Multi-layer knitted component with multi-bed regions and method of making same

Abstract

The present application relates to multi-layer knitted components having multiple bed regions and methods of making the same. In one aspect of the disclosure, a knitted component for use in an article of footwear can include a first layer having a multi-bed first region having a first surface and a second surface facing in an opposite direction. The knitted component can include a second layer, wherein a second region overlaps the first region. The second region can have a first surface and a second surface facing in an opposite direction. The knitted component can include a plurality of interlayer knit stitches interlooping at least one yarn of the first layer with at least one yarn of the second layer at an interface between the first and second surfaces of the first and second regions. The interior surfaces of the first and second regions can define at least a portion of a freely separable region between the first and second regions.

Description

[0001] This application is a divisional application of the application filed on August 6, 2018, with application number 201880058469.7 and invention title "Multi-layer knitted component with multiple bed areas and method of manufacturing thereof". background

[0002] This embodiment generally relates to knitted components and methods of manufacturing knitted components, and more specifically, to knitted components for footwear applications having at least two overlapping knitted layers formed during a knitting process, wherein at least one layer has a multi-bed knit construction.

[0003] Footwear typically includes an upper and optionally a sole structure. The upper can be attached to the sole structure and forms a cavity on the inside of the footwear for comfortably and securely receiving the foot. The sole structure can be attached to the lower surface of the upper for positioning between the upper and the ground.

[0004] A variety of materials are commonly used in the manufacture of shoe uppers. For example, the uppers of athletic footwear can be formed from a variety of material components. Materials can be selected based on a range of properties, including, for example, tensile strength, abrasion resistance, flexibility, breathability, compressibility, and moisture-wicking. Some uppers can be formed from knitted materials. Incorporating knitted components into the upper, or knitted uppers themselves, can offer advantages over conventionally manufactured uppers, for example, due to the knitted properties of the structure, configuration, or material.

[0005] In knitted components, such as those used in footwear, knitted sections comprising freely separable overlapping areas are advantageous. Such knitted components can have several applications, including forming part of a fastening system, serving as storage components, allowing objects (e.g., tension yarns) to pass through, enclosing the wearer's foot, and reducing friction experienced by the wearer. In such applications, it is advantageous to increase the strength and durability of the knitted component, for example, by providing a multi-bed knitted construction to at least one overlapping area. Forming such knitted components from a single knitting process can be even more advantageous to reduce the time and materials associated with costly post-knitting steps.

[0006] Overview

[0007] In one aspect of this disclosure, a knitted component for use in footwear articles may include a first layer having multiple first regions having a first surface and a second surface facing opposite directions. The knitted component may include a second layer, wherein a second region overlaps with the first region. The second region may have a first surface and a second surface facing opposite directions. The knitted component may include a plurality of interlayer knitting stitches at the interface between the second surfaces of the first and second regions, where at least one yarn from the first layer and at least one yarn from the second layer are looped together. The inner surfaces of the first and second regions may define at least a portion of a separable region between the first and second regions. In another aspect, the first region may have a first edge forming part of a first opening in the first layer, and may have a second edge forming part of a second opening in the first layer. The first and second openings, and the separable region, may form a channel. In another aspect, at least one of the first and second edges may have a course-wise orientation. In another aspect, the first and second regions may form a knitted loop structure. In another aspect, the knitted loop structure may include a binding area extending together with either the first or second edge. On the other hand, the knitted loop structure can form part of the fastening system of footwear. On another hand, the first and second regions can have a multi-bed construction. On yet another hand, the upper part of the foot including one of the first and second regions can be connected around its perimeter to the lower part of the foot including the other of the first and second regions. On yet another hand, a first collar portion including one of the first and second regions can be connected to a second collar portion including the other of the first and second regions.

[0008] In another aspect of this disclosure, a method of knitting a knitted component may include knitting a portion of a multi-bed first region of a first layer on a plurality of first region needles on a first needle bed and a second needle bed. The method may include transferring at least a portion of the first region from the first needle bed to the second needle bed. The method may include knitting a second region of a second layer on a plurality of second region needles on the first needle bed. The method may also include forming a plurality of interlayer knitting stitches where the first and second regions extend together between the first and second layers. The first region needles may be different from the second region needles. In another aspect, knitting a portion of a multi-bed first region may further include a knitted edge that defines a portion of an opening in the first layer. In another aspect, knitting a portion of a multi-bed first region may further include a knitted junction area that extends together with the edge. In another aspect, the first and second regions may form at least a portion of a knitted loop structure. In another aspect, an upper portion of the foot including one of the first and second regions may be connected around a perimeter to a lower portion including the other of the first and second regions. In another aspect, a first collar portion including one of the first and second regions may be connected to a second collar portion including the other of the first and second regions. In another aspect, the second region may have a multi-bed construction.

[0009] In another aspect of this disclosure, a method of knitting a knitted component may include knitting a multi-bed first region of a first layer, knitting a freely separable second region of a second layer in an overlapping relationship with the first region while knitting the first region, and looping at least one yarn of the first layer and at least one yarn of the second layer together at the interface between the inner surfaces of the first and second regions. In another aspect, the first and second regions may form at least a portion of a knitted loop structure. In another aspect, the first and second regions may form at least a portion of an upper foot portion and a lower foot portion that can be connected around the perimeter of a lower foot portion. In another aspect, knitting a multi-bed first region of the first layer may include knitting a first region having a single-bed construction, and imparting a multi-bed construction to the first region by performing an inter-bed transfer of at least one stitch of the first region.

[0010] This application also relates to the following aspects:

[0011] 1) A knitted component for use in footwear articles, the knitted component comprising:

[0012] The first layer includes a first region of multiple beds, the first region having a first surface and a second surface facing opposite directions;

[0013] The second layer includes a second region that overlaps with the first region, the second region having a first surface and a second surface facing opposite directions;

[0014] Multiple interlayer knitting stitches are used, wherein at least one yarn from the first layer and at least one yarn from the second layer are interlocked at the interface between the second surface of the first region and the second surface of the second region.

[0015] The inner surfaces of the first region and the second region define at least a portion of a freely separable region between the first region and the second region.

[0016] 2) Knitted components as described in 1),

[0017] The first region includes a first edge and a second edge, the first edge forming part of a first opening in the first layer, and the second edge forming part of a second opening in the first layer.

[0018] The first opening, the second opening, and the freely separable region form a channel.

[0019] 3) The knitted component as described in 2), wherein at least one of the first edge and the second edge has a transverse orientation.

[0020] 4) The knitted component as described in 1), wherein the first region and the second region form a knitted loop structure.

[0021] 5) The knitted component as described in 4), wherein the knitted loop structure includes a bonding area that extends together with the first edge or the second edge.

[0022] 6) The knitted component as described in 4), wherein the knitted loop structure forms part of the fastening system of the footwear article.

[0023] 7) The knitted component as described in 1), wherein the first region and the second region have a multi-bed construction.

[0024] 8) The knitted component as described in 1), wherein the upper foot portion includes one of the first region and the second region, the lower foot portion includes the other of the first region and the second region, and the upper foot portion is connected to the lower foot portion around a perimeter.

[0025] 9) The knitted component as described in 1), wherein the first collar portion includes one of the first region and the second region, the second collar portion includes the other of the first region and the second region, and the first collar portion is connected to the second collar portion.

[0026] 10) A method of knitting a part, the method comprising:

[0027] A portion of the first area of ​​a multi-bed needle layer is knitted on multiple first area needles on the first and second needle beds;

[0028] Transfer at least a portion of the first region from the first needle bed to the second needle bed;

[0029] The second layer of the second area is knitted on multiple second areas of the first needle bed; and

[0030] Multiple interlayer knitted stitches are formed between the first layer and the second layer, and the first region and the second region extend together at the multiple interlayer knitted stitches.

[0031] The first region needle is different from the second region needle.

[0032] 11) The method as described in 10), wherein a portion of the first region of the knitted multi-bed further includes a knitted edge that defines a portion of an opening in the first layer.

[0033] 12) The method as described in 11), wherein a portion of the first region of the knitted multi-bed further includes a bonding region where the knitting extends together with the edge.

[0034] 13) The method as described in 10), wherein the first region and the second region form at least a portion of a knitted loop structure.

[0035] 14) The method as described in 10), wherein the upper part of the foot includes one of the first region and the second region, the lower part of the foot includes the other of the first region and the second region, and the upper part of the foot is connected to the lower part of the foot around a perimeter.

[0036] 15) The method as described in 10), wherein the first collar portion includes one of the first region and the second region, the second collar portion includes the other of the first region and the second region, and the first collar portion is connected to the second collar portion.

[0037] 16) The method as described in 15), wherein the second region has a multi-bed configuration.

[0038] 17) A method of knitting a knitted part, the method comprising:

[0039] The first area of ​​the multi-bed knitted first layer;

[0040] While knitting the first region, a freely separable second region of the second layer is knitted in a relationship overlapping with the first region; and

[0041] At the interface between the inner surface of the first region and the inner surface of the second region, at least one yarn of the first layer and at least one yarn of the second layer are looped together.

[0042] 18) The method as described in 17), wherein the first region and the second region form at least a portion of a knitted loop structure.

[0043] 19) The method as described in 17), wherein the first region and the second region form at least a portion of the foot portion and the foot portion connected by a perimeter surrounding the foot portion.

[0044] 20) The method as described in 17), wherein the first region of a multi-bed knitting first layer comprises knitting the first region having a single-bed construction, and the multi-bed construction is assigned to the first region by performing an inter-bed transfer of at least one stitch of the first region.

[0045] Upon studying the following figures and detailed description, other systems, methods, features, and advantages of the present invention will be apparent or will become apparent to those skilled in the art. It is intended that all such additional systems, methods, features, and advantages are within the scope of the present invention and are covered by the appended claims. Brief description of the attached diagram

[0046] The invention can be better understood by referring to the following figures and description. The components in the figures are not necessarily to scale, but rather the emphasis is on illustrating the principles of the invention. Furthermore, throughout the figures, similar reference numerals denote corresponding parts.

[0047] Figure 1 It depicts footwear items that incorporate knitted components.

[0048] Figure 2 A knitted component with a first layer having an outer region that overlaps with the inner region of a second layer is depicted.

[0049] Figure 3 Depicting Figure 1 The knitted loop structure of the knitted parts.

[0050] Figure 4 Depicting Figure 2 , Figure 3 A cross-sectional view of a knitted loop structure.

[0051] Figure 5 A cross-sectional view of another knitted loop structure is depicted.

[0052] Figure 6 Depicting Figure 1 Another knitted loop structure for the knitted component.

[0053] Figure 7 Depicting Figure 2 , Figure 6 A cross-sectional view of a knitted loop structure.

[0054] Figure 8A Another knitted part is depicted, having an outer area that overlaps with the inner area.

[0055] Figure 8B Depicting Figure 8A Another view of the knitted component.

[0056] Figure 9 Depicting Figure 8A A cross-sectional view of a knitted area of ​​a knitted component.

[0057] Figure 10 Depicting Figure 8A A cross-sectional view of another knitted area of ​​the knitted component.

[0058] Figure 11 Depicting Figure 8A Another cross-sectional view of the knitted section of the knitted component.

[0059] Figure 12 The method for forming knitted parts is illustrated schematically.

[0060] Figures 13A to 13G Depicting the corresponding Figure 12 The knitting pattern is obtained by at least one of the methods.

[0061] Figure 14 Another method for forming knitted parts is illustrated schematically.

[0062] Figure 15 Depicting the corresponding Figure 14 The knitting pattern is obtained by at least one of the methods.

[0063] Figure 16 Another method for forming knitted parts is illustrated schematically.

[0064] Figure 17 Depicting the corresponding Figure 8A The knitted pattern of at least one area of ​​the knitted part.

[0065] Figures 18A to 18D Depicting the corresponding Figure 8A The knitting pattern of another area of ​​the knitted component.

[0066] Figure 19Depicting the corresponding Figure 8A The knitting pattern of another area of ​​the knitted component.

[0067] Detailed description of the preferred implementation scheme

[0068] Figure 1 The illustration shows a footwear article 100 with an upper 104 generally formed as a knitted component 108. As shown, the upper 104 can be attached to at least one sole structure 112. The article 100 has an overall configuration suitable for walking or running. The concepts associated with footwear (including the upper 104 and the knitted component 108) 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.

[0069] exist Figure 1 In this embodiment, the upper 104 can provide comfortable and secure coverage for the wearer's foot. Thus, the upper 104 can define a cavity 90 to effectively receive and secure the foot within the article 100. Furthermore, the sole structure 112 can be attached to the lower region of the upper 104 and can extend between the foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction friction, improve stability, and influence foot movement.

[0070] For reference purposes, article 100 can be generally divided into three general areas along its longitudinal direction (heel to toe): a forefoot area 120, a midfoot area 124, and a heel area 128. The forefoot area 120 can generally include the portion of article 100 corresponding to the toes and the joints connecting the metatarsals and phalanges. The midfoot area 124 can generally include the portion of article 100 corresponding to the arch region of the foot. The heel area 128 can generally correspond to the posterior portion of the foot, including the area covering the calcaneus (which includes a portion of the wearer's heel). Furthermore, the heel area 128 can cover some or all of the wearer's ankle and talus (which includes a portion of the ankle). Article 100 also includes a medial side 132 and a lateral side 136, which can extend through each of the forefoot area 120, the midfoot area 124, and the heel area 128, and can correspond to opposite sides of article 100. More specifically, the outer surface 136 may correspond to the outer region of the foot (i.e., the surface facing away from the other foot), and the inner surface 132 may correspond to the inner region of the foot (i.e., the surface facing the other foot). The forefoot region 120, midfoot region 124, heel region 128, inner surface 132, and outer surface 136 are not intended to define precise areas of the article 100, but rather to represent general areas of the article 100 to facilitate the discussion below.

[0071] like Figure 1As shown, article 100 may have one or more zones, including separable and overlapping areas formed as a result of the knitting process. At least one of the separable areas in each zone may have knitting construction characteristics formed on at least two needle beds of a knitting machine, i.e., a multi-bed construction. For example, a first zone 140 may be present in the throat area of ​​article 100 and may include at least one knitted loop structure 144 formed as a separable zone and having an opening that allows an object, such as a shoelace 148, a tensioning strand, a strip, or other object, to pass through it. The loop structure 144 may form part of a fastening system for securing the wearer's foot within article 100. As another example, a second zone 152 may be present in the inner side 132 of article 100 and may include at least one knitted loop structure 156 formed as a separable zone, which may have an opening and may be oriented differently from the knitted loop structure 144 in the first zone 140. The knitted loop 156 may accommodate a strip 160 or other object, for example, as part of a fastening system. As another example, a third zone 164 may exist in the rear section 128 of the article 100 (e.g., on the inner side 132 or outer side 136) and may not have any openings, but may still have freely separable knitted areas, for example, to facilitate movement of the outer layer relative to the inner layer in order to reduce friction experienced by the wearer. Another zone (not shown) may have a single opening between the two zones, for example, forming a pocket that can hold a component. As another example, a fourth zone 168 may exist on the inner side 132 and / or outer side 136 of the forefoot section 128. As yet another example, a fifth zone 172 may exist in the collar section of the article 100 and may include two or more freely separable and overlapping zones, such as to reduce friction or to form a channel that can accommodate objects (such as tension strands). For clarity, the aforementioned zones are merely exemplary. Similar structures may exist in other locations on the article 100 and may have different orientations, different sizes, etc. Furthermore, any zone may have any of the characteristics described in this application relative to the other zones.

[0072] refer to Figure 2At least a portion, and potentially substantially the entire upper 104, may be formed of a knitted component 108. The knitted component 108 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 the knitting machine can substantially form the knitted structure of the knitted component 108 without requiring significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component 108 may be individually formed as distinct single-piece elements, and then the respective elements may be attached.

[0073] Forming the upper 104 with the knitted component 108 can provide advantages, including but not limited to specific degrees of elasticity (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 knitting structures (e.g., ribbed knit structure, single jersey knit structure, or double jersey knit structure), by varying the size and tension of the knitting structure, by using one or more yarns formed from specific materials (e.g., polyester, relatively inelastic materials, or relatively elastic materials such as elasticated yarns), by selecting yarns of specific dimensions (e.g., denier), and / or combinations thereof. In addition to those defined herein, any section, layer, and area of ​​the knitted component 108 may include one or more materials. The knitted component 108 can also provide desired aesthetic properties by combining yarns with 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 108 may include two or more portions with different properties (e.g., a portion forming the throat region of the shoe upper may be relatively elastic, while another portion may be relatively inelastic). In some embodiments, the knitted component 108 may incorporate one or more materials that have properties that change in response to stimuli (e.g., temperature, humidity, electric current, magnetic field, or light), including materials that may be fusible or infusible. For example, the knitted component 108 may include yarns comprising at least one fusible thermoplastic polymer material or material composition (e.g., at least one polyurethane, polyamide, polyolefin, and / or nylon) that, when subjected to certain temperatures equal to or above its melting point, transitions from a solid to a softened or liquid state, and then transitions back to a solid state upon cooling. When fusible yarns are heated and fused together to form infusible yarns, the process can have the effect of hardening or rigidifying the structure of the knitted component 108 by forming fused regions. Furthermore, using fusible yarns to connect portions of non-fusible yarns can have the effect of fixing or locking the relative position of the non-fusible yarns within the knitted component 108, thereby imparting tensile strength and stiffness. That is, the portions of the non-fusible yarns, when fused with the fusible yarns, can remain relatively stable relative to each other, thus preventing warping or permanent stretching of the knitted component 108 due to relative movement of the knitted structure. Another feature of using fusible yarns in portions of the knitted component 108 involves limiting unwinding if a portion of the knitted component 108 becomes damaged or one of the non-fusible yarns breaks.Therefore, if the area of ​​the knitted part 108 is entirely composed of fusible yarn, then these areas can be configured with both fusible and non-fusible yarns.

[0074] The knitted component 108 can be knitted in a two-dimensional configuration and subsequently shaped into the wearer's foot shape through post-knitting methods. For example, Figure 2 The knitted component 108 reflects a two-dimensional "U" or "horseshoe" shape. However, it should be understood that... Figure 2 The "horseshoe" or "U" shape is merely exemplary, and the knitted component embodying the disclosure of this application can be knitted such that its edges are in harmony with... Figure 2 Different locations, such as "C-shaped" knitted components or two-piece knitted components (e.g., where the heel area is knitted differently from the forefoot and midfoot areas). Alternatively, a brief reference may be made. Figures 8A to 8B The knitted component 366 can be knitted in a three-dimensional configuration, through which the knitted component 366 is generally knitted into the shape of the wearer's foot, i.e., a cavity that generally surrounds the shape of the foot. Such a three-dimensional knitted component 366 may include an upper foot portion 374, which, as a result of the knitting process, is connected to a lower foot portion 378 along a perimeter 394, for example, using interlayer knitting stitches, wherein the stitches of the first layer are interlocked with the stitches of the second layer. Such a three-dimensional knitted component 366 can resemble a shoe insole or shoe lining after the knitting process. As used herein, the term "knitted component" is not intended to limit the knitted component to a particular shape with a specific edge configuration, or to a knitted component knitted in two or three dimensions.

[0075] Return to Figure 2 The knitted component 108 can be divided into a forefoot region 180, a midfoot region 184, and a heel region 188, which can respectively correspond to the forefoot region 120, midfoot region 124, and heel region 128 of the article 100. Similarly, the knitted component 108 can have an inner surface 192 and an outer surface 196, corresponding to the inner surface 132 and outer surface 136 of the article 100.

[0076] like Figure 2 As shown, the knitted component 108 may include one or more knitted areas with a specific knitted structure, particularly overlapping and freely separable knitted areas, which may (but are not required to) have corresponding Figure 1The location and orientation of areas of the item 100. For example, a first area 200 may be present in the throat area of ​​the knitted component 108 and may include at least one knitted loop structure 204 having an opening to allow an object (e.g., shoelace, tension strand, strip, or other object) to pass through. As another example, a second area 208 may be present in the inner side 192 of the knitted component 108, may include at least one knitted loop structure 212, and may be oriented differently from the knitted loop structure 204 in the first area 200. As another example, a third area 216 may be present in the heel area 188 of the knitted component 108 and may form a pocket (with an opening) or may not have any opening. As another example, a fourth area 220 may be present in the forefoot area 180. As yet another example, a fifth area 224 may be present in the collar area of ​​the knitted component 108 and may include a freely separable area.

[0077] Generally speaking, any of the aforementioned areas of the knitted component 108 may have a first knitted layer that can form a first surface and a second knitted layer that can form a second surface. The first and second layers may each comprise one or more materials selected to impart advantageous properties to the knitted component. For example, the first layer may ultimately correspond to the outer surface of the footwear article 100 and may therefore include rows of relatively inelastic first yarns that provide abrasion resistance and durability. On the other hand, the second layer may ultimately correspond to the inner surface of the footwear article 100 and may therefore include one or more rows of yarns with a relatively soft hand feel (e.g., yarns with a napped finish for softness).

[0078] In general (specific references will be discussed later), within each zone, the first layer may include a first knitted area, and the second layer may include a second knitted area. The first area may overlap with and be freely separable from the second area. In other words, the first and second areas may have surfaces facing opposite directions, thereby allowing the first area to be freely separable from the second area. That is, the first area may have a first surface generally facing a first direction and a second surface generally facing the opposite direction. The same applies to the second area. Although the first area of ​​the first layer may be freely separable from the second area of ​​the second layer, it should be understood that other areas of the first layer do not need to be freely separable from the second layer, for example, in cases where interlayer knit stitches interloop the rows of the second and first layers.

[0079] The first region can also coexist with the second region. For example, one aspect of the first and second regions can terminate at one or more interlayer knit stitches (e.g., a row of interlayer knit stitches forming an interlayer knit stitch line, which will be described in detail later). In such a case, the first and second regions will connect where they coexist. As another example, the first and second regions can terminate at an edge that defines at least a portion of an opening in the first layer. Such an edge may exist only in the first region, but can still indicate the location where one dimension of the overlapping second region terminates. In such a case, the first and second regions will remain freely separable where they coexist.

[0080] At least one of the freely separable and overlapping first and second regions can have a knitting construction characteristic formed on at least two needle beds of a knitting machine, i.e., a "multi-bed" knitting construction. Such a multi-bed knitting construction can be characterized by two opposing faces of knitting loops and / or tucks, for example, one face of a loop formed on the first needle bed and a second face of a loop formed on the second needle bed. A knitted part with a "multi-bed" construction has a "multi-bed" knitting structure. Common multi-bed knitting structures include double-knit, rib, interlocking, cardigan, other "double-bed" knitting structures initially formed on at least two needle beds, and other knitting structures with two opposing faces of knitting loops or tucks, including variations in the total number of stitches and less than the total number of stitches for these structures. As used in this application, a "multi-bed" knitting structure can also include a knitting structure initially formed on a single needle bed, but which may ultimately have at least two faces of knitting loops or tucks as a result of additional steps (e.g., inter-bed transfers) performed during the knitting process. As an example, a multi-bed layer, zone, or row of yarns may include multiple loops initially knitted on a first needle bed (e.g., in single-sided plain knit), but during the knitting process, at a subsequent step, at least one loop may be transferred to a second needle bed (e.g., via inter-bed transfer, including inter-bed lateral transfer), after which the zone, layer, area, or row may have two opposite loops or two opposite faces of loops. An example of inter-bed transfer would be transferring a knitted loop from a needle on the first needle bed to an opposite needle on the second needle bed (e.g., from a third needle on the front needle bed to a third needle on the back needle bed). Inter-bed transfer includes inter-bed lateral transfer, where a knitted loop is transferred from a needle on the first needle bed to a non-opposite needle on the second needle bed (e.g., from a third needle on the front needle bed to a second needle on the back needle bed).

[0081] In some embodiments, the first region may have a different stitch density than the second region. For example, the first region may have a half-gauge stitch density, and the second region may have a stitch density less than half-gauge. As used herein, the terms “full gauge,” “half gauge,” and “less than full gauge” generally refer to the stitch density of a knitted component, rather than a specific knitting technique. Generally, knitted components and knitted layers may include regions with a “full gauge” stitch density if the region contains stitches (e.g., loops or tucks) formed on at least two consecutive needles (typically more than two consecutive needles) of the needle bed. Similarly, the same knitted component may include regions with a “half gauge” stitch density, wherein the region contains stitches formed on every other needle. Similarly, the same knitted component may have “less than full gauge” regions that are neither full gauge nor half gauge, such as one-third gauge (stitches formed on every three needles) or one-quarter gauge (stitches formed on every four needles (every other than three needles)).

[0082] In some embodiments, the first region may have a multi-bed knit construction, and the second region may have a knit construction characteristic formed on a single needle bed (“single-bed” knit construction, e.g., plain knit). Alternatively, both the first and second regions may have a multi-bed construction. In other embodiments, the first region may have a single-bed construction and the second region may have a multi-bed construction. For clarification, either or both of the first or second regions may have a multi-bed construction.

[0083] Now for reference Figure 3 , Figure 1 The first region 200 of the integral knitted component 108 may have a first layer 224 (which may ultimately correspond to the exterior of the footwear 100) and a second layer 228 (which may ultimately correspond to the interior of the footwear 100), which together form a channel 232 that may have a wale-wise orientation. The first layer 224 and the second layer 228 may include one or more knitted loop structures 204a, 204b (and may be more or fewer). Figure 3 (The loop structures shown are illustrated). The knitted loop structures 204a and 204b can ultimately form part of the fastening system in article 100, such as a tie system or a strip system. For visualization purposes, Figure 3 The illustration shows a shoelace 236 passing through loop structure 204b. The knitted loop structures 204a and 204b can be integrated with the knitted component 108, i.e., formed during the same knitting process that forms the rest of the knitted component 108, rather than being attached as a result of a post-knitting step. The knitted component 108 can embody a multi-bed knitted construction.

[0084] Let's refer to each other. Figure 3 , Figure 4 and Figure 5 Each knitted loop structure 204 may include an outer region 240 and an inner region 244, wherein, as a result of the knitting process, the outer region 240 overlaps with and is freely separable from the inner region 244. At least one of the outer region 240 and the inner region 244 may have a multi-bed knitted construction. For example, in Figure 4 In the middle, the outer region 240 can have a multi-bed knitted construction. In contrast, in Figure 5 In this configuration, both the outer region 240 and the inner region 244 can have a multi-bed structure. The outer region 240 can have a first surface 248 and a second surface 252 oriented in opposite directions toward the channel 232. Similarly, the inner region 244 can have a first surface 256 and a second surface 260 oriented in opposite directions. The outer region 240 can include a first edge 264 and a second edge 268, which can respectively form at least a portion of a first opening 272 and a second opening 274 in the first layer 224. As a result of the oppositely oriented surfaces of the outer region 240 and the inner region 244, the outer region 240 can remain freely separable from the inner region 244, including along the first edge 264 and the second edge 268. Therefore, the outer region 240 and the inner region 244 can form the channel 232. More specifically, the first surfaces 248 and 256 of the outer region 240 and the inner region 244 can be oriented away from the channel 232, and the oppositely oriented second surfaces 252 and 260 can be oriented toward the channel 232. Figure 3 In one implementation, the outer region 240 may have an approximate geometric shape (e.g., rectangular or hyperbolic) or an organic appearance, and the channel 232 may have an approximate orientation from the front to the back of the shoe, which may correspond to the orientation in the longitudinal direction.

[0085] exist Figure 3In the outer region 240, the first edge 264 and the second edge 268 may have a generally transverse orientation. The first edge 264 and the second edge 268 may also correspond to the first bonding region 278 and the second bonding region 282, respectively, and are designed to resist rolling, unraveling, and loss of resilience or integrity (e.g., due to repeated stretching with shoelaces, strips, tension filaments, or other objects). Bonding regions 278, 282 may be formed from one or more transverses of yarns with relatively high toughness and tensile strength, such as polyester multifilament yarns. Alternatively or additionally, bonding regions 278, 282 may be formed from one or more transverses of yarns or filaments of a thermoplastic material, which, when subjected to a post-knitting heat treatment process, can form a reinforced fusion region. Bonding regions 278, 282 can be formed by performing a series of bonding steps during the knitting process, wherein the transverses of yarns forming the outer region 240 can be gradually bonded into the first layer 224. The bonding regions 278 and 282 may include multiple progressively shorter rows of yarns. More specifically, in all embodiments with edges, the bonding regions may impart advantageous properties to the edges, but remain optional.

[0086] Continue to refer to Figures 3 to 5 The outer region 240 and the inner region 244 may extend together in one or more directions. As an example, the outer region 240 and the inner region 244 may extend together at a first edge 264 and a second edge 268 formed at the boundary of the longitudinal direction of the outer region 240. Although the first edge 264 and the second edge 268 may form part of the outer region 240 and define openings 272, 274 in the first layer 224, they may still indicate the location where the inner region 244 terminates and the second layer 228 continues in one dimension. As another example, the outer region 240 and the inner region 244 may extend together at a first group 286 and a second group 290 of the interlayer knitted stitch, for example, at the boundary of the transverse direction of the outer region 240.

[0087] refer to Figure 3Detail 294 indicates that interlayer knitting stitches may exist, wherein at least one yarn of the first layer 224 may loop with at least one yarn of the second layer 228, thereby preventing separation of the first layer 224 and the second layer 228 at the location of the looped yarns. For example, a first set 286 of interlayer knitting stitches may exist at the interface between the second surface 252 of the outer region 240 and the second surface 260 of the inner region 244. Such a connection can arise directly from the knitting process. In other words, the connection can be continuous because the yarns and / or strands of the first layer 224 and / or the second layer 228 are sufficient to connect the two layers. In other words, no post-knitting step is required to connect the first layer 224 and the second layer 228 at the location of the interlayer knitting stitches. Compared with other connection forms, such a connection form can advantageously save materials, costs, manufacturing time, and weight. In some embodiments, multiple yarns of the first layer and / or multiple yarns of the second layer may loop with each other. The first group 286 and the second group 290 of the interlayer knitted stitches can form interlayer knitted stitch rows, but it is not necessary for them to form rows, as they can be arranged in a non-linear manner (e.g., a pattern over areas). Figure 3 In one embodiment, the first group 286 and the second group 290 of the interlayer knitted stitches can form interlayer knitted stitch rows with a wale orientation; however, in other embodiments, the interlayer knitted stitch rows can have other orientations, such as a row orientation. More specifically, on one side of the first group 286 or the second group 290 of the interlayer knitted stitches, an outer region 240 and an inner region 244 can exist and be freely separable. At the first group 286 and the second group 290 of the interlayer knitted stitches, the outer and inner regions extend together, and the first layer 224 and the second layer 228 are inseparable. On the other side of the first group 286 and the second group 290 of the interlayer knitted stitches, the first layer 224 and the second layer 228 can be inseparable (e.g., if connected by another interlayer knitted stitch) or can be freely separable (e.g., if not connected by another interlayer knitted stitch). Figure 3 In detail representation 294, the first layer 224 and the second layer 228 are inseparable outside the first group 286 of the interlayer knitting stitch. In any case, the interlayer knitting stitch (e.g., the first group 286 and the second group 290) can indicate the position where the outer region 240 and the inner region 244 terminate in one dimension, and transition continuously into the first layer 224 and the second layer 228, respectively.

[0088] Still referencing Figure 3The outer region 240 may include one or more rows of yarns and / or plies extending continuously into the first layer 224. In other words, the one or more rows of yarns and / or plies forming the outer region 240 may have an orientation approximately perpendicular to the channel 232 formed between the outer region 240 and the inner region 244. As a result of pulling or stretching the outer region 240, these rows of yarns and / or plies can withstand tension and can advantageously transfer this tension to the first layer 224, where the tension can be absorbed. To facilitate the transfer of force to the first layer 224, at least a portion of the outer region 240 may have a multi-bed construction, among other benefits. Compared to a single-bed knitting construction, a multi-bed construction can advantageously provide greater strength, tensile strength, and anti-rolling at the edges. Such a construction can provide further advantages by eliminating the need for additional elements to be incorporated into the knitted part 108 or article 100 (e.g., tension plies embedded in the knitted part 108 as part of a fastening system), thereby further reducing weight and cost. Exemplary multi-bed knitting structures suitable for the outer region 240 include double-sided plain weave, interlocking, rib knit (e.g., 1x1 and 2x1), and other structures as described above. The outer region 240 may include multiple knitting structures, including at least one multi-bed knitting structure. For example, the outer region 240 may include certain rows with interlocking constructions and may also include rows knitted on a single needle bed, including floats, to enhance tensile strength.

[0089] To further facilitate the transfer of tension to the first layer 224, the outer region 240 may include rows of yarns and / or plies (e.g., polyester yarns) with relatively low tensile strength. For example, the outer region 240 may be formed of a high-tenacity yarn with relatively high tensile strength and resistance to surface abrasion, and relatively low tensile strength. Alternatively or additionally, the outer region 240 may include one or more rows of monofilament plies, which can provide weight savings compared to multifilament yarns. Monofilament plies can also provide surface properties that reduce friction, which can advantageously facilitate the movement of elements (e.g., shoelaces) within the channel 232 formed by the outer region 240 and the inner region 244. Alternatively or additionally, one or more yarns or plies forming the outer region 240 may include thermoplastic materials, such as monofilament plies coated with thermoplastic polyurethane. When the yarns or plies containing thermoplastic materials are heated above a phase change threshold (e.g., during the post-knitting process), the thermoplastic portions of these yarns melt and integrate into the surrounding yarns. When cooled below the phase change threshold, the thermoplastic material solidifies again, thereby reinforcing these parts by binding the filaments together and creating a resistant fusion zone.

[0090] The inner region 244 may include one or more rows of yarns and / or plies extending continuously into the second layer 228. In other words, the one or more rows of yarns and / or plies forming the inner region 244 may have an orientation approximately perpendicular to the channel 232. In some embodiments, at least a portion of the inner region 244 may have a multi-bed construction, but because the inner region 244 is unlikely to experience the same tension as the outer region 240, in other embodiments, the inner region 240 may have a substantially single-bed knitted construction.

[0091] Although the inner region 244 is unlikely to withstand high tension, it can still be knitted under some positive tension, to resist tension, and / or to bias the knitted loop structure 204 into a contracted state. This characteristic can give the knitted loop structure 204 an ideal level of resilience and allow the outer region 240 to form more pronounced loops. To achieve this, the inner region 244 may comprise one or more elastic yarns with relatively high tensile strength. Suitable elastic yarns may contain elastic fibers, such as those obtained from EIduPont de Nemours under the trademark LYCRA. Such yarns may have a configuration of covered LYCRA, for example, yarns with a LYCRA core surrounded by a nylon sheath. Other fibers or filaments exhibiting elastic properties may also be used. Alternatively or concurrently, the outer region 240 or the inner region 244 may comprise one or more rows of yarns knitted with thermoplastic yarns, such as thermoplastic polyurethane yarns, or yarns or plies of other materials sheatheeded with thermoplastic materials (such as monofilament plies sheatheeded with thermoplastic polyurethane). More specifically, either the outer region 240 or the inner region 244 may embody any combination of the exemplary materials described above and other materials suitable for forming the knitted component.

[0092] In use, Figure 3 The knitted component 108 can be formed into footwear items (such as...) Figure 1 The article 100 comprises at least a portion of the upper of the shoe and may include one or more knitted loop structures 204 as described above. The knitted loop structures 204 may ultimately be located on the inner side 132 and / or outer side 136 of the article 100, and in the forefoot region 120, midfoot region 124, and heel region 128. One or more knitted loop structures 204 may receive laces 236, strands, strips, or other objects through channels 232 formed by the outer region 240 and the inner region 244. The loop structures 204 and the laces 236, strands, strips, or other objects may form part of a fastening system that helps secure the wearer's foot within the cavity 116 formed by the knitted component 108.

[0093] In use, when the wearer pulls one end of the shoelace 236 (or strands, strips, or other material), it can slide within the channel 232 of the knitted loop structure 204. If the loop structure 204 is at least partially knitted with monofilament strands or other low-friction materials, it can reduce the input force required to tighten the fastening system. Additionally, pulling the shoelace 236 applies a force to the loop structure 204, pulling it outwards. This movement can generate tension within the knitted loop structure 204. However, because the outer region 240 of the knitted loop structure can have a multi-bed knitted construction, comprising rows of yarns and / or strands continuously extending into the first layer 224, and can be knitted from tension-resistant yarns and / or strands, the outer region 240 can effectively transfer this tension to the first layer 224 even after repeated use without damaging or stretching the outer region 240. Therefore, the knitted loop structure 204 can provide excellent tensile and breakage resistance.

[0094] Now for reference Figure 6 and Figure 7 , Figure 2 The second region 208 of the integral one-piece knitted component 108 may have a first layer 306 (which may ultimately correspond to the exterior of the article 100) and a second layer 310 (which may ultimately correspond to the interior of the article 100), which together may form a knitted loop structure 314 having transversely oriented channels 318 (with... Figure 3 Compared to the longitudinal channel 232 of the knitted loop structure 204 illustrated in the diagram. (Except as described herein.) Figure 6 The implementation plans can be roughly shared. Figure 3 The knitted structure, materials and other features of the implementation scheme.

[0095] exist Figure 6 In one embodiment, the first layer 306 may have a knitted outer region 322, and the second layer 310 may have a multi-bed knitted inner region 326. The outer region 322 and the inner region 326 may form an integral knitted loop structure 314. Figure 2 The knitted component 108 may include one or more such integral loop structures 314, for example, on the inner side 192 and outer side 196 of the midfoot region 184. Like Figure 3 The knitted loop structure is the same for 240a and 240b. Figure 6 The knitted loop structure 314 can ultimately form part of the fastening system. For visualization purposes, Figure 7 The illustration shows a strip 330 passing through the loop structure 314, which can be used to secure the wearer's foot. Figure 1Of item 100, outer region 322 can overlap with inner region 326 and can be freely separated from inner region 326. Similar to... Figure 3 In one embodiment, at least one of the outer region 322 and the inner region 326 may have a multi-bed knitted construction to impart strength, tensile strength, and roll resistance—in which case, the inner region 326 may also have a multi-bed construction. The outer region 322 may be freely separable from the inner region 326 along a first edge 334 and a second edge 338, the first edge 334 and the second edge 338 forming at least a portion of a first opening 342 and a second opening 346 in the first layer 306. The first edge 334 and the second edge 338 may each have a generally longitudinal orientation (with...). Figure 3 (Compared to the first edge 264 and the second edge 268 in the general transverse direction). As described above, each of the first edge 334 and the second edge 338 may correspond to the first bonding region 350 and the second bonding region 354. The bonding regions 350, 354 may include one or more stitches designed to increase strength and durability, such as multiple stitches of thermoplastic polyurethane yarn, which may form a fusion region when subjected to heat treatment after knitting.

[0096] Since the first edge 334 and the second edge 338 of the outer region 322 can have a longitudinal orientation and thus span at least one row of yarns, a discontinuity can exist between the rows of the outer region 322 and the rows of the first layer 306. In other words, the first edge 334 and the second edge 338 can form the endpoints of the rows of yarns forming the outer region 322. Therefore, in Figure 6 In the implementation plan, with Figure 3 Compared to the previous implementation scheme, the yarn rows in the outer region 322 can extend discontinuously into the first layer 306. Figure 3 In this implementation, the rows of the outer region 240 can extend continuously into the first layer 224. Conversely, Figure 6 The outer region 322 can be continuously interconnected with the first layer 306 by one or more sets of interlayer knitting stitches at the boundaries 358, 362 in the longitudinal direction (e.g., a row of the outer region 322 loops around at least one adjacent row of the first layer 306 and / or the second layer 310).

[0097] In use, Figure 6The knitted loop structure 314 can form part of a fastening system for footwear or another system. Therefore, the outer region 322 can be formed from a multi-bed knitted construction for better stress resistance. However, if the knitted loop structure 314 is unlikely to withstand significant tension in its application, then the outer region 322 can have a single-bed knitted construction to reduce weight and cost. Conversely, the inner region 326 can have, for example... Figure 7 The multi-bed construction shown can provide greater cushioning or other benefits for the wearer's feet.

[0098] Now for reference Figures 8A to 11 The knitted component 366 can be knitted in three dimensions and can include freely separable and overlapping areas with a multi-bed knitted construction, such as... Figures 2 to 7 The implementation scheme is described below. The knitted component 366 can resemble a shoe inner lining or insole, forming an opening 370 and defining a cavity approximating the shape of a human foot. The knitted component 366 may include an upper foot portion 374 and a lower foot portion 378, and may also include a forefoot region 382, ​​a midfoot region 386, and a heel region 390. The aforementioned portions and regions can be knitted integrally in a single knitting process, i.e., without any significant post-knitting steps to form the knitted component 366 as a shoe inner lining or insole defining the cavity of the foot shape. Specifically, the upper foot portion 374 may be knitted together with the lower foot portion 378 around its perimeter 394, for example, using one or more interlayer knit stitches as described above. Specifically, the upper foot portion 374 may be connected to the lower foot portion 378 around its perimeter 394 at interlayer knit stitch rows 398. In some embodiments, a small number of additional stitches on the overfoot portion 374 may extend beyond the interlayer knit stitch line 398, thereby creating a small overhang on the overfoot portion 374 stitches that can conceal the interlayer knit stitch line 398. This results in a significant reduction in post-knitting steps and structures (e.g., seams). Figures 8A to 10 The three-dimensional foot-shaped knitted construction of the knitted component 366 can advantageously provide greater comfort for the wearer. Furthermore, this knitted construction can reduce product costs by eliminating one or more time-consuming and material-intensive post-knitting steps. As described below, this knitted construction can offer additional advantages due to the use of multi-bed knitting in one or more zones.

[0099] Figure 8AThe knitted component 366 may include a number of regions with different materials, knitted constructions, and physical properties. For example, the upper collar area 402 may define an opening 370 for receiving the wearer's foot and may include a front upper collar area 406 having an inner surface 410 oriented toward the opening 370, overlapping with a rear upper collar area 414 having an inner surface 418 also oriented toward the opening 370. (As shown in the section line 9-9) Figure 9 As illustrated in the diagram, as a result of the knitting process, the upper front collar area 406 can overlap with and extend together with the upper rear collar area 414.

[0100] Figure 8A The knitted component 366 may also include one or more zones having two or more freely separable and overlapping knitted areas, wherein at least one zone has a multi-bed knitted construction. For example, the upper collar area 402 may transition to the lower collar area 422, as shown by a section cut along section line 10-10. Figure 10 As shown, the lower collar area 422 may include a multi-bed front lower collar area 426 overlapping with the multi-bed rear lower collar area 430. The lower collar area 422 may transition continuously to the heel area 434 and the vamp zone 438. The vamp zone 438 may have a multi-bed knit construction and may substantially cover a portion of the upper foot portion 374 of the knitted component 366, which corresponds to the top portion of the wearer's foot in the midfoot area 386. The vamp zone 438 may transition continuously to the toe area 442. The heel area 434, vamp zone 438, toe area 442, and other areas may be adjacent to and continuously knitted with the foot area 446 (which may correspond to the foot portion 378), for example, along one or more interlayer knit stitches. The heel area 434, vamp zone 438, toe area 442, foot area 446, and other areas may each have an internal surface oriented toward the cavity. For example, the instep region 438 can transition continuously to the foot region 446 at the interlayer knitting stitch line 398, wherein at least one yarn of the instep region 438 and at least one yarn of the foot region 446 are interlocked, for example at the interface between the inner surface of the instep region 438 and the inner surface of the foot region 446.

[0101] As a result of the knitting process, some of the aforementioned areas may overlap. For example, the instep area 438 can be cut along section line 11-11. Figure 11 The area shown overlaps with the foot region 446. Alternatively, at another location in the knitted component 366, the instep region 438 and the toe region 442 may overlap with the foot region 446.

[0102] Different zones of the knitted component 366 can have different properties, different materials, and different knitting structures. In particular, where one zone overlaps with another, at least one zone can have a multi-bed knitting construction. This can advantageously provide greater regional cushioning, durability, tensile strength, or other properties.

[0103] refer to Figure 9 The upper front collar area 406 and the upper rear collar area 414 can be knitted substantially simultaneously and can be connected at interlayer knit stitch areas 450, 454, 458, and 462. Each interlayer knit stitch area may include at least one instance where the yarns of the upper front collar area 406 and the upper rear collar area 414 are interlocked, for example, at the interface between the inner surfaces 410 and 418. Therefore, the interlayer knit stitch areas 450, 454, 458, and 462 can connect the upper front collar area 406 and the upper rear collar area 414 in an overlapping spatial relationship without post-knitted connections (e.g., seams). The upper front collar area 406 may include an outer layer 466 that is separable from the inner layer 470. The separable outer layer 466 and the inner layer 470 can move relative to each other during use, for example, to reduce friction experienced by the wearer. The upper rear collar area 414 may also include an outer layer 474 that is separable from the inner layer 478. The outer and inner layers of the upper front collar area 406 and the upper rear collar area 414 may have a single-bed construction with less than the full number of stitches, such as a one-third stitch construction (forming loops on every three needles (every two needles) of a needle bed). Therefore, the upper collar area 402 may include four overlapping and separable layers knitted substantially simultaneously, for example on a double-bed knitting machine. Although this knitted structure is depicted in the collar area, it can be knitted into other areas of the knitted part 366.

[0104] Now for reference Figure 10The lower front collar area 426 and the lower rear collar area 430 of the knitted component 366 can be knitted substantially simultaneously and can be connected at interlayer knit stitch areas 482, 486, thus overlapping each other. Like the upper front collar area 406, the lower front collar area 426 can include an initially separable outer layer 490 and an inner layer 494. However, as a result of the knitting process, the outer layer 490 and the inner layer 494 can form a first area 498 with a multi-bed construction. This can be achieved during the knitting process by knitting the outer layer 490 as a single bed (on a first needle bed) and the inner layer 494 as a single bed (on a second needle bed), and then transferring at least one loop of the outer layer 490 from the first needle bed to the second needle bed and then knitting additional rows on the second needle bed. Thus, the outer layer 490 and the inner layer 494 can form a multi-bed knitted layer. The lower rear collar area 430 can have a similar construction to the lower front collar area 426. Although the knitted structure is depicted in the lower collar area 422, it can be knitted into other areas of the knitted part 366.

[0105] Now for reference Figure 11 The instep area 438 can be knitted substantially simultaneously with the foot area 446 and can overlap with the foot area 446, but still remain freely separable. To impart additional cushioning or tensile strength, to provide an attractive aesthetic, or for other advantages, the instep area 438 can have a multi-bed knitting construction and the foot area 446 can have a single-bed construction, or vice versa. For example, the instep area 438 can have at least one row of first yarns including a multi-bed construction (e.g., double-knit). The at least one multi-bed row can have a stitch density less than the full stitch count throughout the row, such as a half stitch count. The instep area 438 can also include rows of second yarns, third yarns, and optionally additional yarns, for example, to give the instep area 438 different visual characteristics or technical properties. The additional rows can have a construction generally less than the full stitch count. The foot area 446 may include a row of fourth yarns with a single-bed knitting construction having a construction with less than the full number of needles, such as a quarter-needle construction (i.e., knitting on every four needles).

[0106] Figure 12 This schematically depicts knitting on a knitting machine (e.g., a double-needle-bed weft knitting machine) as... Figures 1 to 5An exemplary method is shown for a portion of the knitted component. Specifically, the knitted component may have a first layer and a second layer, the first layer including an outer region with a multi-bed knit construction, and the second layer having an inner region. As a result of the knitting process, the outer region may overlap with the inner region, the outer and inner regions may be freely separable and form a channel, and the outer region may have a first edge and a second edge oriented along the transverse direction. The outer and inner regions may extend together at a first and a second set of interlayer knit stitches. While the following description contemplates an outer region with a multi-bed knit construction, it should be understood that substantially the same procedure can be used to form a knitted component including an inner region with a multi-bed construction but not an outer region.

[0107] Throughout this process, the term "inner area needle" refers to the needles on the first and second needle beds primarily used for knitting the inner area, and the term "outer area needle" refers to the needles on the first and second needle beds primarily used for knitting the outer area. Furthermore, outer area needles can include needles on which the stitches of the outer area are transferred and "parked." Generally, outer and inner area needles can exist within the same span of the needle bed, although inner area needles are substantially different from outer area needles. As an example, outer area needles can include all needles on the back needle bed and the even-numbered needles on the front needle bed, while inner needles can include the odd-numbered needles on the front needle bed. In such a case, the stitches of the outer area can be knitted on the odd-numbered needles of the back needle bed and the even-numbered needles of the front needle bed (the even-numbered needles of the front needle bed can periodically transfer to and park on the even-numbered needles of the back needle bed).

[0108] refer to Figure 12At step 502, if desired, the outer area needles on a portion of the first needle bed may be without inner area stitches. This can be achieved by transferring the inner area stitches (e.g., loops or tufts) present on these needles to non-outer area needles (e.g., inner area needles). The next, optional, joining step 506 may include knitting at least one row forming a first edge of the outer area, which may form at least a portion of an opening in the first layer. Joining step 506 may also include a series of transfers that move the stitches of the outer and inner areas on the same needles and also pull these stitches in the row direction. To enhance durability, tensile strength, anti-unraveling, and other properties, the rows knitted during the joining step may have progressively increasing widths and may be knitted from yarns or plies with relatively high toughness and / or tensile strength. Notably, the outer area is freely separable from the inner area at the first edge. Next, at step 510, one or more multi-bed rows of the outer area are knitted on the outer area needles of the first and second needle beds. Multi-bed knitting construction can impart a degree of durability and tensile strength to the outer area. Optionally, during this step, one or more single-bed rows of the outer region may also be knitted on the outer region needles. It is noteworthy that the rows of the outer region may extend continuously into the first layer on either side or both sides of the outer region. That is, a single row of yarn may form part of the first layer, then part of the outer region, and then another part of the first layer. Thus, the first layer can transition continuously to and from the outer region. Next, at step 514, the stitches of the outer region previously formed on the outer region needles of the first needle bed (e.g., loops, tucks, and floats) are transferred to the outer region needles of the second needle bed and left there. As a result of this step, substantially all the outer region stitches knitted on the first needle bed at step 510 are left on the second needle bed, thereby releasing the first needle bed for knitting the inner region. Next, at step 518, one or more rows of the inner region may be knitted on the inner region needles of the first needle bed. It is worth noting that these inner region rows overlap with the outer region rows but may not interlock with them, because the outer region rows knitted during step 510 are stopped on the second needle bed at step 514. Therefore, the outer region rows remain freely separable from the inner region rows. Similarly, the inner region rows can extend continuously into the second layer on either side of the inner region. That is, a single row of yarn can form part of the second layer, then part of the inner region, and then another part of the second layer. Thus, the second layer can transition continuously into and from the inner region.

[0109] After step 518, if additional knitting height is required for the outer and inner areas, an optional step 522 can be performed, where the stitches of the outer area previously stopped at the second needle bed in step 514 can be returned to the outer area needles of the first needle bed, and steps 510, 514, and 518 can be repeated. For example, if a knitting height of twenty (20) rows (in addition to the combined rows) for the outer area is desired, and four (4) rows of the outer area are knitted each time step 510 is performed, then steps 510, 514, 518, and 522 can be repeated five (5) times so that the outer area reaches the desired knitting height of twenty rows. After the desired knitting height is reached, an optional combining step 526 can then be performed to form a second edge of the outer area, where the outer and inner areas remain freely separable.

[0110] Separately from and substantially simultaneously with steps 506-526, steps 530 and 534 may be performed, thereby forming interlayer knitted stitches to connect the first and second layers, thus defining the location where the outer and inner regions can extend together. This connection may include at least one situation where at least one yarn from the first layer and at least one yarn from the second layer loop around each other at or near the interface between the opposing surfaces of the outer and inner regions. Multiple interlayer knitted stitches may form interlayer knitted stitch rows, although they do not necessarily form rows, as they may be arranged in a non-linear configuration (e.g., in a pattern over areas) to connect the first and second layers. More specifically, the outer region may be freely separable from the inner region up to the interlayer knitted stitch, interlayer knitted stitch row, or interlayer knitted stitch area. Therefore, the interlayer stitch or stitch row may indicate the location where one dimension of the outer and inner regions terminates and transitions continuously to the first and second layers, respectively.

[0111] Figures 13A to 13G The diagram shows the corresponding... Figures 2 to 4 The text shows and Figure 12 The diagram describes a method of knitting a knitted component. Specifically, Figures 13A to 13G The illustration depicts exemplary steps of knitting a knitted component (e.g., a knitted loop structure) on a double-needle bed weft knitting machine. The knitted component may have a first layer including a multi-bed outer region and a second layer including an inner region, wherein the outer region overlaps with the inner region, wherein the outer region and the inner region may be freely separable and form a channel, and wherein the outer region may have a first edge and a second edge oriented in the transverse direction.

[0112] refer to Figure 13AThe double-needle-bed weft knitting machine has a front needle bed 536 and a rear needle bed 537. Each of the front needle bed 536 and the rear needle bed 537 has needles 1-5. In this embodiment, the outer area needles may correspond to the even-numbered needles of the front needle bed 536 and the odd-numbered needles of the rear needle bed 537. At step 538, the knitting machine knits the rows of the first and second layers before starting to knit the outer or inner area. At step 542, the knitting machine transfers the loops or stitches present on the even-numbered front needle bed needles to the odd-numbered front needle bed needles, i.e., the knitting machine clears the outer area needles on the front needle bed 536. At (optional) step 546, the knitting machine begins to knit the inner area by gathering one row of the first yarn 548 of the inner area on the odd-numbered front needles. The first yarn 548 may be a yarn with tension, for example, giving the knitted part resilience or recovery. Although in Figures 13A to 13G It is not shown in the text, but the steps (similar to those discussed below regarding step 594) may optionally be performed at this time.

[0113] refer to Figure 13B In step 550, the knitting machine knits a row of second yarns 552 for the outer region. Note that at least one row in step 550 is knitted on both the even-numbered needles of the front needle bed 536 and the back needle bed 537. This multi-bed construction imparts strength, tensile strength, and roll resistance to the outer layer. The second yarn 552 can be a high-tenacity yarn, a monofilament yarn, or other yarns with relatively high tensile strength and tensile resistance. In (optional) step 554, the knitting machine knits a row of third yarns 556 for the outer region (i.e., a multi-bed construction) on the front needle bed 536 (even-numbered needles only) and the back needle bed 537. Including the third yarn 556 can impart advantageous properties to the outer region. For example, the third yarn 556 can be a yarn or ply coated in thermoplastic polyurethane, which can undergo post-knitting heat treatment to form a fused region for providing additional strength.

[0114] At step 558, the knitting machine transfers the loops and stitches of the outer area formed on the even-numbered front needles to the opposing back needles. This step allows the knitting machine to resume knitting of the inner area on the front needle bed 536 without causing the rows of inner and outer areas to interlock, i.e., keeping the inner and outer areas freely separable. After step 558, substantially all the stitches of the outer area formed during steps 550-554 are placed on the back needle bed 537.

[0115] At step 562, the knitting machine knits a row of the fourth yarn 564 and the first yarn 548 in the inner region on an odd-numbered front bed needle. The fourth yarn 564 may be the same as or different from the other yarns. For example, the fourth yarn 564 may be a yarn or ply coated in thermoplastic polyurethane, which may undergo a post-knitting heat treatment to form a fused region to provide additional strength.

[0116] After step 562, substantially all stitches of the outer region formed during steps 550-554 are located on the back needle bed 537, and substantially all stitches of the inner region formed during step 562 are located on the front needle bed 536. At this point, if no additional knitting height is required, a combining step can be performed to gradually knit the outer layer into the inner layer, giving the outer layer additional strength and anti-unraveling properties.

[0117] Now for reference Figure 13C If a different knitting height is required, steps 566-570 can be performed. At step 566, the knitting machine transfers the loops and stitches of the outer area previously placed on the back needle bed 537 in step 558 to the even-numbered needles of the front needle bed 536. This step allows the knitting machine to resume knitting the outer area on the outer area needles of both needle beds 536-537. Because the even-numbered needles on the front needle bed 536 do not form stitches for the inner area, the rows of outer area knitted on those needles after the transfer at step 566 will not interlock with the rows of inner area knitted on them.

[0118] At step 570, the knitting machine may knit additional rows of the second yarn 552 and the third yarn 556 in the outer region. The rows knitted during step 570 may be the same as or different from the other rows in the outer region to impart certain properties to the outer region. For example, the rows knitted during step 570 may have a single-bed construction and / or may include floats to impart tensile strength.

[0119] At step 574, the knitting machine transfers the loops and stitches of the outer area formed on the even-numbered front needles back to the opposing back needles. This step allows the knitting machine to resume knitting the inner area without looping the inner and outer areas together or to begin the joining step. After step 574, substantially all the stitches of the outer area formed during step 570 are rested on the back needle bed 537.

[0120] If additional knitting height is required after step 574, steps 562, 566, and 570 can be repeated, or steps 578, 582, 586, and 590 can be performed. At step 578, the knitting machine can knit additional rows of the inner region on odd-numbered front needles. These additional rows may include rows of the fourth yarn 564, for example, with floating yarns knitted for tensile strength, but may additionally or alternatively include rows of the first yarn 548 or other yarns. At step 582, the knitting machine can transfer the loops and stitches of the outer region previously stopped on the back needle bed 537 at step 574 to even-numbered needles on the front needle bed 536. This step allows the knitting machine to resume knitting the outer region on the outer region needles of both needle beds. At step 586, the knitting machine can knit additional rows of the third yarn 556 of the outer region (i.e., a multi-bed configuration) on the front needle bed 536 (even-numbered needles only) and the back needle bed 537. Although step 586 illustrates three rows, this step may include fewer or more rows. At step 590, the knitting machine may again transfer the loops and stitches formed on the even-numbered front needles to the back needle bed 537, so that the knitting machine can resume knitting the inner areas without looping the inner areas around the outer areas, or be able to begin the bonding step.

[0121] If no additional knitting height is required after step 574 or step 590, then a joining step 594 can be performed to join the edges of the outer region. In addition to a series of transfers of stitches joining the outer region, the joining step may include gradually shortening the rows of the outer region knitted on the back needle bed 537 (e.g., the rows of the second yarn 552), transferring the inner region stitches on the same needles, and also pulling these stitches in the row direction toward a position where the first and second layers can interconnect with the interlayer knitting stitches. Such a joining step can maintain the channel formed by the freely separable outer and inner regions, and can also transform the knitted structure into a position where the first and second layers may not be separable. Joining step 594 can also impart strength and anti-unraveling properties to the outer region. After joining step 594, the loop structure can be substantially completed.

[0122] To interconnect the first and second layers, the knitting machine can form interlayer knitting stitches as described above. As an example ( Figures 13A to 13G(Not shown in the diagram), a yarn feeder corresponding to the yarns of the first layer and the outer region (e.g., a feeder corresponding to the second yarn 552) can form at least one stitch on the back needle bed 537 and also on the front needle bed 536, while the stitches corresponding to the yarns of the second layer and the inner region (e.g., the fourth yarn 564) reside in the front needle bed 536. This can cause the rows of the first layer to become interlocked with the rows of the second layer, thereby forming an interlayer knitting stitch. As a result, the first layer will become inseparable from the second layer at the location of the interlayer knitting stitch, which can also indicate the location where the outer and inner regions extend together.

[0123] Figure 14 The illustration depicts knitting as... Figures 1 to 2 , Figures 6 to 7 An exemplary method for a portion of a knitted component is shown, particularly a knitted component having an inner region with a multi-bed knitted construction overlapping a freely separable outer region as a result of the knitting process, wherein the inner and outer regions form channels oriented in a transverse direction. Furthermore, the outer region may have a first edge and a second edge as boundaries along the transverse direction, each edge forming at least a portion of an opening in a first layer. For example, the first and second edges may have a warp direction orientation and thus span at least one warp of yarn, creating a discontinuity between the warp of the outer region and the warp of the first layer. In the warp direction dimension, the outer and inner regions may extend together at interlayer knitted stitches between the first and second layers. While the following description contemplates an inner region with a multi-bed knitted construction, it should be understood that substantially the same procedure can produce a knitted component including an outer region with a multi-bed construction, but not an inner region.

[0124] refer to Figure 14 At step 598, one or more rows of the first and second layers can be interconnected along the boundaries of the inner and outer regions in the longitudinal direction, for example, using interlayer knitting stitches as described above. The positions of these interlayer knitting stitches can be functionally and structurally related to... Figure 12 The interlayer knitting stitches are similar, but their positions differ. Figure 12 Interlayer knitting stitches can form the horizontal boundaries between the outer and inner areas.

[0125] At step 602, if necessary, the inner area needles on a portion of the first needle bed may be without outer area stitches. Next, at step 606, one or more multi-bed rows of the inner area are knitted on the inner area needles of both the first and second needle beds. This multi-bed knitting construction can provide a degree of cushioning to the inner area. Optionally, during this step, one or more single-bed rows of the inner area may also be knitted on the inner area needles. It is noteworthy that the rows of the inner area can extend continuously into the second layer on either side of the inner area. That is, a single row of yarn can form part of the second layer, then part of the inner area, and then another part of the second layer. Therefore, the second layer can transition continuously to and from the inner area.

[0126] Next, at step 610, the stitches of the inner area previously formed on the inner area needles of the first needle bed are transferred to the inner area needles of the second needle bed and left there. As a result of this step, substantially all the inner area stitches knitted at step 606 are left on the second needle bed, thereby freeing the first needle bed for knitting the outer area. Next, at step 614, one or more rows of the outer area can be knitted on the outer area needles of the first needle bed. It is worth noting that these outer area rows do not loop with the inner area rows because the inner area rows knitted during step 606 are left on the second needle bed at step 610. Therefore, the outer area rows remain freely separable from the inner area rows. It is worth noting that the outer area rows do not extend continuously into the first layer; instead, there is a discontinuity between the rows of the first layer and the rows of the outer area.

[0127] After step 614, if additional knitting height is required for the outer and inner areas, step 618 can be performed, thereby returning the stitches of the inner area previously placed on the second needle bed in step 610 to the inner area needles of the first needle bed, and steps 606-618 can be repeated. After the desired knitting height is achieved, and then after step 614, step 622 can be performed, thereby interconnecting one or more rows of the first and second layers, for example using interlayer knitting stitches as described above. The positions of these interlayer knitting stitches can form another boundary between the outer and inner areas in the warp direction.

[0128] Steps 626 and 630 can be performed separately from and substantially simultaneously with steps 598-622, whereby the rows of the second layer can extend continuously into the inner region (e.g., using a common yarn feeder), and the rows of the first layer can be knitted up to the edge of the outer region (e.g., using different yarn feeders for the first layer and the outer region).

[0129] Figure 15 The diagram shows the corresponding... Figure 2 , Figure 6 The text shows and Figure 14 The diagram illustrates a method of knitting similar knitted components as described in the text. Specifically, Figure 15 The illustration depicts a method for forming a knitted component having a first layer comprising multiple outer beds and a second layer comprising a single inner bed, wherein the outer beds are freely separable from the inner beds at transverse boundaries along first and second edges forming openings in the first layer. For illustrative purposes, eighteen needles are shown on each of a front needle bed 632 and a rear needle bed 633, and each needle bed is further divided into a first zone 634, a second zone 638, and a third zone 642. The outer beds are freely separable from the inner beds in the second zone 638, and openings in the first layer may exist where the first zone 634 meets the second zone 638 and where the second zone 638 meets the third zone 642. In this embodiment, in the second zone 638, the outer bed needles may include even-numbered needles from the front needle bed 632 and odd-numbered needles from the rear needle bed 633. In the first zone 634 and the third zone 642, the first and second layers may be interconnected, for example, with interlayer knitting stitches as described above.

[0130] At the initial step (not shown), the knitting machine releases the outer area needles in the second zone 638 of the inner area stitches (e.g., in such cases, releasing the odd number of back bed needles and the even number of front bed needles). After this point, the inner area stitches can remain only on the even number of back bed needles. By releasing the odd number of back bed needles, the machine can later utilize these needles to knit the outer area with a double-bed construction, while maintaining the freedom of separation between the outer and inner areas.

[0131] After releasing the odd number of back needles, at step 646, the first feeder corresponding to the first yarn 648 can knit at least a portion of the first layer in the first zone 634, the second feeder corresponding to the second yarn 650 can knit at least a portion of the outer region of the multi-bed outer area on the outer region needles in the second zone 638 (i.e., on the odd-numbered needles of the back needle bed and the even-numbered needles of the front needle bed), and the third feeder corresponding to the third yarn 652 can knit a portion of the first layer in the third zone 642. The portion of the outer region knitted at step 646 can have a multi-bed construction as described above, such as a half-needle double-knit construction or other multi-bed knitting construction.

[0132] It is worth noting that at step 646, the rows of the first yarn 648 and the third yarn 652 may not be interlocked with the second yarn 650; instead, discontinuities may exist where the first yarn 648 and the third yarn 652 are adjacent to the second yarn 650. This may require the use of a separate yarn feeder for each of the first yarn 648, the second yarn 650, and the third yarn 652. Therefore, the outer region can remain freely separable from the first layer at these discontinuities. The successive discontinuities between the first layer and the outer region on the successive rows can form a first edge and a second edge of the outer region, which can create openings in the first layer.

[0133] It will be understood that step 646 may include fewer or more rows of first yarn 648, second yarn 650, and third yarn 652 (although two rows are illustrated). As part of step 646, additional rows and yarn types may be knitted to impart certain properties to the knitted part. For example, the second yarn 650 may have relatively high toughness and tensile strength, and relatively low elongation. Alternatively or additionally, the second yarn 650 may be a yarn with elasticity, such as elastic fiber strands wrapped in polyester fibers; such a yarn may provide an attractive visual appeal.

[0134] At step 656, the knitting machine is prepared to knit the second layer and inner area by transferring the stitches of the second yarn 650 (in the second zone 638) from the back needle bed 633 to the opposing needles on the front needle bed 632, where the stitches are stopped in the front needle bed to free the back needle bed for knitting the second layer and inner area.

[0135] At step 660, the fourth feeder corresponding to the fourth yarn 664 can knit at least one full row of the second layer across the back needle bed, spanning the first zone 634, the second zone 638, and the third zone 642. In the second zone 638, the fourth yarn 664 can correspond to the inner region because, as a result of the transfer performed at step 656, it is freely separable from the outer region within that zone. Notably, in the second zone 638, the fourth feeder can knit the inner region at half-needle counts on a single needle bed—in such a case, knitting on the even-numbered needles of the back needle bed 633. When knitting the inner region, the rows of the inner region do not loop around the rows of the outer region by skipping the odd-numbered needles of the back needle bed 633. It will be understood that step 660 can include fewer or more rows of the fourth yarn 664, although two rows are illustrated.

[0136] At step 668, the knitting machine prepares to resume knitting the outer area by transferring the stitches of the outer area (i.e., in the second zone 638) previously resting on the front needle bed 632 to the odd-numbered needles of the rear needle bed 633. After step 668, if an additional knitting height is required, the knitting machine can again perform steps 646, 656, and 660, again using the first, second, and third feeders to knit partial rows of the first yarn 634, second yarn 638, and third yarn 642; then transfer the stitches of the outer area in the second zone 638 to the front needle bed 632; and then use the fourth feeder to knit the full row of the fourth yarn 664 on the rear needle bed 633. Once the desired knitting height is reached, the loops of the second yarn previously transferred to the front needle bed can be transferred to the rear needle bed, as shown in step 668. Thereafter, step 670 can be performed, thereby allowing rows to be knitted on the rear needle bed and / or the front needle bed to interconnect the first and second layers, for example, at the interface between the inner and outer areas. Such interconnections can form interlayer knitting stitches as described above, and can indicate the positions where the outer and inner areas extend together in the longitudinal direction.

[0137] Figure 16 The illustration depicts knitting on a knitting machine (e.g., a double-needle-bed weft knitting machine) as... Figure 8A , Figure 10 An exemplary method is shown for a portion of the knitted component. Specifically, the knitted component may have a first layer and a second layer, the first layer including a first region having a multi-bed knitted structure, and the second layer including a fourth region having a multi-bed knitted structure. The first region may overlap with and be freely separable from the fourth region.

[0138] Throughout this process, the term "first zone needle" refers to the needle on the first needle bed used for knitting the first zone, the term "second zone needle" refers to the needle on the second needle bed used for knitting the second zone, the term "third zone needle" refers to the needle on the first needle bed used for knitting the third zone, and the term "fourth zone needle" refers to the needle on the second needle bed used for knitting the fourth zone. Generally, first zone needles and third zone needles can exist within the same span of the first needle bed, but can be substantially different. Similarly, second zone needles and fourth zone needles can exist within the same span of the second needle bed, but can be substantially different.

[0139] At step 671, the knitting machine can knit one or more rows of the first region on the first region needles (of the first needle bed), and can also knit one or more rows of the second region on the second region needles (of the second needle bed). Thus, step 671 knits two freely separable single-bed regions.

[0140] At step 672, the knitting machine may transfer at least a portion of the second region knitted on the second region needle at step 671 to the opposite needle on the first needle bed. Furthermore, if the stitches of the third region were then residing on the second needle bed (e.g., after an earlier transfer not discussed herein), these third region stitches may be returned to the third region needle (on the first needle bed). Thus, after step 672, the first needle bed is prepared to knit a row of the third region, and the second needle bed is prepared to knit a row of the fourth region. Alternatively, the knitting machine may be prepared to perform one or more inter-bed transfers.

[0141] At step 673, the knitting machine may perform one or more inter-bed transfers of at least one stitch (but not all stitches) in the fourth region to impart a multi-bed construction to the fourth region and interconnect the fourth and third regions. For example, an inter-bed transfer may include transferring one or more stitches of the fourth region from the second needle bed to one or more needles holding stitches of the third region on the first needle bed. Depending on the position of the third region needles relative to the fourth region needles, this step may require an inter-bed lateral transfer, thereby transferring non-opposing needles that move stitches to another needle bed (e.g., from the fourth needle on the second needle bed to the third needle on the first needle bed). By transferring at least one fourth region stitch from the second needle bed to the first needle bed holding at least one third region stitch, step 671 provides the fourth region with a second face of knitted loops or tucks, i.e., imparts a multi-bed construction to the fourth region.

[0142] At step 674, the knitting machine can knit one or more rows of the third region on the third region needles, and can also knit one or more rows of the fourth region on the fourth region needles (of the second needle bed). Therefore, the single-bed rows of the third and fourth regions knitted in step 674 can be freely separated, except where the third and fourth regions are interconnected after step 673.

[0143] At step 675, the knitting machine can return the stitches of the second area previously placed on the first needle bed to the second area needle, and can also transfer the stitches of the third area formed on the third area needle to the second needle bed. Therefore, after step 675, the second needle bed is prepared to knit another row of the second area, and the first needle bed is prepared to knit another row of the first area. Alternatively, the knitting machine is prepared to perform one or more inter-bed transfers.

[0144] At step 676, the knitting machine may perform one or more inter-bed transfers of at least one stitch (but not all stitches) in the first region to impart a multi-bed construction to the first region and interconnect the first and second regions. For example, this step may include transferring one or more stitches of the first region from the first needle bed to one or more needles holding the stitches of the second region on the second needle bed. This may require inter-bed lateral transfers. By transferring at least one stitch of the first region from the first needle bed to the position holding the stitches of the second region on the second needle bed, step 676 provides the first region with a second face of knitted loops or tucks, i.e., imparts a multi-bed construction to the first region.

[0145] After step 676, the knitted component may include two freely separable multi-bed regions—one region comprising a first and second region with a multi-bed construction as a result of the inter-bed transfer at step 676, and the other region comprising a third and fourth region with a multi-bed construction as a result of the inter-bed transfer at step 673. If additional knitting height is required, steps 671-676 may be repeated as needed.

[0146] Figure 17 The illustration shows how knitting is done. Figure 8A and Figure 9 The method of knitting a component shown in the diagram includes, for example, a knitting component having four freely separable areas with a smaller than full needle count (e.g., one-third of a needle count). A portion of the front needle bed 677 and a portion of the rear needle bed 678 may each have five needles. A first knitting area comprising a row of first yarns 682 may be knitted on a first set of needles, which may correspond to the first and fourth needles on the front needle bed 677, i.e., every three needles (every two needles) on the front needle bed. A second knitting area comprising a row of second yarns 686 may be knitted on a second set of needles, which may correspond to the second and fifth needles on the rear needle bed 678.

[0147] The third region, including the row of the third yarn 690, can be knitted on the third set of needles, which can correspond to the second and fifth needles on the front needle bed 677. The fourth region, including the row of the fourth yarn 694, can be knitted on the fourth set of needles, which can correspond to the third and sixth needles (not shown) on the back needle bed 678.

[0148] At step 698, at least one row of needles in the first region can be knitted on the first set of needles. At step 702, at least one row of needles in the second region can be knitted on the second set of needles. At step 706, the stitches in the first region can be transferred to the back bed needles opposite the first set of needles. After step 706, the stitches in the first region knitted in step 698 are placed on the back needle bed 678, and the front needle bed 677 is released to knit another region without looping with either the first or second region. At step 710, at least one row of needles in the third region can be knitted on the third set of needles (the third set of needles may also correspond to empty needles of the front needle bed 677). At step 714, at least one row of needles in the fourth region can be knitted on the fourth set of needles (the fourth set of needles may correspond to needles of the back needle bed 678 that have not previously been used to knit other regions or to place stitches in other regions). After step 714, the resulting knitted part may have four freely separable rows corresponding to the first, second, third, and fourth regions. To obtain a different knitting height, step 718 can be performed to return the stitches previously placed on the first area of ​​the back needle bed to the first set of needles on the front needle bed, and steps 698-714 can be repeated until the desired knitting height is obtained.

[0149] Figures 18A to 18D The illustration shows how knitting is done. Figure 8A , Figure 10 and Figure 16 The method for knitting the parts shown in the figure is similar to that of knitting parts. Figure 17 The method, besides producing a knitted part with two freely separable, overlapping multi-bed areas, allows for the creation of a knitted component. The front needle bed 730 and the back needle bed 734 can each have nine needles. A first knitted area comprising a row of first yarns 738 can be initially knitted on a first set of needles, such as the first, fourth, and seventh needles of the front needle bed 730. A second knitted area comprising a row of second yarns 742 can be initially knitted on a second set of needles, such as the second, fifth, and eighth needles of the back needle bed 734. A third knitted area comprising a row of third yarns 746 can be initially knitted on a third set of needles, such as the third, sixth, and ninth needles of the front needle bed 730. A fourth knitted area comprising a row of fourth yarns 750 can be initially knitted on a fourth set of needles, such as the first, fourth, and seventh needles of the back needle bed 734.

[0150] At step 754, something similar can be performed. Figure 17The sequence is shown below. That is, one or more rows of the first region can be knitted on the first set of needles on the front needle bed 730, for example, a single-sided plain knit structure with one-third stitches. Furthermore, one or more rows of the second region can be knitted on the second set of needles on the back needle bed 734. Then, the stitches of the second region can be transferred to the opposite needles on the front needle bed 730, while the third, sixth, and ninth needles of the front needle bed 730 are released for knitting the third region, and the back needle bed 734 is released for knitting the rows of the fourth region. Then, one or more rows of the third region can be knitted on the third set of needles (on the front needle bed 730), and one or more rows of the fourth region can be knitted on the fourth set of needles (on the back needle bed 734). Then, the stitches of the third region can be transferred to the opposite needles on the back needle bed 734, while the second, fifth, and eighth needles of the back needle bed are released for knitting additional rows of the second region, and the front needle bed 730 is released for knitting additional rows of the first region.

[0151] refer to Figure 18B At step 758, one or more rows of the first region may be knitted on the first set of needles on the front needle bed 730, and one or more rows of the second region may be knitted on the second set of needles on the rear needle bed 734.

[0152] At step 762, the stitches of the second area knitted on the back needle bed 734 during step 758 can be transferred to the opposite needles on the front needle bed 730. Additionally, the stitches of the third area previously transferred to the back needle bed 734 (e.g., during step 754) can be returned to the front needle bed 730. After step 762, substantially all the stitches of the first and second areas knitted during step 758 can rest on the front needle bed.

[0153] At step 766, the machine performs an inter-bed transfer, whereby at least one stitch of the fourth region (e.g., knitted during step 754) can be transferred laterally from the back needle bed 734 to the front needle bed 730—in such a case, the needle on the front needle bed 730 that holds the stitch of the third region. For example, step 766 can transfer the stitch of the fourth region knitted on the fourth needle of the back needle bed 734 (e.g., during step 754) to the third needle of the front needle bed 730 (which holds the stitch of the third region knitted during step 754). This is an example of an inter-bed transfer (inter-bed lateral transfer), which can have at least two main effects. First, it gives the fourth region a multi-bed construction, which, after the inter-bed transfer, has two opposing stitch surfaces (i.e., as a result of the inter-bed lateral transfer, one surface of the knitted stitch formed on the back needle bed 734 and another surface of the knitted stitch located on the front needle bed 730). Therefore, inter-bed transfers (such as inter-bed transverse transfers) can transform the yarn rows initially knitted on a single needle bed into multi-bed rows. Secondly, inter-bed transfers can also place the stitches of the third and fourth zones on the same needles to facilitate subsequent interlocking of the third and fourth zones at that location.

[0154] At step 770, the knitting machine can knit additional rows of the third and fourth regions on the third and fourth sets of needles, respectively.

[0155] At step 774, the knitting machine can return the stitches of the second area previously placed on the front needle bed 730 to the opposite needles of the rear needle bed 730, and can also transfer the stitches of the third area to the opposite needles of the rear needle bed 734.

[0156] At step 778, the knitting machine may perform at least one inter-bed lateral transfer of one or more stitches of the first region from the front needle bed 730 to the rear needle bed 734—specifically to the needles on the rear needle bed 734 that hold the stitches of the second region. For example, step 778 may transfer (e.g., during step 758) the stitches of the first region knitted on the seventh needle of the front needle bed 730 to the eighth needle of the rear needle bed 734, which holds the stitches of the second region after step 758. This inter-bed lateral transfer may give the first region a multi-bed configuration and may also place the stitches of the first and second regions on the same needles, thereby facilitating subsequent interlocking of the first and second regions at that location.

[0157] Following step 778, the knitted part formed by the aforementioned method may include four freely separable and overlapping knitted regions. As a result of the inter-bed lateral transfer performed in steps 766 and 778, the first and / or fourth regions may have a multi-bed configuration, i.e., each of these regions may have at least two opposing toroidal surfaces. If an additional knitting height is required, steps 754-778 may be repeated until the desired knitting height is achieved.

[0158] Alternatively, if additional knitting height is required after step 778, steps 782-814 can be performed. Steps 782-814 illustrate a knitting sequence similar to that shown in steps 754-778: knitting rows of the first and second knitting areas; transferring the stitches of the second area (and other areas previously resting on the back needle bed 734) from the back needle bed 734 to the front needle bed 730; knitting rows of the third and fourth areas: returning the stitches previously resting on the front needle bed 730 to the back needle bed 734; performing at least one inter-bed lateral transfer to assign a multi-bed knitting construction to one of the layers; knitting additional rows of the first and second knitting areas; transferring the stitches of the second knitting area (and other areas previously resting on the back needle bed) from the back needle bed 734 to the front needle bed 730; performing at least one inter-bed lateral transfer to assign a multi-bed knitting construction to one of the layers; and knitting additional rows of the third and fourth knitting areas.

[0159] Figure 19 The illustration shows how knitting is done. Figure 8A and Figure 11 The method of knitting a component shown in the figure is particularly applicable to a knitted component having a multi-bed first region and an overlapping, freely separable second region having a single-bed construction. The first and second regions may correspond to the instep and foot areas, respectively, although it should be understood that the first and second regions may correspond to different areas of the knitted component. For illustrative purposes, the front needle bed 818 and the rear needle bed 822 may each have sixteen needles. The first region may include rows of first yarns 826, second yarns 830, and fourth yarns 838. The second region may include rows of third yarns 834. Any of the first yarns 826, second yarns 830, third yarns 834, and fourth yarns 838 can be selected to give the knitted component specific properties, and therefore may be similar to or different from each other.

[0160] At step 842, one or more rows of the first yarn 826 may be knitted on the back needle bed 822, for example on the first needle, the seventh needle, and the thirteenth needle, and one or more rows of the second yarn 830 may be knitted on different needles of the back needle bed 822, for example on the fourth needle, the tenth needle, and the sixteenth needle.

[0161] At step 846, the stitches of the first yarn 826 and the second yarn 830 knitted during step 842 can be transferred to the opposite needles of the front needle bed 818, thereby freeing the rear needle bed 822 for knitting the second area.

[0162] At step 850, one or more rows of the third yarn 834 (which constitute at least a portion of the second region) may be knitted on needles in the first region of the back needle bed 822 where the yarn is not knitted, such as the second needle, the eighth needle, and the fourteenth needle.

[0163] At step 854, the stitches of the first yarn 826 and the second yarn 830, which were previously transferred to the front needle bed 818 during the second step, can be returned to the rear needle bed 822 to prepare for knitting additional rows of the first yarn 826, the second yarn 830, and / or the fourth yarn 838.

[0164] At step 858, one or more rows of the second yarn 830 may be knitted on the back needle bed 822, including on the needles holding the stitches of the first yarn 818. Thus, as a result of step 858, the rows of the first and second yarns become interlocked and therefore inseparable at these locations. Furthermore, one or more rows of the fourth yarn 838 may be knitted on the needles of both the front needle bed 818 and the back needle bed 822, on needles having rows of the first region (e.g., the stitches of the first yarn 826 and the second yarn 830) but not the stitches of the second region (i.e., the third yarn 834). For example, the fourth yarn 838 may be knitted in double-sided plain knit with a fewer than full stitch count on any front needle and any back needle except the second, eighth, and fourteenth needles (on which the third yarn is knitted during the third step). Thus, as a result of step 858, the second region may have a multi-bed knitting construction but may remain freely separable from the first region.

[0165] If an additional knitting height is required after step 858, steps 842, 846, 850, 854, and 858 can be repeated until the desired knitting height is achieved. For example, the stitches of the fourth yarn 838 knitted during step 858 can be transferred to the front needle bed (as in step 846), additional rows of the third yarn 834 can be knitted on the back needle bed 822 (as in step 850), and the stitches of the first yarn 826, the second yarn 830, and the fourth yarn 838 can be returned to the back needle bed 822 (as in step 854), and additional rows of the first yarn 826, the second yarn 830, and the fourth yarn 838 can be knitted. However, if no additional knitting height is required, the aforementioned method will produce a knitted component that includes a first region and a separable second region, the first region including rows of first yarns 826 and second yarns 830 and multiple rows of fourth yarns 838, and the separable second region including a single row of third yarns 834.

[0166] In summary, each of the aforementioned knitted components may include at least two or more freely separable and overlapping knitted areas, which are formed directly as a result of the knitting process, at least one of which has a multi-bed knitting construction. The multi-bed knitting construction can advantageously impart greater strength, tensile strength, durability, cushioning, or other properties to the knitted component. Because such knitted areas can be formed integrally in a single knitting process, the aforementioned knitting method can advantageously reduce production time and costs.

[0167] While various embodiments of the invention have been described, the invention is not limited except as provided in the appended claims and their equivalents. Furthermore, the advantages described herein are not necessarily the only advantages of the invention, and it is not necessarily contemplated that every embodiment of the invention will achieve all the described advantages.

Claims

1. A knitted component for the upper of footwear articles, the knitted component comprising: A first knitted layer, the first knitted layer including a first region having a first surface and a second surface facing opposite directions; A second knitted layer, which at least partially overlaps the first knitted layer and includes a second region that overlaps the first region, the second region having a first surface and a second surface facing opposite directions, wherein the inner surfaces of the first region and the second region define at least a portion of a freely separable region between the first region and the second region; In the interlocking region, at least one yarn of the first knitted layer is interlocked with at least one yarn of the second knitted layer. as well as A knitted loop structure, wherein the knitted loop structure is adjacent to the interlocking regions and is formed by the first knitted layer and the second knitted layer, wherein: The first region includes a first edge and a second edge, the first edge forming a portion of a first opening in the first knitted layer, and the second edge forming a portion of a second opening in the first knitted layer; The first opening, the second opening, and the freely separable region form a channel; The first edge and the second edge extend in the transverse direction; The channel extends between the first opening and the second opening, and The channel has an orientation from the front to the back of the shoe, which corresponds to the orientation in the longitudinal direction.

2. The knitted component of claim 1, wherein the knitted loop structure includes at least a portion of the fastening system for the upper.

3. The knitted component of claim 2, wherein the knitted loop structure is configured to receive shoelaces.

4. The knitted component according to claim 1, wherein, At least at the knitted loop structure, one of the first knitted layer and the second knitted layer has a multi-bed knitted structure.

5. The knitted component of claim 4, wherein the first knitted layer forms at least a portion of the outer surface of the shoe upper and has the multi-bed knitted structure at the knitted loop structure, and wherein, The second knitted layer forms at least a portion of the inner surface of the shoe upper.

6. The knitted component according to claim 5, wherein, The second knitted layer has the multi-bed knitted structure at the knitted loop structure.

7. The knitted component of claim 1, wherein the first knitted layer includes a first bonding region at the first edge and a second bonding region at the second edge, the first bonding region and the second bonding region being formed by one or more rows of yarns having a thermoplastic material.

8. An upper for footwear articles, said upper comprising: A knitted component having an integral, one-piece knitted construction, the knitted component comprising: The fastening system for the shoe upper includes a knitted loop structure formed by a first knitted layer and a second knitted layer that at least partially overlaps the first knitted layer. The first knitted layer includes a first region having a first surface and a second surface facing opposite directions. The second knitted layer includes a second region overlapping the first region, having a first surface and a second surface facing opposite directions. The knitted loop structure includes a channel in which the first knitted layer and the second knitted layer can be freely separated. In a region adjacent to the knitted loop structure, at least one yarn from the first knitted layer and at least one yarn from the second knitted layer are interlocked at the interface between the second surfaces of the first and second regions by multiple interlayer knitting stitches. The channel of the knitted loop structure extends between a first opening at least partially defined by a first edge of the first knitted layer and a second opening at least partially defined by a second edge of the first knitted layer, the first edge and the second edge each extending in a transverse direction. The channel extends between the first opening and the second opening, and The channel is oriented from the front to the back of the shoe, which corresponds to the orientation in the longitudinal direction.

9. The upper of claim 8, wherein the knitted loop structure is configured to receive shoelaces.

10. The upper according to claim 8, wherein, At least at the knitted loop structure, one of the first knitted layer and the second knitted layer has a multi-bed knitted structure.

11. The upper of claim 10, wherein the first knitted layer forms at least a portion of the outer surface of the upper and has the multi-bed knitted structure at the knitted loop structure, and wherein, The second knitted layer forms at least a portion of the inner surface of the shoe upper.

12. The upper according to claim 11, wherein the second knitted layer has the multi-bed knitted structure at the knitted loop structure.

13. The upper of claim 8, wherein the first knitted layer includes a first bonding region at the first edge and a second bonding region at the second edge, the first bonding region and the second bonding region being formed by one or more rows of yarns having a thermoplastic material.

14. A knitted component, which is knitted in three dimensions, said knitted component comprising: One or more zones having two or more freely separable and overlapping knitted areas, wherein the one or more zones have different properties, different materials and different knitted structures, and wherein at least one knitted area has a multi-bed knitted construction; as well as Open your mouth The multi-bed knitting structure is characterized by two opposing faces of knitting loops and / or tucks, the two opposing faces including one face of the loops formed on the first needle bed and a second face of the loops formed on the second needle bed.

15. The knitted component according to claim 14, wherein, The knitted component includes an upper part and a lower part of the foot, and also includes a forefoot area, a midfoot area and a heel area.

16. The knitted component according to claim 15, further comprising: The first layer includes a first region of multiple beds, the first region having a first surface and a second surface facing opposite directions; The second layer includes a second region that overlaps with the first region, the second region having a first surface and a second surface facing opposite directions; as well as Multiple interlayer knitting stitches are used, wherein at least one yarn from the first layer and at least one yarn from the second layer are interlocked at the interface between the second surface of the first region and the second surface of the second region. The upper part of the foot is knitted together with the lower part of the foot using the plurality of interlayer knitting stitches around the perimeter of the lower part of the foot.

Images