Footwear upper with embedded strand shoelace holes

Abstract

A knitted component for an upper of a shoe is described. The knitted component includes embedded strands through a course of the knitted component extending in a toe-heel direction. The embedded strand may be folded in half within the course such that two segments of the same embedded strand extend alongside each other. Along at least a portion of the courses, the embedded strands are exposed, and segments of the embedded strands may form loops through which laces of a lacing system of the shoe may pass. The embedded strands have sufficient tensile strength to allow the lace to be tensioned without damaging the strands or other portions of the knitted component.

Description

Background Technology

[0001] Conventional footwear typically comprises two main components: the upper and the sole structure. The upper, which may be made of one or more knitted elements, is attached to the sole structure and forms a cavity inside the footwear to securely accommodate the foot. Summary of the Invention

[0002] This disclosure describes an upper for a shoe, comprising a knitted element and insert yarns. The knitted element defines the edge of a tongue opening of the upper. The insert yarns are embedded within a first row of the knitted element, which extends parallel to the edge of the tongue opening. In an example, the first row extends parallel to the inner edge of the tongue opening of the upper, such that the first row is substantially parallel to the heel-toe axis of the shoe. In other words, the machine orientation of the knitting process is inside-outside, rather than heel-toe. This is perpendicular to conventional machine orientation and allows designers to utilize the different aesthetic possibilities achievable with this disclosure.

[0003] In this example, the ends of the embedded yarn exit the row through the same row opening. The embedded yarn bends within the row, causing it to fold in half. In some examples, the row opening is located near the toe of the shoe. This allows the ends of the embedded yarn to be anchored to the sole structure to provide tensile strength to the forces exerted on the shoe when the wearer tightens the laces, while minimizing the number of points along the periphery of the knitted elements on the upper that need to reach the shoe's bite line. This allows for greater flexibility in the design of the shoe and the knitted elements. For example, the knitted elements can be combined with other components to form the upper, with portions of the other components defining the periphery of the upper along the bite line rather than the knitted elements. In this example, the first and second knitted elements each have embedded yarns, used on either side (inner and outer) of the upper, and attached to additional knitted components that collectively define the gaps in the shoe.

[0004] In this example, the insert yarn can leave and re-enter the row of knitted elements at one or more points along the length of the first row. The insert yarn can form one or more loops through which one or more laces can pass. Using loops instead of individual eyelets to provide anchor points for laces reduces the number of parts required to assemble the shoe and allows the insert yarn to provide direct tension support in response to tension generated by the laces, further enhancing the shoe's visual appeal. Loops as lace holes can also be used in conjunction with conventional eyelets and eyelet plates, with each loop positioned on either the inside or outside of the eyelet plate.

[0005] In another example, embroidery strands can be used for embroidery along the transverse rows of the wrapping inlay yarn. The embroidery strands further anchor the inlay yarn in place, preventing twisting of the loop length. Attached Figure Description

[0006] Figure 1 The illustration shows a perspective view of a footwear article comprising one or more knitted components according to an example of this disclosure.

[0007] Figure 2 The illustration shows an example according to this disclosure. Figure 1 Side view of the inside of the footwear.

[0008] Figure 3 The illustration shows an example according to this disclosure. Figure 1 Top partial view of the footwear.

[0009] Figure 4 The illustration shows an example of forming according to the present disclosure. Figure 1 A top view of the knitted fabric on the inside of the upper of a footwear item.

[0010] Figure 4A The illustration shows an example of forming according to the present disclosure. Figure 4 A magnified view of the inner knitted fabric area 4A of the footwear upper.

[0011] Figure 5 The illustration shows an example of forming according to the present disclosure. Figure 1 A top view of the internal knitted components of the upper of footwear.

[0012] Figure 6 This is a flowchart of a method for forming a knitted component for the upper of a footwear article according to an example of this disclosure.

[0013] Figure 7A The illustration shows an enlarged area of ​​the inner knitted fabric for forming the upper of a footwear article according to an example of the present disclosure.

[0014] Figure 7B The illustration shows an enlarged area of ​​the inner knitted fabric for forming the upper of a footwear article according to an example of the present disclosure. Detailed Implementation

[0015] This disclosure relates to a knitted component for a shoe upper. In at least some embodiments, the knitted component includes a row of insert strands extending in a toe-to-heel direction through the knitted component. Along at least a portion of the row, a section of the insert strand is exposed and may extend out of the row in the form of a loop through which the shoelaces of the shoe's lacing system can pass. The insert strand has sufficient tensile strength to allow the shoelaces to be tightened without damaging the strands or other parts of the knitted component.

[0016] Conventional footwear typically comprises two main components: the upper and the sole structure. The upper, formed using one or more knitted elements, is attached to the sole structure and creates a space within the footwear to securely receive the foot. The one or more knitted elements of the upper typically consist of yarns knitted to form multiple loops defining rows and warps.

[0017] This disclosure further improves sustainability by using the inlay yarn itself as the eyelet through which the laces can pass. The inlay yarn can be formed from a strong and durable material and can optionally be treated to provide additional strength, durability, or other desired characteristics (e.g., water resistance, abrasion resistance, etc.). This simplifies manufacturing and reduces costs. One or more conventional eyelets can still be used in conjunction with loops. Inlay yarn loops can also provide different aesthetics to the shoe in terms of appearance (e.g., color, texture, etc.) and positioning (inside or outside the knitted components).

[0018] In this example, the two ends of the embedded yarn exit the row through the same row opening. The embedded yarn bends within the row, causing it to fold in half within the row. In this example, the row opening is located near the toe of the shoe. This allows the ends of the embedded yarn to be anchored to the sole structure to provide tensile strength to the forces exerted on the shoe when the wearer tightens the laces, while minimizing the number of points along the periphery of the knitted elements along the upper that need to reach the shoe's bite line. This allows for greater flexibility in the design of the shoe and the knitted elements. For example, the knitted elements can be combined with other components to form the upper, portions of which define at least a portion of the periphery of the upper along the bite line, rather than the knitted elements. In this example, the first and second knitted elements each have embedded yarns used on either side (inner and outer) of the upper and are attached to additional knitted components that collectively define the gaps in the shoe.

[0019] In this example, the insert yarn can leave and re-enter the row of knitted elements at one or more points along the length of the first row. The insert yarn can form one or more loops through which one or more laces can pass. Using loops instead of individual eyelets to provide anchor points for the laces reduces the number of parts required to assemble the shoe and allows the insert yarn to provide direct tension support in response to the tension caused by the laces, further enhancing the shoe's visual appeal.

[0020] In another example, embroidery strands can be used for embroidery along the transverse rows of the wrapping inlay yarn. The embroidery strands further anchor the inlay yarn in place, preventing twisting of the loop length.

[0021] By using loops formed by embedded strands and then locked by embroidered strands, the tension applied by the laces is “absorbed” by the embedded strands anchored near the toe. This reduces the stress experienced by the rest of the upper, which in turn reduces the minimum strength / elasticity / flexibility requirements of one or more other sections of the upper, allowing for greater flexibility in the selection of materials, configurations, and knit constructions for the rest of the upper.

[0022] In at least some instances, the knitted elements are knitted with yarn formed from recycled leather, which may be referred to herein as waste leather yarn (SLY), thus increasing the sustainability of the shoe upper. The embedded yarn described herein can help provide strength to compensate for any reduction in tensile strength associated with recycled materials such as SLY.

[0023] As used herein, the term "outer-facing surface" refers to the surface of a knitted upper or footwear article that faces the external environment. In some instances, an outer-facing surface may refer to the outermost surface of a knitted upper or footwear article. As used herein, the term "inner-facing surface" refers to the surface of a knitted upper or footwear article that faces the space intended to accommodate the wearer's foot. In some instances, an inner-facing surface may refer to the innermost surface of a knitted upper or footwear article.

[0024] As used herein to describe knitted parts, the term "knit" refers to a piece of fabric formed from at least one yarn that is manipulated (e.g., using a knitting machine) to form multiple interlocking loops (also called weaving) defining rows and warps. As used herein, the term "row" refers to a main horizontal row of knitted loops (in upright fabric knitted on a knitting machine) produced by adjacent needles during the same knitting cycle. Rows can include one or more needle types, such as knitting stitches, skipped stitches, tuck stitches, transfer stitches, rib stitches, etc., terms known in the knitting field. The term "row direction" refers to the direction parallel to the knitted rows of the fabric. As used herein, the term "warp" is a main vertical row of interlocking or weaving knitted loops, typically produced by the same needle in consecutive (but not necessarily all) rows or knitting cycles. The term "warp direction" refers to the direction parallel to the knitted warp of the fabric.

[0025] As used herein, the term "whole knit" can mean a knitted fabric in which yarns from one or more knit rows in a first region are interwoven with one or more knit rows in another region. Interweaving can be achieved through simple knitting stitches, tuck stitches, fixed stitches, float stitches, or skip stitches, etc. In this way, the areas knitted together have a seamless transition, allowing them to extend seamlessly into each other. In some cases, the term is used to describe two layers covering the same area, wherein the two layers are connected to each other by a common yarn that forms at least a portion of a row in one layer and moves to form a portion of a row in the other layer, the yarn extending between each of the two layers and forming at least a portion of each of the two layers, and / or the yarns from each layer are simultaneously formed using overlapping needle sets on a needle bed, such that the yarns of each layer can intertwine with each other, even if they do not interweave. In these cases, the two layers are whole knitted because they are joined at one or more locations by the knitting process rather than by stitches, adhesives, or other bonding.

[0026] As used herein, the term "eyelet" refers to a hole in the upper through which shoelaces extend. Eyelets may be formed integrally with the upper or may be part of a separate component embedded in or attached to the upper. The term "eyelet piece," as used herein, refers to the material of the upper that holds the shoelace holes (such as eyelets or loops) in place.

[0027] As used herein, a knitted part is defined as being formed by an “integral knitted construction” when formed as a single element by a knitting process. That is, the knitting process essentially forms the various features and structures of the knitted part without requiring significant additional manufacturing steps or processes. While the parts of a knitted part may be joined together after the knitting process, the knitted part remains formed by an integral knitted construction because it is formed as a single knitted element. Furthermore, when other elements (e.g., shoelaces or other trims, tongues, logos, trademarks, tags with care instructions and material information) are added after the knitting process (or “post-knitting treatment”), the knitted part remains formed by an integral knitted construction. In one example, one or more sections of a knitted part may include a plush construction. In other examples, a knitted part may be further shaped after knitting is complete, such as by cutting one or more sections from a section of the knitted part. As used herein, “embedded ply” is a ply embedded within the structure of a knitted part, such that the embedded ply typically extends in an un-looped state along a row of knitted loops formed by one or more other yarns.

[0028] Examples of knitted parts described herein may be weft knitting on a weft knitting machine (such as a flat V-bed knitting machine) having an insert feeder capable of embedding yarn within the knitted part during the knitting process.

[0029] As used in this article, “about” includes + / - 10% of a given value.

[0030] Footwear products 100 as disclosed in this article Figures 1 to 3 The shoe is depicted as including a sole structure 110 and an upper 120. Although footwear 100 is illustrated as having a general configuration suitable for running, the concepts associated with footwear 100 can also be applied to a variety of other athletic footwear types, such as baseball shoes, basketball shoes, cycling shoes, rugby shoes, tennis shoes, soccer shoes, training shoes, walking shoes, and hiking boots. The concept can also be applied to footwear types generally considered non-athletic, including dress shoes, loafers, sandals, and work shoes. Therefore, the concepts disclosed regarding footwear 100 are applicable to a wide variety of footwear types.

[0031] For reference purposes, footwear 100 can be divided into three general areas: forefoot area 101, midfoot area 102, and heel area 103. Forefoot area 101 generally includes the portion of footwear 100 corresponding to the toe and the joints connecting the metatarsals and phalanges. Midfoot area 102 generally includes the portion of footwear 100 corresponding to the arch region of the foot. Heel area 103 generally corresponds to the posterior portion of the foot (including the calcaneus). Footwear 100 also includes lateral 104 and medial 105, which extend through each of areas 101 to 103 and correspond to opposite sides of footwear 100. More specifically, lateral 104 corresponds to the lateral region of the foot (i.e., the surface facing away from the other foot), and medial 105 corresponds to the medial region of the foot (i.e., the surface facing the other foot). Areas 101 to 103 and lateral 104 to 105 are not intended to define precise areas of footwear 100. Conversely, zones 101 to 103 and sides 104 to 105 are intended to denote the general areas of footwear 100 to aid the discussion below. In addition to footwear 100, zones 101 to 103 and sides 104 to 105 may also be applied to the sole structure 110, the upper 120, and their individual elements.

[0032] The sole structure 110 is attached to the upper 120 and extends between the foot and the ground when the footwear 100 is worn. The main components of the sole structure 110 are the midsole 111, outsole 112, and insole 113. The midsole 111 is attached to the lower surface of the upper 120 and may be formed of a compressible polymer foam element (e.g., polyurethane or ethylene vinyl acetate (EVA) foam) that reduces ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other walking activities. In further configurations, the midsole 111 may incorporate plates, adjusters, fluid-filled chambers, last elements, or motion control components that further reduce forces, enhance stability, or influence foot movement. The outsole 112 is attached to the lower surface of the midsole 111 and may be formed of an abrasion-resistant rubber material that is textured to provide traction. The insole 113 is located within the upper 120 and is positioned to extend below the lower surface of the foot to enhance the comfort of the footwear 100. While this configuration of the sole structure 110 provides an example of a sole structure that can be used in conjunction with the upper 120, various other conventional or unconventional configurations of the sole structure 110 may also be used. Therefore, the characteristics of the sole structure 110, or any sole structure used with the upper 120, can vary significantly.

[0033] The upper 120 defines a gap within the footwear 100 for receiving and securing the foot relative to the sole structure 110. This gap is shaped to accommodate the foot and extends along the lateral side of the foot, along the medial side of the foot, above the foot, around the heel, and below the foot. Access to the gap is provided via an ankle opening 121 located in at least the heel area 103. Laces 122 extend through various eyelets 123 and allow the wearer to modify the size of the upper 120 to fit the proportions of the foot. More specifically, the laces 122 allow the wearer to tighten the upper 120 around the foot, and the laces 122 allow the wearer to loosen the upper 120 to facilitate entry into and exit from the gap (i.e., through the ankle opening 121). Furthermore, the upper 120 includes a tongue 124 within a throat opening 131, which extends below the laces 122 and eyelets 123 to enhance the comfort of the footwear 100. In some instances, such as Figure 1 In the example shown, the laces 122 may also extend through one or more holes 125 in the tongue. In other configurations, the upper 120 may include additional elements such as (a) a heel stabilizer 126 for enhanced stability in the heel area 103, (b) a toe guard 127 made of abrasion-resistant material in the forefoot area 101, and (c) logos, trademarks, and labels with care instructions and material information. The sole structure 110 and the upper 120 meet along the interlocking line 130.

[0034] Many conventional footwear uppers are formed from multiple material elements (e.g., fabric, polymer foam, polymer sheet, leather, synthetic leather) joined together, for example, by stitching or bonding. In contrast, the majority of the upper 120 is formed from multiple knitted components, including an inner knitted component 140, an outer knitted component 160, and an inner knitted component 400. The inner knitted component 400 may be at least partially covered by the inner knitted component 140 and the outer knitted component 160. In some instances, the inner knitted component 400 forms the tongue 124. The upper 120 formed by these knitted components extends along both the outer side 104 and the inner side 105 through each of zones 101 to 103, across the forefoot zone 101, and around the heel zone 103. Furthermore, the knitted components 140, 160, and 400 collectively form portions of both the outer surface and the opposing inner surface of the upper 120. Thus, the knitted components 140, 160, and 400 define at least a portion of the voids within the upper 120. In some configurations, one or more of the knitted components 140, 160, and 180 may also extend under the foot. In some instances, a strobel liner (not shown) is attached to one or more of the knitted components 140, 160, and 400 and the upper surface of the midsole 111, thereby forming a portion of the upper 120 extending under the insole 113.

[0035] Using a combination of knitted components to form articles such as uppers 120 can provide advantages including, but not limited to, specific degrees of elasticity (e.g., expressed in Young's modulus), breathability, flexibility, strength, moisture absorption, weight, abrasion resistance, and / or combinations thereof. These properties can be achieved by selecting specific combinations of knitted structures, by varying the size and tension of the knitted structures, by using one or more yarns formed from specific materials (e.g., polyester, which is relatively inelastic, or thermoplastic, which is relatively elastic and can be used to form elastic or elastomeric yarns), by selecting yarns of specific dimensions (e.g., denier), and / or combinations thereof. Multi-part construction using knitted components can also provide desired aesthetic properties by combining yarns with different colors, textures, or other visual characteristics arranged in specific patterns. The yarns themselves and / or the knitted structures formed from one or more yarns can vary in different locations, allowing finished uppers from different knitted components to have different properties, as described herein.

[0036] See you again Figure 1 and Figure 2The inner knitted component 140 is formed by an integral knitted construction. The inner knitted component 140 is formed from at least one yarn, which is manipulated (e.g., using a knitting machine) to form multiple interlocking loops defining various rows and warps. That is, the inner knitted component has the structure of a knitted fabric. In an example, the knitted component is knitted on a double-bed weft knitting machine. The knitted component may include two layers (a front layer and a back layer), which may be knitted integrally. The two layers may use different yarns, and one or more different knitting patterns may be used to knit the front and back layers.

[0037] The inner knitted component 140 includes a toe section 511 located in the forefoot region 101 and a heel section 513 located in the heel region 103. The inner knitted component 140 also includes a first edge 142 located inside the throat opening 131 along the tongue 124 in the forefoot region 101 and midfoot region 102. Figure 1 and Figure 2 In one example, the inner eyelet 141 extends adjacent to the first edge 142. The inner eyelet 141 includes two eyelets 123 through which a lace 122 can extend. In other examples, the inner eyelet 141 may have more or fewer eyelets 123, or the inner knitted component 140 may be formed without a conventional eyelet. In some examples, such as Figure 1 In the example shown, the insert can be inserted into one or more of the shoelace eyelets 123. In other examples, the insert is not used, which reduces the number of additional manufacturing steps and the use of potentially unsustainable materials.

[0038] The first row 200 extends along the edge of the inner eyelet piece 141 opposite to the first edge 142. In this example, the first row 200 extends generally in the toe-toe direction. Loop groups 310, 320, 330, 340, and 350, formed by the exposed portions of the embedded yarns 300, extend from the first row 200; loop group 350 extends from the outward-facing surface of the inner knitted component 140, and loop groups 310, 320, 330, and 340 extend from the inward-facing surface of the inner knitted component 140. Figure 3 A similar set of loops 360, 370, 380, and 390 can be seen extending from the outer knitted component 160, with their outer edges 143 pulled toward the outer side 104 to show the loops 360, 370, 380, and 390. Figure 3 As shown, the inward-facing loop group can be used as a shoelace eyelet, through which the shoelace 122 can extend. The outward-facing loop group (e.g., loop group 350) can also be used together with the eyelet 156 as a shoelace eyelet 123.

[0039] exist Figure 2In the example shown, the first row 200 is spaced apart from the inner edge 142 by a first length D1, and the first row 200 is spaced apart from the bite line 130 of the footwear 100 in the midfoot area 102 by a second length D2, wherein the second length D2 is greater than D1. In this example, the ratio of D2 to D1 can be between approximately 3:1 and approximately 4:1. In other examples, this ratio of D2 to D1 can be greater than 4:1 or between 3:1 and 1:1.

[0040] In some instances, the embroidery 250, having embroidery strands 252, is sewn along the first row 200 onto both the inward-facing and outward-facing surfaces of the inner knitted component 140. The embroidery 250 may extend generally parallel to the first row 200 and / or the first edge 142, such that the longitudinal axis of the embroidery 250 may extend from the adjacent ankle opening 121 to the forefoot area 101. In some instances, the embroidery 250 may include a plurality of longer stitches 251 sewn with the embroidery strands 252 and spaced apart along the length of the embroidery 250 to further prevent slippage of the embedded strands 300 and loops.

[0041] Although Figure 1 The example shown uses embroidery 250 as a reinforcing element to hold the embedded ply 300 in place, but the holding of the embedded ply 300 can be achieved using other types of reinforcing elements. In some instances, the knitted component can be knitted with needles (e.g., tuck stitches) in a configuration that holds the embedded ply within the rows. In other instances, one of the yarns used to knit some or all of the first rows 200 can have a low-melting-point thermoplastic polymer. For example, one of the yarns can have a thermoplastic polymer sheath surrounding a core (e.g., a polyester core), wherein the thermoplastic polymer sheath has a melting temperature lower than the melting or decomposition temperature of the core. In this way, heat (and in some instances, pressure) can be applied to or near the first row 200 to the inner knitted component 140 such that the thermoplastic polymer sheath of the yarn can at least partially melt, and upon cooling, fuse or bond the remaining unmelted portion of the yarn in the first row 200 to the embedded ply 300. Furthermore, the embedded ply 300 may be formed of a material having a higher melting or decomposition temperature for the yarn used to knit the first row 200, such that the embedded ply 300 does not melt when the knitted part is heated to a temperature that melts the yarn of the first row 200. In yet another embodiment, the reinforcing element may be a fusible film or skin applied along the outer side of the first row 200 to the inner knitted part 140.

[0042] The inner knitted component 140 also includes bite line edges 144 and 146 extending along the bite line 130 between the upper 120 and the sole structure 110. Between bite line edges 144 and 146 is a cut edge 152 spaced apart from the bite line 130, exposing the outer surface 412 of the inner wing of the inner knitted component 400. In one example, a edging 153 may be attached to the cut edge 152. The inner knitted component 140 also includes a heel stabilizer edge 147 extending along the heel stabilizer 126 in the heel area 103.

[0043] like Figure 1 As shown, the outer knitted component 160 may have all the features described with respect to the inner knitted component 140, including the outer edge 143, the heel edge 149, the heel stabilizer edge 157, and the cut edge 155.

[0044] Figure 4 An inner knitted fabric 500 for forming the inner knitted component 140 is shown, which is in the position of stitching embroidery 250 along the first transverse column and inserting eyelets (such as...) Figure 1 Before the eyelet insert 199 is inserted into the eyelet 151, the insole knitted fabric 500 includes a first edge 142 corresponding to the first edge 142 of the insole knitted part 140. In this example, the first edge 142 is the finished edge that does not surround the fabric and is the first portion of the knitted insole knitted fabric 500, with arrow 501 reflecting the knitting direction, resulting in the insole knitted fabric 500 having a transverse direction as indicated by arrow 505. Knitting the insole knitted fabric 500 in this direction can produce a cleaner first edge 142 in the finished upper 120. However, in other examples, the insole knitted fabric 500 may be knitted in the opposite direction to arrow 501, where the first edge 142 is the last knitted.

[0045] The inner knitted fabric 500 also includes a collar edge 150, a heel edge 148, and a heel stabilizer edge 147, all of which correspond to the collar edge 150, heel edge 148, and heel stabilizer edge 147 of the inner knitted component 140. The inner knitted fabric 500 also includes a lower peripheral edge 502 located between the heel stabilizer edge 147 and the first edge 142. During post-knitting processing, a cut portion 154 can be removed from the knitted component along a portion of the lower peripheral edge 502, resulting in the cut edge 152 of the inner knitted component 140. In some instances, when incorporated into footwear 100, the remaining sections of the lower peripheral edge 502 (edges 503 and 504) can be positioned against the upper surface of the sole structure 110 and can be joined to the Ströbel.

[0046] The first row 200 extends along at least a portion of the inner knitted fabric 500. In some examples, the first row 200 is generally parallel to the first edge 142 and offset from the first edge 142 by a certain number of rows from the inner knitted fabric 500. In other examples, the first row 200 may extend along or be adjacent to the first edge 142. Figure 4 In the example shown, the first row 200 is adjacent to the portion of the inner knitted fabric 500 corresponding to the inner eyelet 141 of the inner knitted component 140. In this example, the inner eyelet 141 is a knitted eyelet integrally formed with the rest of the inner knitted component 140; however, in other examples, the inner eyelet 141 may be knitted separately or otherwise formed. The first row 200 is knitted such that multiple openings corresponding to the positions of loop groups 310, 320, 330, 340, and 350 are formed on the outward-facing and inward-facing surfaces of the inner knitted component 140. Such openings can be knitted by transferring one or more yarn loops from the front needle bed of the knitting machine to the back needle bed (to form an opening in the forward layer) and vice versa (to form an opening in the backward layer).

[0047] During the knitting of the first row 200, the insert ply 300 is inserted into the first row 200. In some instances, the yarn feeder (e.g., a combined yarn feeder) makes a first stroke to insert a first segment of the insert ply 300, starting from one end of the first row 200, into the forefoot area 101 of the inner knitted fabric 500. The yarn feeder then makes a second stroke along the same first row 200 to lay a second length of insert ply into the first row 200. In some instances, after the yarn feeder completes its first insert stroke but before beginning its second insert stroke, an anchoring stitch is performed to secure the insert ply into the first pass at a bend point 305, such that the first insert ply segment is held in place while the yarn feeder makes its second stroke to insert a second segment of the insert ply. During the two insertion strokes, the yarn feeder can feed additional lengths of yarn at certain needle positions corresponding to openings in the first row 200 for loop groups 310, 320, 330, 340, and 350, where these additional lengths will form loop groups 310, 320, 330, 340, and 350. At the end of the insertion, ends 301 and 302 of the inserted yarn 300 extend beyond the ends of the first row 200 near the forefoot area 101.

[0048] After knitting the first row 200, the remaining portion of the inner knitted fabric 500 is knitted. As described above, the inner knitted fabric 500 may include a combination of edges that will become the finished edge, while other edges may undergo post-processing steps to form the finished edge.

[0049] The size of the loop groups 310, 320, 330, 340, and 350 can also be adjusted after the inner knitted fabric 500 is knitted. In some instances, pins of clamps can be inserted into each loop, and each loop can be tightened (i.e., shortened) by pulling one or more other segments of the embedded strand 300 (e.g., segments forming adjacent loop groups, or segments of one or both of ends 301 and 302 extending from the end of the first row 200). The advantage of this manufacturing method is that each loop group can be independently tensioned, loosened, or otherwise adjusted during the manufacturing process of the footwear 100. That is, the loop groups can be independently adjusted to the appropriate size before the embedded strand 300 is secured in place within the first row 200. Once the loops 310, 320, 330, 340 and 350 are adjusted to the correct size, the embroidery strands 252 can be sewn along the first row 200 on both the outward-facing and inward-facing surfaces, thereby securing the embedded strands 300 and the loops 310, 320, 330, 340 and 350 in place.

[0050] like Figure 4 As shown in the attached close-up illustration, each ring group 310, 320, 330, 340, and 350 includes two rings. The first ring is formed by a first segment 303 of the embedded strand, and the second ring is formed by a second segment 304 of the embedded strand. For example, ring group 350 includes a first ring 351 and a second ring 352, and ring group 340 similarly includes two rings 341 and 342. The use of double rings increases the tensile strength of the ring group and provides a different aesthetic. This construction also allows one ring in the ring group to continue to function as a shoelace eyelet in the event that another ring in the ring group is damaged or broken. Figure 4 As shown in the close-up, portions of the loop groups 340 and 350 of the embedded strands 300 enter and exit the first row 200 at paired points 210, 220 and 230, 240, respectively. Therefore, each segment of the embedded strands that together form two loops in a given loop group enters and exits the row in the same opening. Points 210 and 220 represent the ends of openings 215 in the first row through which loop group 340 extends from the inward-facing surface 510 of the inner knitted fabric 500, and points 230 and 240 represent the ends of openings 235 in the first row 200 through which loop group 350 extends out of the first row 200 on the outward-facing surface 520 of the inner knitted fabric 500. The size of openings 215 and 235, and the distance between them, can be adjusted to change the spacing between the eyelets and the size of the loop groups emerging from them.

[0051] Although this example includes two loops within each loop group, other examples may include different numbers. For example, each loop group 310, 320, 330, 340, and 350 may include one loop for embedding the ply 300, such as where the embedded ply 300 is embedded only once in the first row 200. In other examples, more than two loops may exist within each loop group 310, 320, 330, 340, and 350, such as through additional strokes of the yarn feeder and / or through additional ends of the yarn.

[0052] The outer knitted component 160 may be formed from an outer knitted fabric that may have all the features described with respect to the inner knitted fabric 500.

[0053] exist Figure 5 The diagram shows an internal knitted component 400. The internal knitted component 400 includes a tongue section 124 corresponding to the tongue 124 of the upper 120. An inner wing 410 and an outer wing 420 extend from the inner tongue edge 402 and the outer tongue edge 404, respectively. A top edge 406 forms the top edge of the tongue 124. A toe edge 408 is opposite the top edge 406 and positioned in the forefoot area of ​​the assembled upper 120. Holes 125 in the tongue section 124 correspond to tongue lacing holes 125 in the assembled upper 120. The outward-facing surfaces 412 and 422 of the inner wing 410 and the outer wing 420, and the outward-facing surface 407 of the tongue section 124, respectively form portions of the outward-facing surface of the upper 120, while the inward-facing surfaces 414, 424, and 409 form portions of the inward-facing surface of the upper 120. The periphery of the inner wing also includes an inner wing first edge 416 and an inner wing second edge 418, and the periphery of the outer wing 420 also includes an outer wing first edge 426 and an outer wing second edge 428.

[0054] The inner knitted component 140, the outer knitted component 160, and the inner knitted component 400 are assembled together to form the upper 120. The heel edges 148 and 149 of the inner knitted component 140 and the outer knitted component 160 are joined together. In situations such as... Figure 1In the example shown, the first edge 416 of the inner wing is attached to the inward-facing surface 510 of the inner knitted component 140. Similarly, the first edge 426 of the outer wing can be attached to the inward-facing surface of the outer knitted component 160. The inner knitted component 140 can also be attached to the inner knitted component 400 in other areas, such as along the first edge 142 in the forefoot region 101 of the upper 120 and along the cut edge 152. Similarly, the outer knitted component 160 can be attached to the inner knitted component 400 along its first edge 143 in the forefoot region 101 and along the cut edge 155. The upper 120 can then be attached to the sole structure 110 along the interlocking line 130. In this example, the ends 301 and 302 of the embedded strands 300 extend to or pass through the interlocking line 130 and can be secured to the Strombel or sole structure.

[0055] The multi-piece construction of the upper 120 described herein creates a layered appearance and structure for the upper 120. The multi-piece construction also allows for a combination of material properties to be displayed in the upper 120 of the footwear 100. Therefore, different materials and knitting structures can be selected for different parts and layers of the upper, depending on various factors. For example, the material of the inner layer of the upper 120 (e.g., the inner knitted component 400) can be selected based on comfort and breathability, while the materials of the outer layers (e.g., the inner knitted component 140 and the outer knitted component 160) can be selected based on factors such as appearance and durability.

[0056] Knitted components 140, 160, and 400 can incorporate various types of yarns that impart different properties to different areas of the upper 120. That is, one area of ​​the knitted component can be formed by a first type of yarn imparting a first set of properties, and another area of ​​the knitted component can be formed by a second type of yarn imparting a second set of properties. In this configuration, properties can be varied throughout the upper 120 by selecting specific yarns for different areas of the knitted components 140, 160, and 200. The properties imparted to a region of the knitted component by a particular type of yarn depend in part on the materials of the various filaments and fibers forming within the yarn. For example, cotton offers a soft hand feel, natural beauty, and biodegradability. Elastic fibers and stretched polyester fibers each offer significant stretch and resilience, with stretched polyester fibers also providing recyclability. Rayon offers high luster and moisture absorption. Wool offers high moisture absorption in addition to insulation and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also offers relatively high durability.

[0057] In some instances, yarns containing recycled leather (referred to herein as waste leather yarn (“SLY”)) may be used on at least the outward-facing surfaces of the inner knitted part 140 and the outer knitted part 160. In some instances, the recycled leather yarn comprises a combination of leather waste and PET, which may be in the form of recycled PET. In one instance, the recycled leather yarn is formed from approximately 50% leather waste and approximately 50% PET (e.g., by weight). In other instances, the recycled leather yarn is formed from approximately 25% leather waste and approximately 75% PET; approximately 35% leather waste and approximately 65% ​​PET; or approximately 70% leather waste and approximately 30% PET. Other proportions of leather waste and PET (or another material, including another recyclable material) may also be considered. The leather waste and PET may be blended together before carding and spinning into the recycled leather yarn. Compared to PET yarn without recycled leather waste, the leather waste can give the recycled leather yarn a softer hand feel and relatively greater abrasion resistance. Furthermore, recycled leather yarn is sustainable because it can be formed from recycled materials (i.e., leather waste, and in some instances, recycled PET). Additionally, as mentioned above, one or more of the yarns used to form the shoe upper may comprise a thermoplastic polymer that can be at least partially melted and cooled to fuse the different yarns together.

[0058] Besides the material, other examples of yarns selected for the knitted components 140, 160, and 400 can affect the properties of the upper 120. For example, the yarn forming any of the knitted components 140, 160, and 400 can be a monofilament yarn or a multifilament yarn. The yarn can also include individual filaments each formed of different materials. Alternatively, the yarn can include filaments each formed of two or more different materials, such as bicomponent yarns with filaments having a core-sheath configuration or two halves formed of different materials. Different degrees of twist and crimp, as well as different deniers, can also affect the properties of the upper 120. Therefore, the materials forming the yarns and other examples of yarns can be selected to impart various properties to different areas of the upper 120.

[0059] Compared to one or more yarns used in the knitted components of the upper 120, insert yarns (such as insert yarn 300) can exhibit greater tensile strength. That is, insert yarn 300 can stretch less than the rest of the upper 120. Insert yarn 300 can also exhibit greater resistance to breakage under tension than one or more yarns used in the rest of the upper 120. Therefore, loops and loop sets formed by insert yarns can be adapted to serve as eyelets 123, which are subjected to increased tension during the tightening of the laces 122 and once the laces 122 are secured in a tightened state (e.g., by knotting the ends or securing the ends to the upper 120 or other shoe components). Applying tension to the laces 122 applies tension to the insert yarns, thereby causing the portion of the upper 120 between the throat region and the bite line 130 to fit more closely to the foot. Thus, the insert yarns operate in conjunction with the laces 122 to enhance the fit of the footwear 100.

[0060] Similar to the yarns forming the knitted components 140, 160, and 400, the configuration of the insert ply can also vary significantly. Besides yarns, the insert ply can have configurations such as filaments (e.g., monofilaments), threads, ropes, ribbons, cables, or chains. The insert ply 300 can be thicker than the yarns forming the knitted components. In some configurations, the insert ply can have a significantly greater thickness than the yarns in the knitted components. While the cross-sectional shape of the insert ply can be circular, triangular, square, rectangular, elliptical, or irregular shapes can also be used. Furthermore, the materials forming the insert ply can include any materials used for the yarns within the knitted components, such as cotton, elastic fibers, polyester, rayon, wool, and nylon. As mentioned above, the insert ply can exhibit greater tensile strength compared to the knitted components forming the upper 120. Therefore, suitable materials for the insert ply can include a variety of engineered filaments for high tensile strength applications, including glass, aramids (e.g., para-aramids and meta-aramids), ultra-high molecular weight polyethylene, and liquid crystal polymers. In some instances, high-tenacity yarns comprising polyester and having a tensile strength greater than 5 g / denier can be used, wherein the yarn has a diameter larger than that of the yarns used to form the knitted components of the upper 120. As another example, braided polyester yarns can also be used as embedded strands.

[0061] Figure 6This is a flowchart of the steps of a method 600 for forming a knitted component for an upper of footwear articles. In a first step 610, a plurality of rows are knitted together to form at least a portion of a knitted component (such as an insole knitted component 140), which defines at least one of the inner or outer edges of the tongue opening of the upper, the plurality of rows including at least a first row, such as a first row 200. In a second step 620, during the knitting step, a first insert segment of an insert ply (such as an insert ply 300) is inserted into the first row, such that the insert ply also includes a first exposed segment at which the insert ply leaves and re-enters the knitted component at least once along the first row. In some instances, additional steps may include: embedding a second embedded segment of the embedded strand along the first embedded segment within the first row; arranging a first exposed portion of the embedded strand into a first loop positioned outside the first row; after the first embedded segment has been embedded within the first row, expanding or contracting the first loop by pulling a segment of the embedded strand; arranging the second exposed segment of the embedded strand into a second loop positioned outside the first row; and sewing embroidery strands along the outside of the first row to secure the first embedded segment within the first row.

[0062] While the non-limiting examples discussed above may include single strands embedded in knitted components (e.g., the inside or outside of an upper), the aspects described herein are not limited to single strands embedded in a single row. For example, in various aspects, an upper formed from knitted components may have a first strand embedded in a first row and a second strand embedded in a second row, and so on. Loops of the second embedded strand may be configured for use in combination with loops of the first embedded strand (e.g., the loops of the first and second strands may overlap or interact to form a common eyelet), or they may be configured for use separately (e.g., the loops of the first and second embedded strands serve as separate eyelets). In some aspects, the second strand may be embedded in the same row as the first strand, wherein the second strand may have different properties (e.g., different colors, diameters, deniers, elasticity, textures) and / or may be formed of a different material than the first strand. In some respects, the loop of the first insert strand can extend from one side of the upper around the eyelet or eyelet plate, and the loop of the second insert strand can extend from the other side of the upper around the same eyelet or eyelet plate. These respects are provided as examples, and other configurations of the upper with knitted components are also possible and are contemplated herein, the knitted components comprising multiple strands in common or separate rows.

[0063] See Figure 7A and Figure 7B This shows some examples of the aspects described above. Figure 7A The inner knitted fabric is depicted, such as Figure 4A The inner knitted fabric 500, wherein the second embedded ply 702 is embedded within the second row 700, while loops 704 and 706 extend out of the second row 700. For example... Figure 7A As shown, loop 704 may overlap with loop 350 of the first insert yarn 300, but is located on the opposite side of the inner knitted fabric 500. In all respects, loop 704 may extend a second row 700 on the same side as loop 350. Loop 706 does not overlap with any loop from the first insert yarn 300 and can be used as a separate eyelet. Figure 7B In this example, both the first embedded strand 712 and the second embedded strand 714 are embedded within the same row 200. For example... Figure 7B The first embedded strand 712 and the second embedded strand 714 shown each have ends 724, 726 anchored to the knitted component, while the other end extends to the edge of the interlocking thread. However, the first embedded strand 712 and the second embedded strand 714 can also be as follows: Figure 7A The configuration is such that both ends of each strand extend to the interlocking line, with two lengths of each strand embedded within the first row 200. The loops 716 and 720 of the first embedded strand 712 overlap with the loops 718 and 722 of the second embedded strand 714 to form eyelets (with or without eyelet pieces, such as eyelet 156). In various aspects, the first embedded strand 712 and the second embedded strand 714 can have different characteristics, such as different colors, deniers, or materials, to provide different aesthetic or desired properties.

[0064] The following clauses represent examples of the concepts envisioned herein. Any of the following clauses may be combined in a multi-subordinate manner to be subordinate to one or more other clauses. Furthermore, any combination of subordinate clauses (clauses that explicitly depend on preceding clauses) may be combined while remaining within the scope of the examples envisioned herein. The following clauses are examples and not limitations.

[0065] Clause 1. An upper for footwear articles, the upper comprising: a knitted component including a first row and a first edge, the first edge at least partially defining an inner or outer side of a throat opening of the upper; and an insert strand comprising: an insert segment embedded within at least a portion of the first row of the knitted component; and an exposed segment at which the insert strand leaves and re-enters the knitted component at least once along the first row.

[0066] Clause 2. The upper according to Clause 1, wherein the exposed section is a first exposed section, the first exposed section being configured as a first loop extending from the knitted component.

[0067] Clause 3. The upper according to Clause 2, wherein the embedded strand includes a second exposed section configured as a second loop extending from the knitted component.

[0068] Clause 4. The upper according to Clause 3, wherein the knitted component further includes an edge portion located between the first edge and the first row, and the first loop and the second loop are positioned on opposite sides of the edge portion.

[0069] Clause 5. The upper according to any one of Clauses 1 to 4, wherein the embedded segment is fixed within the first row.

[0070] Clause 6. The upper as described in Clause 4, wherein the embedded strands are secured within the first row via embroidered strands.

[0071] Clause 7. The upper according to any one of Clauses 1 to 6, wherein the embedded strand further includes a bend between a first end and a second end, and the bend is located within the first transverse row.

[0072] Clause 8. The upper according to any one of Clauses 1 to 7, wherein at least a portion of the first row is substantially parallel to the first edge of the knitted component.

[0073] Clause 9. A footwear article comprising an upper and a sole structure attached to the upper along a mortise line, the upper comprising: a knitted component having a first edge that at least partially defines an inner or outer side of a throat opening of the upper, the knitted component having a first row extending in a toe-heel direction; and an insert strand comprising an insert section embedded within at least a portion of the first row of the knitted component, the insert strand further comprising an exposed section at which the insert strand leaves and re-enters the knitted component at least once along the first row.

[0074] Clause 10. Footwear article according to Clause 9, wherein the embedded strand has a first end and a second end, wherein the first row has a first end opening along the peripheral edge of the knitted element, and the first end and the second end of the embedded strand exit the first row through the first end opening.

[0075] Clause 11. Footwear article according to Clause 10, wherein the first and second ends of the embedded strands extend to the interlocking line.

[0076] Clause 12. Footwear article according to Clause 11, wherein the first end and the second end of the embedded strand are fixed to the sole structure.

[0077] Clause 13. Footwear article according to any one of Clauses 9 to 12, wherein the knitted component is a first knitted component, and the upper further includes a tongue comprising a second knitted component attached to the first knitted component.

[0078] Clause 14. The footwear article according to Clause 13 further includes a third knitted component attached to the second knitted component, wherein the first edge of the first knitted component defines the inner side of the throat opening, and the third knitted component includes a second edge defining the outer side of the throat opening, the third knitted component further including a second row and a second embedded strand embedded in at least a portion of the second row.

[0079] Clause 15. A method of forming a knitted component for an upper of a footwear article, comprising the steps of: knitting a plurality of rows together to form at least a portion of the knitted component, the at least a portion of the knitted component defining at least one of an inner edge or an outer edge of a tongue opening of the upper, the plurality of rows including at least a first row; and during the knitting step, embedding a first embedding segment of an embedding yarn within the first row, such that the embedding yarn further includes a first exposed segment at which the embedding yarn leaves and re-enters the knitted component at least once along the first row.

[0080] Clause 16. The method according to Clause 15, wherein the embedding step further includes the step of embedding a second embedding segment of the embedding strand alongside the first embedding segment within the first row.

[0081] Clause 17. The method according to Clause 15 or 16 further includes the step of arranging the first exposed portion of the embedded strand into a first loop positioned outside the first row.

[0082] Clause 18. The method according to Clause 17 further includes the step of shrinking the first loop by pulling the embedded yarn after knitting.

[0083] Clause 19. The method according to Clause 18 further includes the step of arranging the second exposed segment of the embedded strand into a second loop positioned outside the first row.

[0084] Clause 20. The method according to any one of Clauses 15 to 19 further includes the step of: sewing the embroidery thread along the outside of the first row to secure the first embedded segment within the first row.

[0085] This document specifically describes the subject matter of this disclosure to meet legal requirements. However, this description itself is not intended to limit the scope of this disclosure. Rather, the inventors have envisioned that the claimed or disclosed subject matter may also be embodied in other ways in combination with other current or future techniques to include different steps or combinations of steps similar to those described in this document. Furthermore, although the terms “step” and / or “box” may be used herein to refer to different elements of the method employed, these terms should not be construed as implying any particular order among or between the various steps disclosed herein, unless the order of the steps is expressly stated.

Claims

1. An upper for footwear articles, the upper comprising: A knitted component, the knitted component including a first row and a first edge, the first edge at least partially defining the inner or outer side of the throat opening of the shoe upper; And embedded strands, the embedded strands comprising: embedded segments embedded within at least a portion of the first row of the knitted part; And an exposed section, at which the embedded strands leave and re-enter the knitted part at least once along the first row.

2. The upper of claim 1, wherein the exposed section is a first exposed section, the first exposed section being configured as a first loop extending from the knitted component.

3. The upper of claim 2, wherein the embedded strand includes a second exposed section configured as a second loop extending from the knitted component.

4. The upper of claim 3, wherein the knitted component further comprises an edge portion located between the first edge and the first row, and the first loop and the second loop are positioned on opposite sides of the edge portion.

5. The upper according to claim 4, wherein the embedded segment is fixed within the first transverse row.

6. The upper according to claim 5, wherein the embedded strands are fixed within the first row via embroidered strands.

7. The upper according to claim 6, wherein the embedded thread further includes a curved portion between a first end and a second end of the embedded thread, and wherein the curved portion is located within the first transverse row.

8. The upper of claim 1, wherein at least a portion of the first row is substantially parallel to the first edge of the knitted component.

9. A footwear article comprising an upper and a sole structure attached to the upper along a seam line, the upper comprising: A knitted component having a first edge that at least partially defines the inner or outer side of the throat opening of the upper, the knitted component having a first row extending in the toe-heel direction; And embedded strands, the embedded strands including embedded sections embedded within at least a portion of the first row of the knitted part, the embedded strands also including exposed sections, wherein the embedded strands leave and re-enter the knitted part at least once along the first row.

10. The footwear article of claim 9, wherein the embedded yarn has a first end and a second end, wherein the first row has a first end opening along the peripheral edge of the knitted component, and the first end and the second end of the embedded yarn exit the first row through the first end opening.

11. The footwear article of claim 10, wherein the first end and the second end of the embedded strand extend to the interlocking line.

12. The footwear article of claim 11, wherein the first end and the second end of the embedded strand are fixed to the sole structure.

13. The footwear article of claim 9, wherein the knitted component is a first knitted component, and the upper further includes a tongue, the tongue including a second knitted component attached to the first knitted component.

14. The footwear article of claim 13, further comprising a third knitted member attached to the second knitted member, wherein the first edge of the first knitted member defines the inner side of the throat opening, and the third knitted member includes a second edge defining the outer side of the throat opening, the third knitted member further including a second row and a second embedded strand embedded within at least a portion of the second row.

15. A method of forming a knitted component for an upper of a footwear article, the method comprising: Multiple rows are knitted together to form at least a portion of the knitted component, the at least a portion of the knitted component defining at least one of the inner or outer edges of the tongue opening of the shoe upper, the multiple rows including at least a first row; and during knitting, a first embedded section of embedded yarn is embedded in the first row, such that the embedded yarn also includes a first exposed section, wherein the embedded yarn leaves and re-enters the knitted component at least once along the first row.

16. The method of claim 15, wherein embedding further comprises embedding a second embedding segment of the embedded strand alongside the first embedding segment within the first row.

17. The method of claim 16, further comprising arranging the first exposed segment of the embedded strand into a first loop positioned outside the first row.

18. The method of claim 17, further comprising shrinking the first loop by pulling the embedded yarn after knitting.

19. The method of claim 18, further comprising arranging the second exposed segment of the embedded strand into a second loop positioned outside the first row.

20. The method of claim 19, further comprising sewing embroidery threads along the outside of the first row to secure the first embedded segment within the first row.

Images