Knitted component including cushioning structure, upper, and method of manufacturing article of footwear

Abstract

The invention relates to a knitted component including a cushioning structure, an upper, and a method of manufacturing an article of footwear. In one example, an upper (12) for an article of footwear (10) includes a knitted component (14). The knitted component (14) includes a plurality of knitted cushioning structures (46) defining a cushioning area (42).

Description

[0001] This application is a continuation-in-part of application number 202311261228.1, filed August 3, 2017, entitled "Knitted Component Including Cushioning Structure, Upper, and Method of Manufacturing an Article of Footwear."

[0002] Application number 202311261228.1, filed August 3, 2017, entitled "Knitted Component Including Cushioning Structure, Upper, and Method of Manufacturing an Article of Footwear" is a continuation-in-part of application number 201780049319.5, filed August 3, 2017, entitled "Article of Footwear Having an Upper with a Knitted Component Including a Cushioning Region, Upper, and Method of Manufacturing an Article of Footwear." Related Applications

[0003] This application claims the benefit of U.S. Provisional Application No. 62 / 380,035, filed August 26, 2016, entitled "Articles of Footwear Having an Upper that Includes a Knitted Component With a Cushioning Region and Methods for Fabricating the Same," which is incorporated herein in its entirety. TECHNICAL FIELD

[0004] The technical field is generally related to footwear, and more specifically, to an article of footwear having an upper that includes a knitted component having a region configured to provide enhanced cushioning. BACKGROUND

[0005] Conventional articles of footwear typically include an upper and a sole structure. The upper is secured to the sole structure and forms a void for receiving the foot of the wearer in comfort and stability. Foot comfort is a factor considered by footwear consumers. Thus, it is desirable to provide an article of footwear having an upper with enhanced foot cushioning and a method for manufacturing such footwear. SUMMARY

[0006] Articles of footwear, uppers for articles of footwear, and methods for manufacturing articles of footwear are provided herein. In example embodiments, an upper for an article of footwear includes a knitted component. The knitted component includes a plurality of knitted cushioning structures that define a cushioning region.

[0007] In an example embodiment, an article of footwear is provided. The article of footwear includes a sole structure and an upper secured to the sole structure. The upper includes a knitted component that includes a plurality of knitted cushioning structures that bound a cushioning region.

[0008] According to an example embodiment, a method for manufacturing an article of footwear is provided. The method includes forming an upper that includes a knitted component. The upper is formed by knitting a plurality of cushioning tubes that bound a cushioning region of the knitted component.

[0009] Other objects, features, and advantages of the present application will become apparent to one skilled in the art from the following description and accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0010] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. In the drawings, like numbers indicate like elements.

[0011] Figure 1 FIG. 1 illustrates a lateral side view of an article of footwear according to an example embodiment; Figure 2 FIG. 2 illustrates a medial side view of an article of footwear according to an example embodiment; Figure 3 FIG. 3 illustrates a cross-sectional view of the article of footwear depicted in FIG. 1 along line 3-3; Figure 1 Figure 4 FIG. 4 illustrates a top view of an article of footwear according to an example embodiment; Figure 5 FIG. 5 illustrates a perspective top view of an upper including a knitted component having a cushioning region according to an example embodiment; Figure 6 FIG. 6 illustrates an enlarged top view of a portion of the knitted component including a cushioning region depicted in FIG. 5; Figure 5 FIG. 7 illustrates an enlarged view of a portion of the view in FIG. 6; Figure 6A Figure 6 FIG. 8 illustrates a cross-sectional view of a portion of the cushioning region depicted in FIG. 5 along line 7-7 according to one embodiment; Figure 7A FIG. 9 illustrates a cross-sectional view of a portion of the cushioning region depicted in FIG. 5 along line 7B-7B according to another embodiment; Figure 6 Figure 7B FIG. 10 illustrates a cross-sectional view of a portion of the cushioning region depicted in FIG. 5 along line 7B-7B according to another embodiment; Figure 7A FIG. 11 illustrates a cross-sectional view of a portion of the cushioning region depicted in FIG. 5 along line 7B-7B according to another embodiment; Figure 7C Figure 6 ​​​​the cross-sectional view along line 7-7 of the cushioning region depicted in Figure 8 is a loop diagram of the knit structure of the first portion of the knitted component depicted in Figure 5 and Figure 6 is a loop diagram of the knit structure of the first portion of the knitted component depicted in Figure 9 is a loop diagram of the knit structure of the second portion of the knitted component depicted in Figure 5 and Figure 6 is a loop diagram of the knit structure of the second portion of the knitted component depicted in Figure 10 is a loop diagram of the knit structure of the third portion of the knitted component depicted in Figure 5 and Figure 6 is a loop diagram of the knit structure of the third portion of the knitted component depicted in DETAILED DESCRIPTION

[0012] The following description is merely exemplary in nature and is not intended to limit the disclosure or the application and uses of it.

[0013] Referring now to the drawings, Figures 1 to 3 An example of an article of footwear 10 having an upper 12 formed at least primarily from a knitted component 14 is illustrated. The article of footwear 10 has a general construction suitable for walking or running, and can also be applied to various other athletic footwear types, including for example baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, soccer shoes, sprinting shoes, tennis shoes, and hiking boots. Alternatively, the article of footwear 10 can also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, casual shoes, sandals, and work boots.

[0014] For example, as illustrated in Figure 3 and Figure 5 The upper 12 of the article of footwear 10 can also include an underfoot portion 15 (indicated by dashed lines in the figures) that generally lies between the wearer’s foot and the ground surface when the article of footwear 10 is assembled and configured to receive the wearer’s foot. In other words, the underfoot portion 15 can be associated with the plantar aspect of the foot (also referred to as the sole or bottom of the foot), and the remainder of the upper 12 can be configured to correspond to an overfoot portion associated with the remainder of the foot including the dorsal surface (i.e., the top of the foot). The underfoot portion can extend from the lateral side 24 of the upper 12 to the medial side 26 of the upper 12, and from the toe or forefoot region 18 to the heel region 22.

[0015] The sole portion 15 may include one or more desired properties, such as suitable strength, durability, flexibility, water permeability, tensile strength, and the like. Because the sole portion 15 can bear the wearer's weight during use, the sole portion 15 of the upper 12 may be particularly thick and / or denser than other parts of the upper 12 to provide a relatively high degree of support, durability, protection, and even cushioning between the ground and the sole of the foot.

[0016] The upper 12, and particularly the sole portion 15 (if present), can be configured to attach to the sole structure 16. The sole portion 15 can be bonded to the sole structure 16 using any suitable technique, such as by using adhesives, by sewing, bonding, welding, etc. The sole structure 16 can be any suitable type of sole structure and can form an outsole 30 configured to contact the ground during use. The sole structure 16 can have a bottom surface configured for a specific activity. For example, the sole structure 16 may include one or more cleats configured to provide sufficient traction friction on grass and / or artificial turf during sporting activities such as rugby, football, or baseball. In other embodiments, the sole structure 16 may have a tread or other features suitable for use in walking shoes, running shoes, indoor or outdoor athletic shoes, casual shoes, etc. It is contemplated that another component, such as a separate midsole, could be placed between the sole structure 16 and the sole portion 15 of the upper 12, but this is not necessary. It is also envisioned that the sole portion 15 of the upper 12 (if present) may include a surface configured to directly contact the ground when the footwear article 10 is in use, thereby eliminating the need for a separate sole structure 16. For example, the sole portion 15 may be strong, durable, and protective enough to serve as the bottom end surface of the footwear article 10, thus eliminating the need for a separate sole structure 16.

[0017] like Figure 3 As shown, the sole portion 15 is attached to the sole structure 16. The sole structure 16 is located under the wearer's foot and supports the wearer's foot, while the upper 12 provides a comfortable and stable cover for the foot. Thus, the wearer's foot can be positioned within the space formed by the upper 12 to effectively secure the foot within the footwear article 10 or otherwise connect the foot to the footwear article 10. Furthermore, the sole structure 16 is attached to the lower region of the upper 12 and extends between the foot and the ground to, for example, attenuate ground reaction forces (e.g., cushion the foot), provide traction friction, enhance stability, and influence foot movement.

[0018] The article of footwear 10 can be divided into three general regions: an anterior region 18, a midfoot region 20, and a heel region 22. The anterior region 18 generally includes portions of the article of footwear 10 corresponding with anterior portions of the foot, including the toes and the joints connecting the metatarsal bones with the phalangeal bones. The midfoot region 20 generally includes portions of the article of footwear 10 corresponding with intermediate portions of the foot, including the arch area. The heel region 22 generally includes portions of the article of footwear 10 corresponding with posterior portions of the foot, including the heel and calcaneal bones.

[0019] The article of footwear 10 also includes a lateral side 24 and a medial side 26 that extend through each of the regions 18, 20, and 22 and correspond with opposite sides of the article of footwear 10. In one example, the lateral side 24 corresponds with a lateral area of the foot (e.g., the surface that faces away from the other foot), and the medial side 26 corresponds with a medial area of the foot (e.g., the surface that faces toward the other foot). These regions 18, 20, and 22, and sides 24 and 26 are not intended to demarcate precise areas of the article of footwear 10. Rather, the regions 18, 20, and 22, and sides 24 and 26 are intended to represent general areas of the article of footwear 10 to aid in the following discussion. In addition to the article of footwear 10, the regions 18, 20, and 22, and sides 24 and 26 can also be applied when referring to the sole structure 16, the upper 12, and the various elements thereof.

[0020] With continued reference to Figures 1 to 3 In example embodiments, the sole structure 16 includes a midsole 28, an outsole 30, and an optional sockliner 32. The midsole 28 is secured to an underside of the upper 12 and can be formed of a compressible polymeric foam element (e.g., polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further constructions, the midsole 28 can include plates, moderators, fluid-filled chambers, durability elements, or motion control members that further attenuate forces, enhance stability, or influence the motion of the foot, or the midsole 28 can be formed primarily of fluid-filled chambers. The outsole 30 is secured to an underside of the midsole 28 and can be formed of a wear-resistant rubber material that is textured to impart traction. The sockliner 32, if present, is located within a void in the upper 12 and is positioned to extend beneath a foot to enhance the comfort of the article of footwear 10. The sole structure construction can vary significantly, and thus, it should be appreciated that other constructions for the sole structure 16 can be used in conjunction with the upper 12.

[0021] As illustrated, the upper 12, including the knitted component 14, passes through each of regions 18, 20, and 22, along both the outer side 24 and the inner side 26, on the forefoot region 18, around the heel region 22, and as shown... Figure 3 As shown, the upper 12 extends above the upper surface of the sole structure 16. When the foot is located within the space shaped to accommodate the foot, the upper 12 extends along the outer side of the foot, along the inner side of the foot, over the foot, and around the heel, and as in some embodiments described above, the upper can also be configured to extend below the foot. The upper 12 includes an outer surface 34 and an opposite inner surface 36. While the outer surface 34 faces outward and away from the footwear article 10, the inner surface 36 faces inward and defines most or a relatively large portion of the space in the upper 12. Furthermore, the inner surface 36 may rest against the foot or cover the wearer's foot with a sock. The upper 12 also includes a collar 38, which is at least partially located in the heel region 22 and defines an opening leading to the space in the upper 12, thereby providing an entrance for the foot into the space. That is, the foot can be inserted into and removed from the upper 12 through the opening formed by the collar 38.

[0022] The knitted component 14 of the upper 12 is shown having a throat 40 extending from the collar 38, between and / or from the outer side 24 and the inner side 26, and over the midfoot region 20 and the forefoot region 18. In an exemplary embodiment, the knitted component 14 includes a cushioning region 42, which may be at least partially arranged and positioned within the throat 40 of the upper 12, for example, surrounded by a peripheral region 45. In one example, the cushioning region 42 provides enhanced cushioning for the upper area or top of the wearer's foot adjacent to the cushioning region 42 (e.g., below the cushioning region 42). In another example, and as will be discussed further in detail below, the cushioning region 42 provides enhanced cushioning in an area of ​​the upper 12 that may be adjacent to and / or otherwise connected to the laces 43 (shown in...). Figure 4 (in the middle) or other fixing or attachment mechanisms, including but not limited to straps, straps, hooks, elastic bands, fasteners and the like or combinations thereof for fastening and securing the footwear article 10 to the wearer's foot.

[0023] In a non-limiting example, the cushioning area may disperse and / or absorb localized tension, compression, force, and / or pressure from the lacing 43 (or other fastening mechanism) to minimize and / or reduce the transmission of these forces from the lacing 43 (or other fastening mechanism) to the upper area of ​​the wearer's foot. Although the cushioning area 42 is illustrated as being formed in the throat 40 of the knitted component 14, it will be understood that the cushioning area 42 may be located in another area or more areas of the knitted component 14. For example, the cushioning area 42 may be primarily located on the outer lateral portion 24 and / or the inner lateral portion 26 of the knitted component 14 to provide additional cushioning to the corresponding area of ​​the wearer's foot. Additionally or alternatively, one or more cushioning areas 42 may also be located in any other portion of the forefoot area 18, heel area 22, or upper 12 where enhanced cushioning may be advantageous or desirable.

[0024] In an exemplary embodiment and as described further in detail below, the cushioning region 42 is configured as a plurality of cushioning structures. In one example and as shown, each of the plurality of cushioning structures has a tubular construction. The tubular structure may be an extended, fluffy, bulging, or otherwise enlarged construction formed by a knitting process (e.g., knitted cushioning structure 46). The knitted cushioning structure is constructed and configured to yield or collapse proportionally under applied forces and to recover when the applied forces are relieved to provide a cushioning effect. In one example and as illustrated, the knitted cushioning structure 46 is shown as generally elongated tubular members arranged side-by-side (e.g., juxtaposed) or generally parallel to each other, extending generally horizontally across the throat 40 of the knitted component 14 from the outer portion 24 to the inner portion 26. It is also contemplated that the knitted cushioning structure 46 may be other shapes and / or constructions oriented in various other patterns, orientations, or arrangements.

[0025] Figure 5 This is a perspective top view of an example of a knitted component 14 formed by a knitting process according to an exemplary embodiment, prior to being shaped into a three-dimensional structure to receive the foot and before being fixed to any sole structure 16. (See also...) Figures 1 to 3 and Figure 5 During the manufacture of the knitted component 14, a cushioning area 42 is produced. Specifically, the knitted component 14 is formed by a knitting process and extends over the entire upper 12. In one example, a seam 48 extends through the heel region 22 on the inner side 26 to join the edge 50 of the knitted component 14. In another example, in the manufacture of the upper 12 including the sole portion 15, alternative or additional seams may be present that attach the edge 49 of the sole portion 15 to the edge 51 of the outer side 24 or the inner side 26 of the upper 12 to form a space configured to receive the foot.

[0026] The upper 12 may also include one or more additional or optional features for functional and / or aesthetic purposes, including but not limited to the attachment mechanisms or lacing 43 (shown in the image) mentioned above that help to tighten the upper 12 around the foot. Figure 4 The upper 12 may include heel stabilizers in the heel region 22 for enhanced stability, toe protection in the forefoot region 18 made of abrasion-resistant material, and / or logos, trademarks, and labels with care instructions and material information. Therefore, in addition to the features and elements discussed herein and shown in the accompanying drawings, the upper 12 may incorporate a variety of other features and elements.

[0027] As described above, seams may exist in one or more areas of the knitted component 14. It is also envisioned that the knitted component 14 may be formed as a single, integral element during a knitting process, such as a weft knitting process (e.g., using a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process may substantially form the knitted structure of the knitted component 14 without requiring significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component 14 may be individually formed as a single, integral element and then attached to the respective elements. In some embodiments, the knitted component 14 may be shaped after the knitting process to form and maintain the desired shape of the upper (e.g., by using a last shaped like the foot). The shaping process may include attaching the knitted component 14 to another object (e.g., strobel) at one or more seams as described above by sewing, by using an adhesive, by bonding, or by another suitable attachment process, and / or attaching one portion of the knitted component 14 to another portion of the knitted component 14.

[0028] Forming the upper 12 with knitted components 14 can provide the upper 12 with advantageous properties, including but not limited to specific degrees of elasticity (e.g., expressed in Young's modulus), breathability, flexibility, strength, moisture absorption, weight, and abrasion resistance. These properties can be achieved by selecting specific single- or multi-layer knitted structures (e.g., rib knitted structures, single-jersey plain knitted structures, or double-jersey plain knitted structures), by varying the dimensions and tension of the knitted structure 14, by using one or more yarns formed from specific materials (e.g., polyester or elastic materials such as spandex) or constructions (e.g., multifilament or monofilament), by selecting yarns of specific dimensions (e.g., denier), or combinations thereof. The knitted components 14 can also provide desired aesthetic properties by combining yarns with different colors, textures, or other visual characteristics arranged in a specific pattern. The yarn itself and / or the knitted structure formed by one or more yarns of the knitted component 14 can vary at different locations, such that the knitted component 14 has two or more sections with different properties (e.g., the section forming the throat area 40 of the upper 12 and / or the section forming the collar 38 can be relatively elastic, while another section can be relatively less elastic or inelastic). In some embodiments, the knitted component 14 can incorporate one or more materials having properties that change in response to stimuli (e.g., temperature, humidity, electric current, magnetic field, or light). For example, the knitted component 14 may comprise yarns formed of thermoplastic polymer materials (e.g., polyurethane, polyamide, polyolefin, and nylon), which change from a solid to a softened or liquid state when subjected to a specific temperature at or above their melting point, and then change back to a solid state upon cooling. The thermoplastic polymer material can provide the ability to heat and then cool a portion of the knitted component 14 to form a region of bonded or continuous material that exhibits certain advantageous properties, such as relatively high levels of rigidity, strength, and water resistance.

[0029] In some implementation schemes and as in Figure 4 and Figure 5As illustrated, the knitted component 14 may include one or more yarns or strands, referred to herein as “stretch strands” 57, that are at least partially embedded or otherwise inserted into the knitted structure of the knitted component 14 during or after the knitting process. The stretch strands 57 may be substantially inelastic to have a substantially fixed length. The stretch strands 57 may extend through a plurality of rows of the knitted component 14 or through channels formed within the knitted component 14 and may restrict the stretching of the knitted component 14 in at least one direction. For example, the stretch strands 57 may extend from a region in the sole portion 15 and / or approximately from the bite line of the upper 12 to the throat region 40 of the upper 12 to restrict the stretching of the upper 12 in the lateral direction. The stretch strands 57 may form one or more lacing holes 55 for receiving lacing straps 43 and / or may extend around at least a portion of the lacing holes 55 formed in the knitted structure of the knitted component 14.

[0030] refer to Figures 5 to 7B In the exemplary embodiment and as discussed above, preferably, the cushioning region 42, including the knitted cushioning structure 46, is knitted during the knitting of the knitted part 14. Specifically, each of the knitted cushioning structures 46 forms a knitted wall 52 surrounding the channel 54. One or more strands 56 extend longitudinally through the channel 54. In the exemplary embodiment, each strand 56 is intermittently joined or “tucked” along the entire length of the tubular or elongated channel 54 by one or more knitted tuck stitches to a knitted structure on opposite sides 58 and 60 of the knitted wall 52. In an exemplary embodiment, it has been found that by intermittently gathering the strands 56 to opposite sides 58 and 60 of the knitted wall 52, the strands 56 form a “scaffold-like structure” that supports and maintains the expanded and fluffy shape, structure, and contour of the knitted cushioning structure 46 and maintains the generally open volume of the channel 54, thus producing enhanced cushioning when forces are applied to one or more knitted cushioning structures 46 within the cushioning area 42.

[0031] In exemplary embodiments, each of the knitted cushioning structures 46 may have multiple strands 56 extending through it, such as at least two strands 56, and in some embodiments, the knitted cushioning structure 46 may include four to eight strands 56 extending longitudinally through any one or more of the respective channels 54. Furthermore, the cushioning region 42 may include different zones, each containing different groups of knitted cushioning structures 46, with different numbers of strands 56 extending through the respective channels 54 in each group. It has been found that the number of strands 56 extending through each respective knitted cushioning structure 46 can affect the outer profile of the individual knitted cushioning structure 46, with a larger number of strands 56 within the channels 54 providing channels with a relatively larger diameter. The number of strands 56 extending through the channels 54 of the knitted cushioning structure 46 can also result in a relatively greater amount of reinforced cushioning provided by the knitted cushioning structure 46.

[0032] In one example, the buffer area 42 includes a first group 62 of knitted buffer structures 46, a second group 64 of knitted buffer structures 46, and a third group 66 of knitted buffer structures 46. In the exemplary... Figure 5 and Figure 6 In the diagram, the corresponding groups 62, 64, and 66 are indicated by parentheses. Each of the corresponding groups 62, 64, and 66 contains at least one knitted cushioning structure 46 within that group, and more preferably, each of the corresponding groups 62, 64, and 66 contains two or more knitted cushioning structures 46 within each group. The corresponding groups 62, 64, and 66 may each contain the same number of knitted cushioning structures 46 or they may contain different numbers of knitted cushioning structures 46.

[0033] like Figure 5 As shown, each of the knitted cushioning structures 46 in the first group 62 has a first number of strands 56, for example, four strands 56, extending longitudinally through a corresponding channel 54 in each of the knitted cushioning structures 46. Each of the knitted cushioning structures 46 in the second group 64 has a second number of strands 56, for example, six strands 56, extending longitudinally through a corresponding channel 54 in each of the knitted cushioning structures 46. Each of the knitted cushioning structures 46 in the third group 66 has a third number of strands 56, for example, eight strands, extending longitudinally through a corresponding channel 54.

[0034] As illustrated, the buffer region 42 is configured such that the knitted buffer structure 46 of the third group 66 is disposed between the first portion 68 and the second portion 70 of the knitted buffer structure 46 comprising the second group 64. In other words, the knitted buffer structure of the third group 66 (which comprises eight strands of yarn extending through the channel 54 of each knitted buffer structure 46) is disposed between two separate groups 64 of the knitted buffer structure 46 (each comprising six strands of yarn extending through the channel 54 of each knitted buffer structure 46). The first portion 72 and the second portion 74 of the knitted buffer structure 46 comprising the first group 62 are disposed adjacent to the first portion 68 and the second portion 70 of the knitted buffer structure 46 comprising the second group 64 (e.g., on the side opposite to the knitted buffer structure 46 of the third group 66). In this example, it has been found that the knitted cushioning structure 46 of the third group 66 has greater "loft" or enhanced cushioning than the knitted cushioning structure 46 of the second group 64, and the knitted cushioning structure 46 of the second group 64 has greater "loft" or enhanced cushioning than the knitted cushioning structure 46 of the first group 62. This is due to the number of strands 56 extending through the channels 54 in each of the knitted cushioning structures 46. For example, a greater number of strands 56 extending through the channels 54 of the knitted cushioning structure 46 results in greater loft and enhanced cushioning than a knitted cushioning structure 46 with fewer strands 56 extending through the channels 54.

[0035] like Figure 7A As illustrated, some or all of the knitted walls 52 of the knitted cushioning structure 46 can be constructed as generally circular knitted tubular walls 52. In other words, the cross-section of a single knitted cushioning structure 46 can have a generally rounded or circular shape; however, it is also conceivable that the cross-section can be oval or egg-shaped. In this example, the knitted walls 52 are generally symmetrical, wherein the outward-facing wall portion 76 (e.g., the portion forming the outer surface 34) and the inward-facing wall portion 78 (e.g., the portion forming the inner surface 36) have generally the same external profile shape and form generally similar cushioning volumes. This structure can be formed by knitting with "tubular stitches" and / or other known or suitable stitch types (including but not limited to "ottoman" type stitches), where the number of rows on one knitting bed (i.e., the front bed) is the same or substantially the same as the number of rows on the other bed (i.e., the back bed).

[0036] Alternatively and as Figure 7CAs illustrated, some or all of the knitted walls 52 can be constructed as asymmetrical knitted tubular walls 52. In this example, the knitted walls 52 are generally asymmetrical, for example, wherein the outward-facing wall portion 76 has a larger outer contour shape than the inward-facing wall portion 78, such that the buffer volume defined by the outward-facing wall portion 76 is larger than that of the inward-facing wall portion 78. Preferably, this structure can also be formed by knitting with tubular stitches, wherein the number of rows forming the outward-facing wall portion 76 is greater than the number of rows forming the inward-facing wall portion 78.

[0037] Reference Figures 5 to 7C As illustrated, knitted cushioning structure 46 can be connected to adjacent knitted cushioning structures 46 via transverse strands 80 (e.g., monofilament yarns). In an exemplary embodiment, the distance (d) between adjacent knitted cushioning structures 46 ranges from about 0.01 mm to about 0.3 mm. In an exemplary embodiment, each knitted cushioning structure 46 has a diameter or maximum cross-sectional dimension (D) ranging from about 0.5 mm to about 5 mm, such as from about 0.5 mm to about 3 mm, for example from about 1 mm to about 2 mm.

[0038] The knitted component 14 forming the upper 12 can incorporate various types and combinations of stitches and yarns. Regarding the stitches, the yarns forming the knitted component 14 can have one type of stitch in one area of ​​the knitted component 14 and another type of stitch in another area. Depending on the type and combination of stitches used, the areas of the knitted component 14 can have, for example, a plain weft knit structure, a mesh knit structure, or a rib knit structure. In an exemplary embodiment and as will be discussed further in detail below, the cushioning area 42 of the knitted component 14 can be formed using the tubular type of stitches mentioned above; however, any other suitable stitch type can be used as required or desired.

[0039] Regarding yarn, the types of yarn that can be used include, but are not limited to, filament yarns and spunyarns. Filament yarns are formed from continuous filaments that can be twisted or grouped together. Monofilament yarns are formed from a single, long, continuous filament. Stapleyarns are made by twisting short fibers together to create a cohesive strand. The process of forming yarn from short fibers typically involves carding and drawing the fibers to form a sliver, lengthening and twisting the sliver to form a roving, and spinning the roving to form a ply. Multiple plies can be combined (twisted together) to create a thicker yarn. The twisting direction of the short fibers and plies can affect the final properties of the yarn. Stapleyarns can contain a single type of fiber or can be made from a blend of fibers. Similarly, filament yarns can contain a single type of filament or can be formed using multiple types of filaments. Once formed, the filament yarns and staple yarns can undergo further processing, such as dyeing, texturing, or coating with materials such as synthetic polymers.

[0040] In one example, the knitted component 14 may have one type of yarn in one area and another type of yarn in another area. Depending on various design criteria, the knitted component 14 may combine yarns with, for example, different deniers, materials (e.g., cotton, elastic fibers, polyester, rayon, wool, and nylon), and twists. Different types of yarn can affect the physical properties of the knitted component 14, including aesthetics, tensile strength, thickness, breathability, and abrasion resistance. In one example, the cushioning area 42 is formed by a first yarn 82 and a second yarn 84, the first yarn 82 forming the knitted wall 52 of the knitted cushioning structure 46, and the second yarn 84 comprising strands 56 extending within corresponding channels 54 of the knitted cushioning structure 46. In an exemplary embodiment, the first yarn 82 is a multi-ply yarn, such as a yarn formed from two textured polyester strands wound around an elastic fiber. The yarns used to form other parts of the shoe upper (including, but not limited to, the collar 38 and / or the outer perimeter region 45) may be formed from the same yarns (such as the first yarn 82 or the second yarn 84) used to form the cushioning region 42, or alternatively, the yarns used to form the collar and / or the perimeter (or any other part of the shoe upper) may be formed from different yarns. In an exemplary embodiment, the second yarn 84 is a monofilament, such as a polyester monofilament.

[0041] Figure 8 It is a loop diagram of the first group 62 of the knitted cushioning structure 46 used for the knitted cushioning area 42. Figure 9 This is a loop diagram of the second group 64 of the knitted cushioning structure 46 used for the knitted cushioning area 42. Figure 10This is a loop diagram of the third group 66 of the knitted cushioning structure 46 used in the knitted cushioning area 42. Figure 8 The circular diagram illustrated depicts a non-limiting example of the structure of the knitted wall 52 of the first group 62 knitted cushioning structure 46, which is formed by stitches formed by first yarns 82 on each needle in the first and second needle beds. Then, ply yarns 56 formed by second yarns 84 (preferably monofilament ply yarn) extend through the channel 54 and intermittently join to the knitted structure forming the knitted wall 52, such as through tuck stitches on the first and second needle beds, each tuck stitch spaced three needles apart on a given bed. In other words, as the first group 62 knitted cushioning structure 46 is formed on one needle bed, the second yarns 84 (preferably monofilament ply yarn) are gathered, then float over three needles, and then gathered again on one needle bed in a repeating pattern. Figure 8 As shown, the same repeating pattern appears on another needle bed. Similarly... Figure 8 As shown, the tuck stitches on opposite needle beds can be offset from each other. In other words, tuck stitches appearing on opposite needle beds do not appear on needles directly opposite each other on the corresponding first and second (e.g., front and back) needle beds. Furthermore, for each consecutive row of the knitted yarn 56, for example, as... Figure 8 As shown in rows 7 to 10, compared to the previous row, the tuck stitch is shifted down by one or more needles on each of the front and back needle beds. More specifically, compared to the previous row in row 7, the tuck stitch on each of the front and back needle beds in row 8 is shifted down by one or more needles. When the four strands 56 are used to extend through the channels 54 in each of the knitted cushioning structures, it is preferable to knit four rows, in which three needles float between each tuck on the respective front and back needle beds. In this way, after all four rows are completed, all (or substantially all) of the needles on each of the front and back beds will be used for the tuck.

[0042] Figure 9The circular diagram illustrated in the figure depicts the construction of the knitted cushioning structure 46 of the second group 64 of the cushioning area 42. Specifically, the knitted wall 52 of the knitted cushioning structure 46 of the second group 64 can be formed by the first yarn 82 on each needle of the first needle bed and on each needle of the second needle bed. The ply 56 formed by the second yarn 84 (preferably monofilament ply) extends through the channel 54 and is intermittently joined to the knitted structure forming the knitted wall 52 by tuft stitches on the first and second needle beds, each tuft stitch in the first and second needle beds being spaced five needles apart on a given bed. In other words, when the knitted cushioning structure 46 of the second group 64 is formed on one needle bed, the second yarn 84 (preferably monofilament ply) is gathered, then floats over five needles, and then gathered again on one needle bed in a repeating pattern. Figure 9 As shown, the same repeating pattern appears on another needle bed. Similarly... Figure 9 As shown, the tuck stitches on opposite needle beds can be offset from each other. In other words, tuck stitches appearing on opposite needle beds do not appear on needles directly opposite each other on the corresponding first and second (e.g., front and back) needle beds. Furthermore, for each consecutive row of the knitted strands 56, for example, as... Figure 9 As shown in rows 7 to 12, compared to the previous row, the tuck stitch is shifted down by one or more needles on each of the front and back needle beds. More specifically, compared to the position of the tuck in the previous row of row 7, the tuck stitch on each of the front and back needle beds in row 8 is shifted down by one or more needles. When the six strands 56 are used to extend through the channels 54 in each of the knitted cushioning structures, it is preferable to knit six rows, with five needles floating between each tuck on the respective front and back needle beds. In this way, after all six rows are completed, all (or substantially all) of the needles on each of the front and back beds will have been used for the tuck.

[0043] Figure 10 The circular diagram illustrated depicts the construction of the third group 66 of the knitted cushioning structure 46 of the cushioning area 42. Specifically, the knitted wall 52 of the third group 66 knitted cushioning structure 46 can be formed by the first yarn 82 on each needle of the first needle bed and on each needle of the second needle bed. Then, the ply 56 formed by the second yarn 84 (such as monofilament ply yarn) extends through the channel 54 and is intermittently joined to the knitted structure forming the knitted wall 52 by tuft stitches on the first and second needle beds, each tuft stitch in the first and second needle beds being spaced seven needles apart on a given needle bed. In other words, when the third group 66 knitted cushioning structure 46 is formed on a needle bed, the second yarn 84 (preferably monofilament ply yarn) is gathered, then floats over seven needles, and then gathered again on a needle bed in a repeating pattern. Figure 10 As shown, the same repeating pattern appears on another needle bed. Similarly...Figure 10 As shown, the tuck stitches on opposite needle beds can be offset from each other. In other words, tuck stitches appearing on opposite needle beds do not appear on needles directly opposite each other on the corresponding first and second (e.g., front and back) needle beds. Furthermore, for each consecutive row of the 56 strands being knitted, for example, as... Figure 10 As shown in rows 7 to 14, compared to the previous row, the tuck stitch is shifted down by one or more needles on each of the front and back needle beds. More specifically, compared to the tuck position in the previous row of row 7, the tuck stitch on each of the front and back needle beds in row 8 is shifted down by one or more needles. When the eight strands 56 are used to extend through the channels 54 in each of the knitted cushioning structures, it is preferable to knit eight rows, in which seven needles float between each tuck on the respective front and back needle beds. In this way, after all eight rows have been completed, all (or substantially all) of the needles on each of the front and back beds will have been used for the tuck.

[0044] Figures 8 to 10 The knitting pattern shown is an exemplary representation of one method of constructing the knitted cushioning structure 46 constituting the cushioning area 42; however, other methods of constructing the knitted cushioning structure 46 may also be used as required or desired. For example, more or fewer strands 56 may extend through the channels 54 of the knitted cushioning structure compared to those shown and described above. Furthermore, it is contemplated that multiple strands 56 of the second yarn 84 may extend parallel and / or together as bundles of two or more twisted or knitted strands through the channels 54 of each respective knitted cushioning structure. In other words, two or more monofilament strands can be considered as described above and as... Figures 8 to 10 The method shown is to pass through the channel and knit a single unit in one or more rows.

[0045] As will be readily understood by those skilled in the art, the above description is intended to illustrate the implementation of the principles of the invention. This description is not intended to limit the scope or application of the invention, as modifications, variations, and alterations are permitted without departing from the spirit of the invention as defined in the claims.

[0046] Various aspects of this disclosure may be implemented in one or more of the embodiments described below.

[0047] 1) An upper for footwear articles, said upper comprising: A knitted component comprising multiple knitted cushioning structures that define a cushioning area.

[0048] 2) The upper according to 1), wherein the knitted cushioning structure is arranged as juxtaposed knitted cushioning structures.

[0049] 3) The upper according to 1), wherein the knitted component comprises: The collar defines an opening leading to a space within the upper for receiving the foot; The cushioning area extends outward from the collar; and The outer area extends at least partially around the buffer zone.

[0050] 4) The upper according to 1), wherein each of the knitted cushioning structures comprises: The knitted wall that defines the channel; and One or more strands, which extend within the channel.

[0051] 5) The upper according to 4), wherein the one or more strands are intermittently joined to the knitted wall defining the channel.

[0052] 6) The upper according to 4), wherein each of the knitted cushioning structures includes at least two strands extending longitudinally through the channel.

[0053] 7) The upper according to 6), wherein the cushioning area includes a first group of knitted cushioning structures, a second group of knitted cushioning structures and a third group of knitted cushioning structures, wherein each knitted cushioning structure of the first group of knitted cushioning structures has a first number of strands extending through the channel, each knitted cushioning structure of the second group of knitted cushioning structures has a second number of strands extending through the channel, and each knitted cushioning structure of the third group of knitted cushioning structures has a third number of strands extending through the channel.

[0054] 8) The upper according to 7), wherein the first number of strands is four strands, the second number of strands is six strands and the third number of strands is eight strands.

[0055] 9) The upper according to 8), wherein the third set of knitted cushioning structures is disposed between the first part and the second part of the second set of knitted cushioning structures, and wherein the first part and the second part of the first set of knitted cushioning structures are respectively disposed adjacent to the first part and the second part of the second set of knitted cushioning structures.

[0056] 10) The upper according to 4), wherein the knitted wall comprises a first yarn, and the one or more strands comprise a second yarn.

[0057] 11) The upper according to 10), wherein the second yarn is a monofilament yarn.

[0058] 12) The upper according to 11), wherein the monofilament yarn is a polyester monofilament yarn.

[0059] 13) The upper according to 10), wherein the first yarn comprises two textured polyester strands wound around an elastic fiber.

[0060] 14) The upper according to 4), wherein the knitted wall is constructed as a generally circular knitted tubular wall.

[0061] 15) The upper according to 4), wherein the knitted wall is an asymmetrical knitted tubular wall having an outward-facing wall portion and an inward-facing wall portion opposite to the outward-facing wall portion.

[0062] 16) According to the upper described in 15), the outward-facing wall portion is configured to form a larger cushioning volume than the inward-facing wall portion.

[0063] 17) A type of footwear, comprising: Sole structure; and The upper is attached to the sole structure and includes a knitted component, wherein the knitted component includes a plurality of knitted cushioning structures defining a cushioning area.

[0064] 18) A method for manufacturing footwear articles, the method comprising: An upper is formed that includes knitted components, wherein forming the upper includes knitting a plurality of cushioning tubular members that define cushioning areas of the knitted components.

[0065] 19) The method according to 18), wherein knitting the plurality of cushioning tubular members includes knitting the plurality of cushioning tubular members using tubular stitches.

Claims

1. A knitted component comprising: a first knitted structure including a first knitted wall and a first number of continuous strands, the first knitted wall surrounding a first channel, the first number of continuous strands intermittently bound to the first knitted wall and continuously extending through the first channel from a first side of the knitted component to a second side of the knitted component and forming a first scaffold-like structure.

2. The knitted component of claim 1, further comprising a second knitted structure having a second knitted wall and a second number of continuous strands, the second knitted wall surrounding a second channel, the second number of continuous strands intermittently bound to the second knitted wall and continuously extending through the second channel from the first side of the knitted component to the second side of the knitted component and forming a second scaffold-like structure, wherein the first knitted structure and the second knitted structure are arranged as juxtaposed knitted structures.

3. The knitted component of claim 2, wherein, the knitted component forms an upper for an article of footwear, wherein the upper includes a collar that defines an opening to a void within the upper for receiving a foot of a wearer, wherein the first knitted structure and the second knitted structure extend outwardly from the first side to the second side in a throat area of the upper.

4. The knitted component of claim 1, wherein, the first knitted structure is surrounded by a peripheral region of the knitted component.

5. The knitted component of claim 2, wherein, the second number of continuous strands is greater than the first number of continuous strands.

6. The knitted component of claim 1, further comprising a third knitted structure including a third knitted wall and a third number of continuous strands, the third knitted wall surrounding a third channel, the third number of continuous strands intermittently bound to the third knitted wall and continuously extending through the third channel from the first side of the knitted component to the second side of the knitted component and forming a third scaffold-like structure.

7. The knitted component of claim 1, wherein, each of the first number of continuous strands is intermittently bound to the first knitted wall by one or more knitted tuck stitches.

8. The knitted component of claim 2, wherein, the first knitted wall and the second knitted wall each include a first yarn, and wherein the first number of continuous strands and the second number of continuous strands each include a second yarn.

9. The knitted component of claim 8, wherein, the second yarn is a monofilament yarn.

10. The knitted component of claim 9, wherein, the monofilament yarn is a polyester monofilament yarn.

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