surface of the shoe, the cushioning area comprising a plurality of non-planar structures that protrude toward the cavity from the inner surface of the knitted component and extend vertically and parallel to the heel centerline of the shoe upper, wherein the cushioning area is located in the rear region of the shoe.

20. The upper according to claim 19, wherein, The cushioning area extends 20mm-30mm on either side of the center line of the heel in both the inward and outward directions.

21. The upper according to claim 19, wherein, The buffer area includes a first buffer area and a second buffer area, the first buffer area being configured to cover at least a portion of the wearer's calcaneal region, and the second buffer area being configured to extend only partially into the wearer's Achilles tendon region.

22. A footwear article comprising an upper according to any one of claims 19-21.

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