Upper with angled tubular knit structure for article of footwear

Abstract

The invention relates to an upper with an angled tubular knit structure for an article of footwear. An upper for an article of footwear may include a first tubular knit structure, where the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passage is between the first layer and the second layer. A second tubular knit structure may be included, where the second tubular knit structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passageway is located between the third layer and the fourth layer. The lengthwise direction of the first tubular knit structure may be at an angle of at least 5 degrees relative to the lengthwise direction of the second tubular knit structure.

Description

[0001] This application is a divisional application of the application with the filing date of March 4, 2021, application number 202180019601.5, and invention title "Upper for Footwear with Angled Tubular Knit Structure". BACKGROUND OF THE DISCLOSURE

[0002] Conventional footwear typically includes two main components: an upper and a sole structure. Generally, the upper is secured to the sole structure and forms a void within the footwear for comfortably and securely receiving a foot. Typically, the sole structure is secured to the lower surface of the upper so as to be positioned between the upper and the ground. For example, in some athletic footwear, the sole structure may include a midsole and an outsole. The midsole may be formed of a polymeric foam material that attenuates ground reaction forces to reduce stress on the foot and leg during walking, running, and other locomotive activities. The outsole may be secured to the lower surface of the midsole and may form the ground engaging portion of the sole structure, which is formed of a durable and abrasion resistant material.

[0003] The upper of a footwear typically extends over the dorsal and toe regions of the foot, along the medial and lateral sides of the foot, and around the heel region of the foot, and in some cases, under the foot. The entrance to the void within the upper is typically provided by an ankle opening in (and / or adjacent to) the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper to facilitate entry into and removal from the void within the upper. Additionally, the upper may include a tongue that extends beneath the lacing system to enhance the adjustability of the footwear, and the upper may incorporate other structures, such as for example a heel stabilizer, to support and limit movement of the heel. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Aspects of the present disclosure may be better understood with reference to the following drawings and description. The components in the drawings are not necessarily to scale, but rather emphasis is placed on illustrating the principles of the present disclosure. Additionally, in the drawings, like reference numerals denote like or identical features.

[0005] Figure 1 is a perspective view illustration of a footwear having a fastening system incorporating an angled tubular knit structure in accordance with certain aspects of the present disclosure.

[0006] Figure 2 is an illustration of a knit component forming at least a portion of an upper for a footwear in accordance with certain aspects of the present disclosure.

[0007] Figure 3 is an illustration of when Figure 2 the knit component is manipulated into a wearable shape in accordance with certain aspects of the present disclosure.

[0008] Figure 4 is an illustration showing a cross-sectional view of cross-section 4-4 of Figure 3 .

[0009] Figure 5 is an illustration showing a close-up view of an angled first tubular structure and a second tubular knitted structure in accordance with certain aspects of the present disclosure.

[0010] Figure 6 is an illustration showing a close-up view of a merged tubular region of a knitted component in accordance with certain aspects of the present disclosure.

[0011] Figure 7 is an illustration showing a close-up view of another aspect of a merged tubular region in accordance with certain aspects of the present disclosure.

[0012] Figure 8 is an illustration showing a close-up view of another aspect of a merged tubular region in accordance with certain aspects of the present disclosure.

[0013] Figure 9 is an illustration showing a knitting diagram representing a merged tubular knitted region in accordance with certain aspects of the present disclosure.

[0014] Figure 10 is an illustration showing a knitting diagram representing a base region having at least one surface characteristic in accordance with certain aspects of the present disclosure. DETAILED DESCRIPTION

[0015] Aspects are described below with reference to the accompanying drawings, in which like elements are generally denoted by like reference numerals. The relationships and functions of the various elements of the aspects can be better understood by reference to the following detailed description. However, the aspects are not limited to those illustrated in the drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale and that in some instances, details unnecessary for an understanding of the aspects disclosed herein (such as conventional manufacturing and assembly) may be omitted.

[0016] Certain aspects of the present disclosure relate to uppers configured for use in footwear articles and / or other articles such as apparel articles. When referring to footwear articles, the present disclosure may describe basketball shoes, running shoes, cycling shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboard boots, rugby shoes, tennis shoes, and / or walking shoes, as well as footwear types generally considered non-sporting, including but not limited to dress shoes, loafers, and sandals.

[0017] Figure 1FIG. is an illustration showing a footwear article 100 having an upper 102, where the upper 102 can be formed of any suitable type of textile (e.g., woven or non-woven textile) or another suitable material, and in some aspects, the textile can be formed into a knitted component 104 by mechanical manipulation of yarns (described in more detail below).

[0018] The upper 102 can be attached to a sole structure 106. The area where the sole structure 106 engages the upper 102 can be referred to as a biteline 108. The upper 102 can be attached to the sole structure 106 in a fixed manner using any suitable technique, such as by using adhesives, stitching, etc. The sole structure 106 can define a bottom surface for receiving and accommodating the void of the user's foot. The void can be accessed through an ankle opening 110.

[0019] The upper 102 can include a lateral side 112 and a medial side 114. A throat region 116 can be included between the lateral side 112 and the medial side 114, and the throat region 116 can be positioned to cover the top (back) surface of the foot during typical use. The midfoot region 118 of the upper 102 can be located between a heel region 120 and a toe region 122. The throat region 116 can be mainly located in the midfoot region 118.

[0020] In some aspects, an optional tongue can be at least partially disposed in the throat region 116. The tongue can be any type of tongue, such as a gusseted tongue or a rolled tongue. If no tongue is included (or in combination with a tongue), the lateral and medial sides of the throat region 116 can be joined together. In the depicted example, a tongue 117 is located in the throat region 116, and the tongue 117 is attached to the knitted component 104 after a knitting process (e.g., via non-knitting means, such as stitching or knotting, using adhesives, using clamps or other mechanical fasteners, etc.). Alternatively, the tongue 117 can be knitted integrally with the rest of the knitted component (e.g., as described in U.S. Patent No. 8,448,474, titled "ARTICLE OF FOOTWEAR INCORPORATING A KNITTED COMPONENT WITH A TONGUE", assigned to NIKE, Inc., the entire content of which is incorporated herein by reference).

[0021] As described above, at least a portion of the upper 102 can be formed from a knitted component (or another suitable textile component). For example, the upper 102 can be formed as an integral single-piece element primarily during a knitting process such as a weft knitting process (e.g., using a flat knitting machine or a circular knitting machine), a warp knitting process, 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 without significant post-knitting processes or steps. Alternatively, the knitted component 104 can be formed separately as distinct integral single-piece elements, and then the individual elements can be attached (e.g., by stitching).

[0022] Forming the upper 102 with the knitted component 104 can impart advantageous properties, including but not limited to a particular degree of elasticity (e.g., expressed as Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and / or combinations thereof. These properties can be achieved by selecting a particular single-layer or multi-layer knitted structure (e.g., a ribbed knitted structure, a single-jersey knitted structure, or a double-jersey knitted structure), by varying the size and tension of the knitted structure, by using one or more yarns formed from a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting a yarn of a particular size (e.g., denier), and / or combinations thereof. The weight of the upper 102 and thus the total weight of the footwear article 100 can be reduced relative to alternative components commonly used in footwear. The knitted component 104 can also provide desired aesthetic properties by incorporating yarns having different colors, textures, or other visual properties arranged in a particular pattern. The yarns themselves and / or the knitted structure formed by one or more yarns of the knitted component can vary at different locations to provide different knitted portions having different properties (e.g., the portion of the knitted component 104 forming the throat region 116 of the shoe can be relatively elastic, while the portion forming the heel region 120 or another region can be relatively inelastic).

[0023] In some aspects, the knitted component 104 can incorporate one or more materials having properties that change in response to a stimulus (e.g., temperature, humidity, electric current, magnetic field, or light). For example, as described in more detail below, the knitted component 104 can include a yarn formed from a thermoplastic polymer material (e.g., polyurethane, polyamide, polyolefin, and / or nylon) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures equal to or above its melting point and then transitions back to a solid state when cooled. The thermoplastic polymer material can provide the ability to heat and then cool a portion of the knitted component 104 to form regions of bonded or continuous material (referred to herein as "fusion regions") that exhibit certain advantageous properties, including, for example, a relatively high degree of rigidity, strength, and water resistance.

[0024] In some aspects, the lacing pattern of footwear article 100 can include a fastening system 123 (which can also be referred to as a “tensioning system”) to move the upper 102 between a loose state and a tightened state (e.g., to adjust the geometry of the upper 102 to tighten the upper 102 around a user's foot). In some aspects, the fastening system 123 can incorporate a shoelace 126, but can alternatively include other means for manipulating the fastening system 123 (e.g., more advanced tensioning members, such as those involved in systems related to dynamic lacing systems, such as the tensioning members described in U.S. Patent Application No. 15 / 655,769, filed on July 20, 2017, and titled “Dynamic Lacing System,” and / or U.S. Patent Application No. 16 / 534,702, filed on August 7, 2019, and titled “Knitted Component Having a Knitted Anchor Portion” (and variations thereof), the entire contents of both of these U.S. patent applications are incorporated herein by reference). Optionally, it is contemplated that the shoelace 126 or other tensioning members can be knitted (e.g., fixed to the remainder of the knitted component 104 on a knitting machine).

[0025] Figure 2 A top view is shown of the knitted component 104 in a flat state, for example, before it is manipulated into a wearable shape. Figure 3 is a side view of the knitted component 104 when it is manipulated into a wearable shape (but before the footwear article is complete), and Figure 4 is with respect to Figure 3 section 4-4 in. Referring to Figures 2 to 4 , the knitted component 104 can form at least a portion of the fastening system 123. As discussed above, the fastening system 123 can operate to tighten and / or otherwise adjust the footwear article 100 around a wearer's foot. While certain variations are contemplated (e.g., such as one or more of the dynamic lacing systems mentioned above), in the depicted example, the fastening system 123 can be adjusted by manually adjusting a tensioning member, which in this case is the shoelace 126. That is, the shoelace 126 can be manually manipulated (e.g., pulled) and tied by a user, thereby providing tension to one or more tensile strands 124 that extend through the outer side 112 and the inner side 114 of the knitted component 104.

[0026] To transfer force / tension to the stretch strand 124, the shoelace 126 can pass through various anchors 132 formed by the stretch strand 124 along the outer side and the inner side of the throat region 116 of the shoe. As shown, the anchor 132 can be defined by a coil 150, where the stretch strand 124 changes direction (i.e., such that the stretch strand 124 extends from the bite line 108 ( Figure 1 as shown) to the throat region 116 and returns). Without limitation, the stretch strand 124 (or strands) can include at least one of a cable, a yarn (e.g., having multiple filaments), a monofilament strand, or any other suitable elongate member. The stretch strand 124 (which can incorporate more than one individual strand) can form a plurality of anchors 132 on each of the outer side 112 and the inner side 114 of the throat region 116 as shown to ensure that the fastening system 123 provides sufficient tightening.

[0027] The knitted component 104 can include one or more passageways for guiding the stretch strand 124. For example, the knitted component 104 can include one or more tubular knitted structures 134 (e.g., a multi-layer knitted structure formed with a tubular knitting process) or other knitted features incorporated into the fastening system 123. In the depicted aspect, the knitted component 104 includes a first tubular knitted structure 140, a second tubular knitted structure 142, and several other tubular knitted structures positioned and oriented to guide the path of the stretch strand 124. For example, without limitation, a sufficient number of tubular knitted structures 134 can be included such that there are at least three anchors 132 on each side of the throat region 116. For example (and as discussed in more detail below), these tubular knitted structures can be positioned and / or angled (or otherwise oriented) such that the stretch strand 124 distributes force throughout the footwear to enhance footwear performance and user comfort. While in the depicted example the tubular knitted structures 134 are only located on the outer side 112 and the inner side 114 of the upper 102, they can also (or alternatively) be located in other regions (such as the heel region 120, the toe region 122, etc.). As discussed in more detail below, the corresponding tubular knitted structures can be angled relative to each other to enhance force distribution through the upper 102 during footwear use.

[0028] As Figures 2 to 3As shown, the tubular knitted structure 134 can generally extend longitudinally in the course direction (e.g., in the direction corresponding to the length dimension of the plurality of courses forming the knitted component 104), but there can also be an angled orientation as discussed below. For example, in the depicted aspect, the courses can generally extend from the inside to the outside, and the wales can extend from the heel to the toe. Such an orientation facilitates allowing a knitting machine to form the tubular knitted structure 134 using tubular knitting, where during formation, the longitudinal length direction of the tubular knitted structure 134 is substantially parallel to the length direction of the needle bed of the knitting machine.

[0029] Optionally, each of the tubular knitted structures 134 can have a similar multi-layered construction, but variations can also be envisioned. For simplicity, this specification discusses the specific multi-layered construction of the first tubular knitted structure 140, which can represent the other tubular knitted structures 134. As Figure 4 shown, the first tubular knitted structure 140 can include a first layer 144 and a second layer 146 (see Figure 4 ). A first passage 136 (which can also be referred to as a pocket or a channel) can be located between the first layer 144 and the second layer 146 such that components can be inserted between the first layer 144 and the second layer 146. In this example, the tension strand 124 is at least partially located within the first passage 136, for example, between the first layer 144 and the second layer 146. The first layer 144 of the tubular knitted structure 134 can be on the first side 190 of the knitted component 104 and thus on the front surface (e.g., the outer surface 194) of the knitted component 104, and the second layer 146 of the tubular knitted structure 134 can be on the second side 192 of the knitted component 104 and thus on the inward-facing surface (e.g., the second surface 196) of the knitted component 104.

[0030] The tubular knitted structure 134 can be formed using a tubular knitting process where the first layer 144 is formed on the first needle bed of a knitting flatbed machine and where the second layer 146 is formed on the second needle bed of the knitting flatbed machine (e.g., where a base region 156 can be formed using two needle beds). Although any suitable tubular knitting construction can be used, certain specific examples of suitable knitting techniques will be described in more detail below (e.g., with reference to Figures 9 to 10 ).

[0031] Referring again to Figures 2 to 3 , a second tubular knitted structure 142 can be included, where the second tubular knitted structure 142 is adjacent to the first tubular knitted structure 140 at at least one location (in this case at the throat region 116 of the shoe). Similar to the first tubular knitted structure 140, the second tubular knitted structure 142 can include a multi-layer knitted structure that defines a second passage 138 for receiving the tension strand 124. As Figure 2As shown, the stretch strand 124 can also extend through the first tubular knitted structure 140 and the second tubular knitted structure 142. At the location where the stretch strand 124 transitions from the first tubular knitted structure 140 to the second tubular knitted structure 142, a loop 150 can be formed, and the loop can be configured (e.g., sized, shaped, provided with specific frictional characteristics, etc.) to engage a shoelace (as Figure 1 shown) and / or another fastening system. As discussed above, the loop 150 can be considered an "anchor" used in the fastening system that manually or automatically tightens the footwear article 100 around the wearer's foot.

[0032] The first tubular knitted structure 140 and / or the second tubular knitted structure 142 can extend from the bite line of the upper 102 to the throat region 116 of the upper 102. Such a configuration is advantageous for distributing forces through the footwear article 100 in an appropriate manner. For example, when the footwear article 100 is in use, forces can be distributed from the throat region 116 through the stretch strand 124 (e.g., due to engagement with a shoelace, for example) to the sole structure 106 (as Figure 1 shown). Such force distribution can prevent "hot spots" or high-pressure areas and / or wear, and / or otherwise increase the comfort and / or performance of the footwear article 100. Additionally or alternatively, the knitted loops and / or other knitted structures of the knitted component 104 can be designed to distribute forces across the entire footwear article in a desired manner.

[0033] The stretch strand 124 can be inserted into the first tubular knitted structure 140 and / or the second tubular knitted structure 142 during the knitting process, such as by utilizing an inlay process. For example, the inlay process can include using an inlay feeder or other mechanical inlay device on a knitting machine (e.g., a combined feeder) to place the stretch strand 124 between two needle beds (e.g., a front needle bed and a rear needle bed) during the knitting process. An example of an inlay process and a combined feeder for implementing such a process is described in U.S. Patent Application Publication No. 2013 / 0145652, published on June 13, 2013, the applicant of which is Nike, Inc., and the entire content of which is incorporated herein by reference. Optionally, a similar insertion technique as described in U.S. Provisional Patent Application No. 62 / 863,660, filed on June 19, 2019, can be used (e.g., which may include a guiding element located in Figure 7 the shown merged tubular region 170), the applicant of which is Nike, Inc., and the entire content of which is incorporated herein by reference.

[0034] Alternatively, the stretch yarn 124 can be fed through the first tubular knit structure 140 and / or the second tubular knit structure 142 of the knit component 104 by hand and / or other manual methods (e.g., after knitting is complete). Additionally, it is contemplated that the stretch yarn 124 can be attached to the remainder of the knit component 104 in different ways (e.g., other than being located within a tube), such as by directly securing the stretch yarn 124 to the outer surface 194 of the footwear article using an adhesive.

[0035] In some aspects, the first tubular knit structure 140 can be angled relative to the second tubular knit structure 142. For example, referring to Figure 2 , the first tubular knit structure 140 and the second tubular knit structure 142 can be oriented such that they are closer together in or near the throat region 116 of the shoe than at the bite line 108. The inventors have found that such aspects are advantageous for creating a more natural force distribution through the upper 102 and reducing hot spots on the user's foot. Additionally, due to the better distribution of forces, the components of the footwear article 100 (particularly the components of the fastening system) can be better able to handle specific loads, increasing the overall durability of the footwear article 100 (and / or providing the ability to use different materials, which can reduce the total weight and / or cost of the footwear article 100). This aspect is also advantageous for providing enhanced aesthetics relative to other aspects.

[0036] While any suitable angle can be contemplated, the first tubular knit structure 140 can be angled relative to the second tubular knit structure 142 by between about 5 degrees and about 85 degrees (such as between about 10 degrees and about 45 degrees). The depicted aspect includes an angle of about 35 degrees, and it is contemplated that the angle can vary along the length of the tubular knit structure. Measurement of such an angle is preferably performed when the footwear article 100 is at rest. In the depicted example (and referring to Figure 5 , which shows a close-up view of the first tubular knit structure 140 and the second tubular knit structure 142), the first tubular knit structure 140 is located at a first distance 152 from the second tubular knit structure 142 at the bite line 108 of the upper 102. When the footwear article is at rest, in certain non-limiting example aspects, the first distance can be between about 1 cm and about 5 cm, such as between about 2 cm and about 4 cm, such as about 3 cm. In the throat region 116, the first tubular knit structure 140 can be located at a second distance 154 from the second tubular knit structure 142, where the second distance 154 is less than the first distance. Without limitation, when the footwear article 100 is at rest, the second distance 154 can be less than about 2 cm, such as less than about 1 cm, and in certain example aspects such as less than about 0.5 cm.

[0037] As Figures 2 to 5As shown, the base region 156 can be located between the first tubular knit structure 140 and the second tubular knit structure 142 (and between other tubular knit structures). Optionally, the base region 156 can vary throughout the knit component 104 to impart a banding characteristic (such as elasticity and / or other functional characteristics) throughout the footwear article 100. Optionally, the base region 156 of the knit component 104 can include one or more surface features that provide a unique and desired aesthetic as well as certain functional characteristics to the upper 102. For example, the base region 156 can include one or more scallop elements 198. The scallop elements 198 can be similar or identical to the scallop elements described in U.S. Patent Application No. 15 / 429,945, filed on February 10, 2017, entitled "Knitted Article with at Least One Scallop Element and Methods of Manufacture," assigned to Nike, Inc., the entire content of which is incorporated herein by reference. Other suitable texture-related and / or surface-related features in the base region 156 are also contemplated. For example, in some aspects, the base region 156 can include one or more pods that impart functional characteristics similar and / or identical to those described in U.S. Patent Application No. 16 / 054,132, filed on August 3, 2018, entitled "Article with at Least One Layered Pod," assigned to Nike, Inc., the entire content of which is incorporated herein by reference.

[0038] In some aspects, the knit structure within the base region 156 can include knit wedges or other structures to form an angle between the first tubular knit structure 140 and the second tubular knit structure 142. That is, referring to Figure 5 , a first region 158 of the base region 156 (corresponding to the first distance 152) can include a first number of courses of loops, and a second region 160 of the base region 156 (corresponding to the second distance 154) can include a second number of courses of loops, where the first number of courses of loops can be greater than the second number of courses of loops. Such an aspect can be formed by varying the number of courses of loops along the length of the needle bed over a period of time. For example, the first region 158 and the second region 160 can be completed on the knitting machine in approximately (or precisely) the same amount of time, but the first region 158 can be formed via the effective travel of more knitting feeders (and thus more courses of loops, and generally more knit loops) than the second region 160.

[0039] In some aspects, certain yarns within the tubular structure may also extend through the base region 156. For example, referring to the first tubular knitted structure 140 (and it is noted that the same can apply to other tubular regions), at least one layer of the first tubular knitted structure 140 may include yarns shared with the base region 156. Other yarns of the first tubular knitted structure 140 may not be included in the base region 156. For illustration, referring again to Figure 4 , the first layer 144 of the first tubular knitted structure 140 may include a first yarn 162 that is substantially not included in the base region 156, and the second layer 146 of the first tubular knitted structure 140 may include a second yarn 164 that is shared with the base region 156 (and thus extends through the base region 156, possibly forming knitted loops in the second layer 146 of the first tubular knitted structure 140 and in the base region 156). Thus, the connection between the first tubular knitted structure 140 and the surrounding base region 156 may be mainly via the second yarn 164.

[0040] Advantageously, by isolating the first yarn 162 on the first layer 144 of the first tubular knitted structure 140 (i.e., such that the first yarn 162 does not extend into the base region 156 beyond the loops at the edge of the first tubular knitted structure 140), the first yarn 162 can be specifically selected and configured to have desired surface characteristics without affecting the rest of the structure. In some aspects, the first layer 144 may be formed substantially entirely of the first yarn 162 to enhance this feature (but this is optional). For example, in some cases, it may be desirable to use a transparent yarn such that the tensile strand 124 within the tubular knitted structure 134 is visible, but the available yarns with the desired aesthetics may not be suitable for inclusion in the base region 156 (e.g., due to specific elasticity, incompatible bending moduli of the loops within the base region 156, etc.). Additionally, the yarn that may be desired to be used as the first yarn 162 may be incompatible with certain post-knitting manufacturing processes that affect the base region 156 (e.g., the heat applied to the base region 156 to activate the fusible yarn may be incompatible with the first yarn 162).

[0041] From a manufacturing efficiency perspective, this unique feature of separating the first yarn 162 from the base region 156 is advantageous for allowing a simple replacement of one yarn type with another (as the first yarn 162) without the need for reprogramming of the knitting machine to address yarn changes during knitting of the base region 156 (which is typically required when replacing one yarn type with another). Thus, it is envisioned that a consumer can customize a footwear article having a specific appearance (e.g., color, transparency, etc. of the top layer of the tubular knit structure) and / or functional characteristics determined by the first yarn 162, and the customized footwear article can be quickly formed on a knitting machine without extensive reprogramming of the corresponding knitting machine.

[0042] The first yarn 162 and the second yarn 164 can be the same yarn type or different yarn types. For example, the first yarn 162 can be a monofilament yarn, a high tenacity yarn (e.g., a yarn having a tenacity of at least 5 g / D, such as at least 10 g / D, 20 g / D or higher), etc. In some aspects, the second yarn 164 can preferably be a polyester yarn, which the inventors have found to be suitable for forming the inner surface of the footwear article and primarily forming the base region 156. Optionally, the depicted first yarn 162 and second yarn 164 can represent multi-strand yarns (e.g., the second yarn 164 shown in the figures can represent one or more strands of the same or different yarn types, such as one or more strands of a polyester yarn combined with one or more strands of a fusible yarn configured for heat treatment).

[0043] Figure 6 is shown Figure 2 A close-up perspective view of the area 6 shown. As Figure 6 shown, the first tubular knit structure 140 and the second tubular knit structure 142 can optionally merge at at least one location (i.e., come together such that there is no space between them). In the depicted example, the first tubular knit structure 140 and the second tubular knit structure 142 merge near or within the shoe throat region 116 such that a merged tubular region 170 is formed. Similar to the first tubular knit structure 140 and / or the second tubular knit structure 142, the merged tubular region 170 can include a tubular knit structure having a plurality of separable layers (e.g., where the first layer 172 of the merged tubular region 170 is formed on a first needle bed, where the second layer 174 of the merged tubular region 170 is formed on a second needle bed, and where a cavity / pocket between the first layer 172 and the second layer 174 forms a cavity 176 for receiving the tension strand 124).

[0044] The first layer 172 of the merged tubular region 170 can be continuous with the first layer 144 of the first tubular knit structure 140 ( Figure 4)(and similarly the first layer of the second tubular knit structure 142) is continuous, and the second layer 174 of the merged tubular region 170 can be continuous with the second layer 146 of the first tubular knit structure 140( Figure 4 )(and similarly the second layer of the second tubular knit structure 142). Additionally, the cavity 176 formed by the merged tubular region 170 can be in direct communication (i.e., form a continuous passageway) with the first passageway 136 of the first tubular knit structure 140 and the second passageway 138 of the second tubular knit structure 142. Thus, the same (continuous) stretch strand 124 can extend through each of the first passageway 136 of the first tubular knit structure 140, the cavity 176 of the merged tubular region 170, and the second passageway 138 of the second tubular knit structure 142.

[0045] In some aspects, the opening 178 can provide access to the cavity 176 of the merged tubular region 170. For example, the opening 178 can be a location where the first layer 172 and the second layer 174 of the merged tubular region 170 terminate (in the throat region 116 of the shoe) without connecting at the edges such that direct access to the cavity 176 is possible. Advantageously, the opening 178 can allow the loops 150 of the stretch strand 124 to extend beyond the edges 180 of the first layer 172 and / or the second layer 174, thereby providing space for engagement with a shoelace and / or other tensioning member. Advantageously, such aspects can facilitate, for example, the quick and efficient installation (e.g., lacing) of a shoelace.

[0046] Figure 7 An aspect similar to Figure 6 is shown, but where the loops 150 of the stretch strand 124 remain within the cavity 176 of the merged tubular region 170. When a tensioning member (such as a shoelace 126) is included, it can extend into the cavity 176 of the merged tubular region 170 such that it reaches the loops 150. From an external perspective (e.g., when the footwear article 100 is in use), the loops 150 can be invisible, and / or the arrival of the shoelace 126 at the merged tubular region 170 can be visually apparent. For example, such aspects can be advantageous in terms of protecting the stretch strand 124 from abrasion and / or for unique and eye-catching visual characteristics. It is also contemplated that when the performance of the footwear article 100 involves certain friction-related characteristics (e.g., lubrication) of the stretch strand 124, such aspects can protect the stretch strand 124 from loss of such characteristics.

[0047] To facilitate in Figure 7In aspects of tying the shoelace 126 (or otherwise installing the fastening system components), the first layer 172 and / or the second layer 174 can have sufficient elasticity such that the user can move them sufficiently to cause engagement between the shoelace 126 and the coil 150. Additionally or alternatively, it is contemplated that the tensioning strand 124 can be pulled out of the cavity 176 during lacing (e.g., via stretchability and / or another type of elongation or displacement of the tensioning strand 124).

[0048] Figure 8 One aspect incorporating the tubular region 170 is shown, where the opening 186 extends through the first layer 172 and / or the second layer 174, and where the opening 186 is configured (e.g., sized, shaped, and positioned) to receive the shoelace 126 (or other tensioning member). As shown, the tensioning strand 124 can extend around the opening 186 such that lacing of the shoelace 126 causes engagement between the shoelace 126 and the tensioning strand 124. In this aspect, the opening 178 ( Figure 6 instead of Figure 8 shown) is not required. The opening 186 in the knitted component 104 can be formed by any suitable process. In some aspects, a piece of the knitted component 104 can be cut out, punched out, or otherwise removed to form the opening 186. In other aspects, the opening 186 can be formed by a specific structure of the knitted component 104. For example, during the knitting process on a knitting flatbed machine having at least one needle bed, one or more needles of the needle bed can be skipped while forming certain wales of the knitted component 104, thereby forming a void, and the void can ultimately define the opening 186. Other suitable knitted structures can be additionally or alternatively used to form the opening 186. When the opening 186 is formed by a specific knitted structure rather than by cutting, punching, or other methods of removing a portion of the knitted component 104, the opening 186 is referred to in this disclosure as "knit-formed".

[0049] Other suitable aspects are also contemplated. For example, in certain variations, the shoelace or other tensioning member can extend through a channel or passage of a tubular knitted structure similar to those disclosed herein, such that a separate anchor is not required. Additionally or alternatively, certain tubular knitted structures can have different lengths (e.g., terminate before reaching the bite line and / or the throat region of the upper), can extend in different directions (e.g., extend substantially longitudinally along the upper), can be located in different regions (e.g., in the toe region, the heel region, in the underfoot region), etc.

[0050] Figures 9 to 10 is an illustration showing an example knitting diagram representing the knitting process for forming different parts of the knitted component 104 discussed above. Figure 9 is, for example, representative of Figure 2Diagram of the knitting process of the knitted area 9 shown. Figure 10 An example of forming a fan portion in a base region (e.g., similar to Figure 2 the base region 156 shown) is shown. These diagrams are non-limiting, and one or both of these diagrams can be changed in a suitable manner to accommodate changes in other aspects of the knitted component.

[0051] As Figure 9 shown, the first yarn 262 can form the first layer of the first tubular knitted structure 240 and the second tubular knitted structure 242 (e.g., similar to Figure 4 the first layer 144). The first tubular knitted structure 240 and the second tubular knitted structure 242 are each shown as being formed by a tubular knitting construction (e.g., where the yarn on the first needle bed 302 does not loop onto the needles of the second needle bed 304 and vice versa). The first tubular knitted structure 240 and the second tubular knitted structure 242 can be separated by a base region 256, which is a region where the yarn loops on both the front and back needle beds (e.g., such that the cavity or passage formed between the needle beds is traversed by such yarn).

[0052] On Figure 9 the left side, a merged tubular region 270 can be formed, where the merged tubular region 270 includes a tubular construction. As shown, there is no base region 256 between the merged tubular regions 270. In other words, the base region 256 terminates before reaching the merged tubular region 270, and thus the passages of the first tubular knitted structure 240 and the second tubular knitted structure 242 are continuous with the cavity located within the merged tubular region 270.

[0053] As discussed above, the first yarn 262 can be isolated from the base region 256. In fact, in this example, the first yarn 262 loops only on one of the two needle beds (e.g., the first yarn 262 loops only on the needles of the first needle bed 302), and it never reaches any needles of the second needle bed 304. Thus, the first yarn 262 in this example is only located in a single layer (e.g., similar to the first layer 144 discussed above) and is excluded elsewhere. In contrast, the second yarn loops on the needles of both needle beds (at least in the base region 256). Advantageously, such an aspect allows the replacement of the first yarn 262 with a different yarn type without the need to re-design and / or re-program the base region 256 and / or other parts of the knitted component to accommodate the new yarn type (as discussed above).

[0054] Various aspects of the subject matter have been described. Additional disclosure is provided below, which includes certain aspects consistent with the originally filed claims located at the end of this specification.

[0055] The first aspect includes an upper for a footwear article, the upper including one or more of the following: a first tubular knitted structure, wherein the first tubular knitted structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passageway is located between the first layer and the second layer; and a second tubular knitted structure, wherein the second tubular knitted structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passageway is located between the third layer and the fourth layer. The first tubular knitted structure may extend from a bite line of the upper to a throat region of the upper, wherein the second tubular knitted structure extends from the bite line of the upper to the throat region of the upper, and wherein a longitudinal direction of the first tubular knitted structure is at an angle of at least 5 degrees relative to a longitudinal direction of the second tubular knitted structure. Embodiments may include one or more of the following aspects in the paragraphs below.

[0056] A first portion of a stretch strand may extend through the first passageway, and a second portion of the stretch strand extends through the second passageway. Loops of the stretch strand may be located between the first portion of the stretch strand and the second portion of the stretch strand, wherein the loops are configured to engage a tension member of a fastening system. The loops may extend from an opening that provides an entrance to a cavity located in a throat region of the upper in a merged tubular region. Alternatively, the loops may be located inside a cavity located in a throat region of the upper in the merged tubular region.

[0057] The first tubular knitted structure and the second tubular knitted structure may merge in or adjacent to a throat region of the upper.

[0058] The first tubular knitted structure may be a first distance from the second tubular knitted structure at a bite line of the upper, wherein the first tubular knitted structure is a second distance from the second tubular knitted structure at a throat region of the upper, and wherein the first distance is greater than the second distance.

[0059] A knitted base region may be located between the first tubular knitted structure and the second tubular knitted structure. The knitted base region may include a first number of wales in a first region adjacent to the throat region, wherein the knitted base region includes a second number of wales adjacent to the bite line, and wherein the first number of wales is greater than the second number of wales to create an angled orientation of the first tubular knitted structure relative to the second tubular knitted structure.

[0060] The first layer may include a first yarn, wherein the first yarn is not included in the knitted base region.

[0061] Additional aspects relate to an upper for a footwear article, the upper including one or more of the following: a first tubular knit structure, wherein the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a first passageway is located between the first layer and the second layer; and a second tubular knit structure, wherein the second tubular knit structure includes a third layer and a fourth layer, the third layer and the fourth layer being separable such that a second passageway is located between the third layer and the fourth layer. The first tubular knit structure can extend from a bite line of the upper to a throat region of the upper, wherein the second tubular knit structure extends from the bite line of the upper to the throat region of the upper, wherein a knit base region is located between the first tubular knit structure and the second tubular knit structure at a location adjacent to the bite line, and wherein the first tubular knit structure and the second tubular knit structure merge at a merged tubular region located in or adjacent to the throat region of the upper. Embodiments can include one or more of the following aspects in the paragraphs below.

[0062] A first portion of a stretch strand can extend through the first passageway, wherein a second portion of the stretch strand extends through the second passageway, wherein loops of the stretch strand are located between the first portion of the stretch strand and the second portion of the stretch strand, and wherein the loops are configured to engage a tension member of a fastening system. The loops can extend from an opening that provides an entrance to a cavity located in the throat region of the upper in the merged tubular region. Alternatively, the loops can be located inside a cavity located in the throat region of the upper in the merged tubular region.

[0063] The knit base region can include a first number of courses of loops in a first region adjacent to the throat region, wherein the knit base region includes a second number of courses of loops adjacent to the bite line, and wherein the first number of courses of loops is greater than the second number of courses of loops to produce an angled orientation of the first tubular knit structure relative to the second tubular knit structure.

[0064] The first layer can include a first yarn, wherein the first yarn is not included in the knit base region.

[0065] Additional aspects relate to an upper for a footwear article, the upper including one or more of the following: a first tubular knit structure, wherein the first tubular knit structure includes a first layer and a second layer, the first layer and the second layer being separable such that a pouch is located between the first layer and the second layer; and a knit base region, the knit base region positioned adjacent to the first tubular knit structure on at least one side of the first tubular knit structure. The first layer of the first tubular knit structure can include a first yarn, wherein the second layer of the first tubular knit structure includes a second yarn, and wherein the first yarn is substantially not included in the knit base region. Embodiments can include one or more of the following aspects in the paragraphs below.

[0066] The first yarn and the second yarn may comprise different yarn types.

[0067] The second yarn may be knitted within the knitted base region.

[0068] The first yarn may comprise a monofilament yarn, and wherein the second yarn comprises a polyester yarn.

[0069] Although various embodiments of the present disclosure have been described, the present disclosure is not limited except as by the appended claims and their equivalents. Those skilled in the relevant art will recognize that various changes and modifications can be made to the above embodiments without departing from the scope of the invention as defined by the appended claims. Additionally, the advantages described herein are not necessarily the only advantages of the present disclosure, and it is not necessarily expected that every embodiment of the present disclosure will achieve all of the advantages described.

Claims

1. An upper for a footwear article, comprising: A knitted component, the knitted component comprising: -- A first tubular knitted structure and a second tubular knitted structure, the first tubular knitted structure and the second tubular knitted structure converging at a merged tubular region located in or adjacent to the throat region of the shoe upper, wherein the merged tubular region includes an opening extending through the inner and outer surfaces of the knitted component.

2. The upper for a footwear article according to claim 1, wherein the opening is formed by the knitting structure of the knitted component.

3. The upper for a footwear article according to claim 2, wherein the opening is a void in the knitted component formed by skipping one or more needles of the needle bed during knitting of the knitted component.

4. The upper for a footwear article according to claim 1, wherein the opening is formed by cutting or punching away a portion of the knitted component.

5. The upper for a footwear article according to any one of claims 1-4, wherein the opening is configured to receive a tension member of a fastening system.

6. An upper for a footwear article, comprising: A knitted component, the knitted component comprising: -- A first tubular knitted structure and a second tubular knitted structure, the first tubular knitted structure and the second tubular knitted structure converging at a merged tubular region located in or adjacent to the throat region of the shoe upper, wherein the merged tubular region includes an opening extending through the knitted component; and -- A stretch yarn, the stretch yarn extending through the first tubular knitted structure, around the opening and through the second tubular knitted structure.

7. The upper for a footwear article according to claim 6, wherein the opening is configured to receive a tension member of a fastening system.

8. The upper for a footwear article according to claim 7, wherein the tension member includes a shoelace, and lacing of the shoelace causes an engagement between the shoelace and the stretch strand.

9. The upper for a footwear article according to any one of claims 6-8, wherein the merged tubular region includes a first layer and a second layer, and the opening extends through the first layer and / or the second layer.

10. A footwear article, comprising an upper according to any one of claims 1 to 9 and a sole structure fixed to the upper.

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