Knit bag portion with inserted elements

Abstract

This invention relates to a method of manufacturing a sporting article, the method comprising a knitting process including the steps of: a) providing a knitting machine, yarn for knitting, and at least one insert element; b) knitting a fabric such that the fabric includes at least one open gap between at least two layers; c) inserting at least one insert element into the at least one open gap while the fabric is held in the knitting machine; and d) further knitting the fabric such that the at least one gap is at least partially closed around the insert element by connecting the at least two layers. The invention also relates to a sporting article.

Description

Technical Field

[0001] This invention relates to a method for manufacturing sportswear and a sportswear product, wherein the method includes a knitting process. Background Technology

[0002] This invention relates to the field of manufacturing sportswear using a knitting process. Conventional manufacturing methods for sportswear (such as shoes and apparel) typically involve multiple steps, including cutting, sewing, and adhesive bonding, to integrate various functional elements (such as reinforcements and / or cushioning) into the fabric. These methods can be labor-intensive, prone to inconsistencies, and may compromise the structural integrity and flexibility of the final product.

[0003] US 9,538,803 B2 discloses a footwear article comprising a textile upper. The upper includes a knitted component. The knitted component may be warp-knitted. The knitted component has an outer side and an inner side, which may have different knitting configurations. The knitted component may also include single-layer and double-layer construction portions.

[0004] Other prior art can be found in DE 10 2005 030 651 A1.

[0005] The disadvantage here is that the fabric needs to be cut to fit the insert into the pocket formed in the fabric. Therefore, a manufacturing process is needed that allows the insert to be placed without a cutting step.

[0006] The main problem addressed by this invention is the need for an efficient, consistent, and seamless method to integrate various functional elements into sportswear during the knitting process itself. Conventional methods of attaching elements (such as padding or reinforcement) to fabric often result in weak joints, increased bulk, and potential user discomfort. Furthermore, these methods can be inefficient and costly due to the multiple steps and manual labor involved. This invention provides a method for seamlessly integrating functional elements into sportswear during the knitting process. By creating gaps within the knitted fabric and inserting elements (such as reinforcement pads, cushioning, magnets, or electronic components) while the fabric is still on the knitting machine, this method ensures the secure and precise placement of these elements. The integration can be further enhanced by using shrinkable or meltable yarns to tightly wrap the elements within the fabric, eliminating the need for additional cutting or bonding steps.

[0007] In view of the above, there is a need for an improved manufacturing process for knitted sportswear. Therefore, one object of the present invention is to overcome some or all of the deficiencies of the prior art. Summary of the Invention

[0008] The above objectives are achieved through embodiments of this application. Preferred embodiments of these embodiments are provided below, and those skilled in the art will find clues to other suitable aspects of the invention throughout the entire disclosure of this application.

[0009] One aspect of the invention relates to a method of manufacturing a sporting article, the method comprising a knitting process including the steps of: a) providing a knitting machine, yarn for knitting, and at least one insert element; b) knitting a fabric such that the fabric includes at least one open gap between at least two layers; c) inserting at least one insert element into the at least one open gap while the fabric is held in the knitting machine; and d) further knitting the fabric such that the at least one gap is at least partially closed around the insert element by connecting the at least two layers. Specifically, during knitting step b), the gap is accessible through an orifice, which is subsequently closed in step d).

[0010] This method can be used, for example, to create athletic shoes with enhanced support. The insert element could be a cushioning pad or reinforcing band. By inserting the insert element (such as a pad) into the gaps between knitted layers and then further knitting to secure it, athletic garments gain additional structural support and comfort without the need for external stitching or adhesives. This method ensures a more seamless design, reduces manufacturing steps, and enhances the durability and performance of athletic garments.

[0011] The method can be further improved when it does not include creating openings by cutting the knitted fabric.

[0012] Using this method, open gaps are formed directly during the knitting process by manipulating the yarns and machine settings to leave gaps or voids between fabric layers. This technique eliminates the need for cutting (common in existing technologies) and preserves the integrity and strength of the fabric. For example, in creating seamless sportswear, this method allows for the strategic placement of breathable or reinforced sections without weakening the material. This results in more durable and comfortable products because the fabric retains its original strength and flexibility.

[0013] Further improvements were made, particularly during steps b)-d), when the fabric was continuously held on the knitting machine.

[0014] Using this method, the fabric remains on the knitting machine throughout the entire process—forming the openings, inserting elements, and knitting to close the openings. For example, in manufacturing sporting goods such as shoes or gloves, this continuous process ensures precise placement and secure integration of elements such as padding or support. This method improves productivity by reducing handling and potential errors associated with moving fabric between machines. Furthermore, it improves the alignment and consistency of the final product, resulting in higher quality and reduced production time. This means that during these steps, the knitted fabric is not removed from the knitting machine but remains on the machine's needles, although the specific needles holding the fabric may change over time during manufacturing.

[0015] Further improvements are achieved when the insertion of the insert element is performed automatically, preferably by supplying the insert element from the storage area.

[0016] Using this method, the insertion of insert elements (such as cushioning pads or reinforcing strips) into the fabric is done automatically using a mechanism that retrieves these elements from a designated storage area. For example, in the production of sporting goods, this automated insertion ensures, for instance, the precise and consistent placement of protective and / or cushioning elements without human intervention. Automated insertion can be achieved using a robotic arm—integrated with and / or mounted on the knitting machine. This configuration not only ensures precise positioning of the inserts but also facilitates manipulation of the inserts within the machine's confined space (e.g., in the area between needle beds). This automation increases production speed and accuracy, and reduces labor costs, resulting in a more efficient manufacturing process and higher-quality products (with consistently placed insert elements). The storage area can be, for example, a hopper for storing and supplying insert elements.

[0017] Another improvement was achieved when the insertion of the insert element was performed manually by the operator.

[0018] Using this method, the insertion of insert elements, such as padding or reinforcing strips, is performed manually by the operator. For example, in the creation of custom-made motion products, the operator can precisely place and adjust each insert element according to specific design requirements. This manual insertion allows for greater flexibility and customization, ensuring that each product meets precise specifications and individual needs. This method can be advantageous for limited production batches or special items where precision and customization take precedence over automation.

[0019] Further improvements can be made when the knitting machine size is up to 14.

[0020] Using this method, the maximum knitting machine size used in the process is 18, meaning it can produce relatively fine and delicate fabrics. For example, when producing sportswear, using a machine with a size of 18 allows for the creation of lightweight and fine fabrics. As the size increases, the material becomes finer; however, this also reduces the distance between the needle beds, making it more challenging to introduce inserts between them. The configuration of a size 18 machine provides a balance between being fine enough to produce delicate materials and maintaining sufficient distance between the needle beds to allow elements to be inserted between them and into the knitted material.

[0021] A further improvement is achieved when the width of the orifice (through which the gap is accessible) is greater than the maximum width of the insert element. This allows the insert element to be fully introduced into the gap in step c) without deforming it. This may require the knitted fabric and knitting program to be designed appropriately to allow the insert element to be placed during knitting.

[0022] A further improvement is achieved when the maximum thickness of the insert element is less than the distance between the layers of the fabric defining the void (when they are held on the knitting machine). This allows the insert element to be fully introduced into the void in step c) without deforming it. Alternatively, the maximum thickness of the insert element can be greater than the distance between the layers of the fabric (when they are held on the knitting machine), and the insert element can be made of an elastically deformable material so that it can be compressed in step c) to be introduced into the void. In particular, the distance between the layers of the fabric is determined by the distance between the needle beds.

[0023] Further improvements are achieved when the fabric is knitted as a double, triple, or quadruple fabric (where at least two layers are connected to each other by the knitting process) and the opening is defined in selected areas of the fabric (where the at least two layers are separate and overlapping). For example, the fabric can be a double-layered fabric where, in selected areas, the two layers are separate (i.e., they are not connected) and overlap to define the opening.

[0024] Further improvements are achieved if, after step b), the fabric comprises two or more layers and includes two or more gaps defined between the layers, such that after the insertion element is inserted, the insertion element and the layers are stacked alternately.

[0025] This method yields multi-layered fabrics with multiple gaps—for inserting elements. For example, in the production of high-performance sportswear, this technique allows for the insertion of cushioning and structural support elements within the same fabric. By alternately stacking inserting elements (such as structural and cushioning layers) with fabric layers, sportswear can provide enhanced cushioning, breathability, and structural integrity. This layered construction improves the functionality and comfort of sportswear, providing tailored performance advantages for a variety of sporting activities. This method can be implemented on a knitting machine with two needle beds, using alternating needles with a 1x1 technique. Alternatively, it can be performed on a knitting machine with additional needle beds, such as a four-needle machine, which simplifies the process and allows knitting on all needles.

[0026] Further improvements were achieved when the height of the gap was greater than the height of the inserted element, and / or the width of the gap was greater than the width of the inserted element.

[0027] This method creates a larger gap than the insert element to ensure easy insertion and slight movement within the gap. This design enhances comfort and adaptability because the insert element can adjust within the gap to provide optimal support and reduce pressure points. This flexibility also simplifies the manufacturing process—by accommodating variations in the insert element's size. This is particularly advantageous when elastic yarns are not used in the knitting. When elastic yarns are used, the gap size can actually be smaller than the insert element's size because the elastic yarn allows for compensation of dimensional differences through stretching.

[0028] Further improvements were achieved when at least one insert element was secured in the gap by a yarn extending through it.

[0029] Using this method, the insert element—knitted by passing yarn through the insert element itself—is secured within the gap. For example, when creating protective sports equipment such as knee braces, the padding element can be firmly anchored in place by passing yarn through holes or loops in the pad. This ensures the insert remains firmly in place, providing consistent protection and support during use. This method enhances the durability and stability of sportswear, preventing the insert element from shifting or falling off during strenuous physical activity.

[0030] This method can be performed specifically for insert elements that are not made of rigid materials, such as padding elements made of foam, reinforcing membrane, or fabric, simply by using a knitting needle to pass through the insert element. For the same purpose, this method can also be performed for insert elements made of rigid materials, provided that holes or rings are provided in the insert element.

[0031] Further improvements are achieved when the insert element has a shape suitable for insertion—between the needle beds of a knitting machine. For example, when using a flat knitting machine with a flat needle bed, the insert element should advantageously have a flat shape for easy insertion between the needle beds. In cases where a different shape is desired, the desired shape can be given to the insert element, and the latter can be made of an elastically deformable material so as to deform during the insertion step c). Alternatively, the insert element can be initially given a flat shape, and the insert element can be made of a plastically deformable material so as to be shaped into the desired shape after the knitting process by, for example, a thermoforming step.

[0032] The difference is that when using a circular knitting machine with a circular cylinder and needle plate, the insert should have an arc shape suitable for insertion between the cylinder and needle plate, or it should be made of a flexible material that can be easily bent into place.

[0033] Further improvements are achieved if the yarn contains shrinkable yarn and the method includes a shrinking step such that the fabric around the gap follows the contour of the inserted element, wherein the shrinking is preferably achieved by applying heat.

[0034] Using this method, the fabric is knitted with shrinkable yarns, and after the insert elements are placed, the fabric undergoes a shrinkage process. For example, in manufacturing custom-fit sportswear, heat can be applied to the fabric, causing the shrinkable yarns to shrink and closely follow around the padding or support elements. This ensures a tight and precise fit, enhancing the functionality and comfort of the sportswear. The heat-shrinking step ensures that the inserts remain firmly in place, preventing them from shifting within gaps, and that the fabric perfectly conforms to its desired shape, providing improved performance. Knitted products can contain many different yarns, and the shrinkable yarns can be knitted together with other different yarns, or used only where they are needed and not in other areas. Heat can be applied, for example, by steam, ironing, autoclaving, or using an oven.

[0035] Further improvements are achieved when the layers contain different yarns—and where preferably one layer of the fabric contains elastic and / or shrinkable yarns while another layer contains inelastic and / or non-shrinkable yarns.

[0036] Using this method, fabrics comprise layers made of different types of yarn. For example, in creating sports compression garments, the inner layer can be made of elastic and shrinkable yarns to provide a snug, close fit, while the outer layer can be made of non-elastic, durable yarns to provide support and protection. This combination allows the garment to stretch and adapt to the wearer's body while maintaining structural integrity and durability. This dual-layer construction enhances the comfort, performance, and lifespan of sportswear, providing targeted support and flexibility where needed.

[0037] Further improvements were achieved when the yarn contained elastic and / or shrinkable yarns.

[0038] Using this method, the knitting process employs elastic and / or shrinkable yarns. For example, in the manufacture of sportswear, elastic yarns ensure that the fabric can stretch and conform to foot movement, providing a comfortable and flexible fit. Furthermore, shrinkable yarns can be used to further enhance the fit and shape retention of garments after heat treatment. The use of these special yarns improves the overall performance, durability, and comfort of sportswear, making it ideal for dynamic and high-intensity activities.

[0039] Furthermore, when the yarn contains elastic / shrinkable yarn, the insert element can fit better within the gap, thanks to the fabric layer that shapes the insert element. The elastic or shrinkable yarn may contain elastomers and / or thermoplastic polyurethane (TPU).

[0040] Further improvements are achieved when one of the layers contains molten yarn—which is adapted to form a connection with the insert element upon melting.

[0041] Using this method, the fabric layer contains molten yarns that, when heat is applied, at least partially melt and bond with insert elements. For example, in the production of athletic shoes, molten yarns can be used for the inner layer of the shoe insole. When heat is applied, these yarns melt and bond with insert elements, such as shock-absorbing pads, creating a robust and integral structure. This method enhances the durability and stability of the insole, ensuring it remains firmly in place during use. The melting process also simplifies manufacturing steps, eliminating the need for additional adhesives, thus enabling streamlined and efficient production.

[0042] This method can be further improved when the molten yarn is also a shrinkable yarn.

[0043] Using this method, the molten yarn used in the fabric layer is also shrinkable. When heat is applied, this yarn not only melts at least partially to connect with the insert elements, but also shrinks to fit snugly around them. This dual function ensures a strong bond and a tight fit, enhancing the support and stability of athletic garments. The combination of molten and shrinkable properties simplifies the manufacturing process and improves the overall effectiveness and comfort of athletic garments. The molten yarn, which is also a shrinkable yarn, can be, for example, a blended or twisted yarn.

[0044] This method of using yarn—which is both molten and shrinkable—is particularly advantageous in footwear manufacturing, for example, when inserts placed in knitted materials are rigid and require precise placement, such as support rods.

[0045] Further improvements can be achieved when the yarn contains—inelastic and / or non-shrinkable yarns containing polyester.

[0046] Using this method, the fabric incorporates non-elastic and non-shrink polyester yarns. For example, in the production of sporting goods such as footwear or sports bags, polyester yarns provide durability and tensile strength, ensuring that the footwear or bag retains its shape and can withstand frequent use. Polyester's inherent strength and resistance to environmental factors such as moisture and UV radiation make it ideal for outdoor sports equipment. This use of polyester yarns improves the lifespan, structural integrity, and reliability of sporting goods, making them suitable for demanding applications.

[0047] Further improvements are achieved if the yarn contains shrinkable yarn and the gap has one or more openings smaller than the insertion element, and the method includes a shrinking step such that, after shrinking the yarn, the insertion element partially extends through the openings. Specifically, the one or more openings can be independent of the orifice used to insert the insertion element into the gap, or can be created by only partially closing the orifice.

[0048] Using this method, the fabric employs shrinkable yarn and features an opening smaller than the insert element. For example, in the creation of sporting articles, after the insert element is placed within the fabric, heat is applied to shrink the yarn. This causes the fabric to tighten, and the insert element extends partially through the opening. This design ensures that the insert element remains securely in place while allowing a portion of it—by extending through the opening—to be accessible. This is particularly advantageous, for example, when the insert element is an electronic component and a portion of it needs to be accessible to allow charging or data transfer. The shrinking process ensures a precise and tight fit around the insert element, improving the performance and aesthetics of the sporting article. The opening of the gap is preferably not an orifice—allowing access to the gap for inserting the insert element—but rather a different opening that provides additional functionality to the sporting article, for example, by allowing the insert element to extend through this additional opening.

[0049] Further improvements were achieved when the knitted fabric contained one or more holes (particularly through-holes connected to the gaps) and the insert element was partially visible through these holes. This design enhanced breathability and ensured that the insert element remained securely in place while allowing additional airflow.

[0050] Further improvements were achieved when the insert element included reinforcement and / or cushioning devices.

[0051] Using this method, insert elements provide reinforcement and / or cushioning. For example, in the manufacture of athletic shoes, insert elements can be reinforcements for increased support or cushioning pads for comfort. Reinforcing elements can enhance the structural integrity and durability of the shoe, making it more resistant to abrasion and tearing. Examples of such reinforcing elements include: forefoot reinforcements or toe boxes to reinforce the toe and forefoot areas; heel stabilizers to provide necessary stiffness to the heel area and more support for the wearer's foot; or eyelet reinforcements to reinforce the lacing area. Other reinforcing elements can be provided to improve shoe performance. Examples of such reinforcing elements are stiffening elements, such as plates or bars, placed in the sole area of ​​the shoe to increase sole stiffness, thereby allowing for better force transfer—from the ankle to the ground. Cushioning elements improve comfort by absorbing impact and reducing foot pressure. Examples of cushioning elements are heel or tongue padding. This combination ensures that athletic products meet the specific performance needs of athletes, providing both strength and comfort. Such cushioning devices can be made of foam, for example, or they can be made of spherical or granular foam.

[0052] Further improvements were achieved when the inserted element contained a magnet.

[0053] For example, by integrating magnets directly into the fabric, the garment can be used to produce detachable fasteners that can replace zipper or hook-and-loop fasteners. Such fasteners can be used, for example, in bras, belts, waistbands, pockets, or bags. This approach enhances the functionality of sportswear and allows for streamlined designs. Further improvements are achieved when the insert element incorporates one or more electronic components (preferably microchips).

[0054] Using this method, the insert element can contain electronic components, such as microchips. For example, in the production of smart sportswear, microchips can be integrated into the fabric to monitor and collect data about the wearer's performance, such as heart rate, location, movement, speed, kicking force, and temperature. These electronic components can, for example, connect to a mobile application to provide users with real-time feedback and analysis. This integration of electronics enhances the functionality of sportswear, transforming it into high-tech clothing that provides both performance monitoring and improved training outcomes.

[0055] In one embodiment, the insert element contains an RFID tag, for example, for identification or tracking purposes.

[0056] In another embodiment, the insert element can also be a small device for generating vibrations, heat (e.g., infrared heating), and / or mild electrical pulses. These can be used, for example, to warm muscles before a competition, to warm body parts in a cold environment, or for pain relief purposes, such as relieving menstrual cramps.

[0057] The insert element can also be a light-emitting device for aesthetic or safety purposes, such as for nighttime visibility. In this case, the yarn used to create at least a portion of the bag portion can be a transparent or semi-transparent yarn, such as a monofilament yarn.

[0058] Further improvements were made when the sporting goods were footwear.

[0059] For example, this method can be applied to create uppers with integrated cushioning or reinforcing elements to enhance comfort or support. Alternatively or additionally, it can be applied to create insoles, strobelboards, or more generally, sole components for creating the shoe. Using a knitting process to form one or more parts of the shoe allows for precise placement of these elements within the fabric, resulting in a seamless design. Furthermore, incorporating features such as shrinkable yarns and electronic components like microchips can provide a customized fit and performance tracking. This approach enhances the overall quality, functionality, and innovation of athletic shoes, making them ideal for a wide range of sports activities.

[0060] In one embodiment, the knitted pouch is located in the sole area of ​​the shoe to accommodate, for example, a midsole or a portion thereof. The midsole may be a solid foam or in the form of granules, which may be loose or connected together. In this case, at least a portion of the pouch may be knitted using transparent or semi-transparent yarns (e.g., monofilament yarns) to make the insert visible.

[0061] Knitted materials can also be used to define insoles or insoles. Pockets can be defined to cover only a portion of the sole, for example, to create customized cushioning or support areas. For instance, when creating insoles or insoles, pockets of different shapes and sizes can be knitted into the arch area to accommodate support materials such as foam. This allows for customized fits and different levels of arch support. The orientation of the pocket openings can be controlled by the knitting direction of the sole elements, such as by longitudinal or transverse knitting, to facilitate the insertion of support material.

[0062] Furthermore, sporting goods such as shoes may include additional components manufactured by methods other than those claimed. For example, knitted material can be formed into a tubular structure for receiving a midsole element (e.g., expanded thermoplastic polyurethane foam). In this case, the tubular pouch portion can be knitted, and the midsole element can be inserted in a subsequent post-processing step—after the component has been removed from the knitting machine. The outsole can then be attached to the bottom of this knitted structure to complete the sole assembly. This component can exist in the shoe along with other components manufactured according to the method of the invention.

[0063] In another embodiment, the sporting goods are clothing items.

[0064] For example, this process can be used to produce garments with integrated cushioning or support elements to improve performance, comfort, or safety. Knitting techniques allow for the strategic placement of these elements within the fabric, resulting in a seamless and ergonomic design. Furthermore, the use of elastic or shrinkable yarns can provide a snug, adaptive fit, while electronic components such as microchips can provide advanced features such as performance monitoring. This approach enhances the functionality, comfort, and innovation of sportswear, making it suitable for a wide range of sporting activities.

[0065] Examples of sportswear items include: tops for motorsports, where inserts may be safety pads or reinforcements; socks with inserts that are shin guards, for example, for playing American football, baseball, or hockey; cycling shorts or tights with saddle pads; protective compression sportswear with integrated protective padding; and bottoms with moisture-wicking and leak-proof padding.

[0066] Another embodiment of the present invention is a sports article obtained by the above method.

[0067] For example, the sporting goods can be sports accessories, such as knee or elbow protectors for playing volleyball or skating; balls, and the knitted material can be the ball's body, while the insert element can be, for example, a sensor; a bag or backpack, and the insert element can be a reinforcing element or a padding element.

[0068] For example, athletic shoes produced using this method can feature integrated cushioning, reinforcement elements, and possibly electronic components for performance tracking. The seamless design ensures durability and comfort, while the use of advanced materials, such as shrinkable and elastic yarns, provides a customized fit. Similarly, athletic apparel made using this method can include compression garments—with strategically placed support and cushioning elements—offering enhanced performance and comfort. Attached Figure Description

[0069] Preferred embodiments of the present disclosure are disclosed below with reference to the accompanying drawings.

[0070] Figure 1 The diagram illustrates how an insert element is inserted into an opening in the fabric.

[0071] Figure 2 The sectional view shows the inserted element inside the gap between the two layers.

[0072] Figure 3 The illustration depicts inserting an insert element into an opening in a fabric, and the insert element extending through the opening after the fabric is contracted.

[0073] Figure 4The diagram illustrates the insertion of a trapezoidal insert element into an opening in the fabric, and the insert element within the fabric.

[0074] Figure 5 The concave insertion element inside the stretchable fabric is depicted in a schematic diagram.

[0075] Figure 6 The diagram illustrates the insertion element visible through a hole in the fabric.

[0076] Figure 7 The diagram illustrates a fabric with two insert elements in two gaps and a fabric with three insert elements in three gaps.

[0077] Figure 8 The illustration depicts a fabric with three insert elements as a footwear component.

[0078] Figure 9 The schematic diagram shows a fabric containing four insert elements—as Figure 8 The corresponding component.

[0079] Figure 10 The image shows a photograph of inserting the insert element manually between the needle beds of a knitting machine.

[0080] Figure 11 : Showed Figure 10 A close-up photo of inserting the insert element between the needle beds of a knitting machine.

[0081] Figure 12 : Shown as a side view Figure 10 A photo of inserting a component into a knitting machine.

[0082] Figure 13 : Depicted Figure 9 A photograph of the back of a fabric with insert elements.

[0083] Figure 14 : Showed Figure 9 A frontal photograph of a fabric with insert elements.

[0084] Figure 15 : Showed Figure 8 A frontal photograph of a fabric with insert elements.

[0085] Figure 16 : Showed Figure 15 A close-up photo of the fabric.

[0086] Figure 17 : A photograph depicting a piece of fabric with insert elements serving as a shoe tongue.

[0087] Figure 18 : Showed Figure 17 A close-up photo of the fabric. Detailed Implementation

[0088] The following sections provide a detailed description of the invention, with reference to the accompanying drawings for clarity. These descriptions are illustrative only and are not intended to limit the scope of the invention. The same reference numerals denote the same parts in the drawings and text. The illustrations may not reflect actual dimensions or scale; their dimensions, scales, and depictions of elements may have been enhanced for ease of understanding and visual convenience.

[0089] Figure 1 The diagram illustrates the insertion of an insert element into an opening in a fabric. Fabric 100 is suspended from needles 150 of a knitting machine and comprises a first layer 101 and a second layer 102. Between the first and second layers 101, 102 is an opening 110 configured to receive the insert element 1000. The opening 110 is accessible, specifically, through an aperture 103.

[0090] Throughout the process, fabric 100 is held on the knitting needles 150 of the knitting machine, ensuring that the first layer 101 and the second layer 102 are held apart by their respective needles, and ensuring that the opening 103 remains open, thereby allowing for the precise placement of the insert element 1000. This method enhances the structural integrity and comfort of the sportswear by securely integrating the insert element (e.g., a cushioning pad) within the fabric layers 101, 102. This technique produces seamless, durable sportswear.

[0091] Figure 2 The insert element is shown in cross-sectional view inside the gap between the two layers. Fabric 100 includes first and second layers 101, 102 and a gap 110 between the layers. Insert element 1000 is located in the gap and is wrapped by layers 101, 102.

[0092] The first and second layers 101, 102 of fabric 100 create a gap 110 in which the insert element 1000 is placed. This cross-sectional view illustrates how the insert element 1000 is securely encased within the fabric layers 101, 102, ensuring it remains in place during use. This approach provides enhanced protection and comfort because the insert element (e.g., in the form of a reinforcement or pad) can absorb impacts while the fabric layers remain flexible and durable.

[0093] Figure 3The diagram illustrates an insert element that, after being inserted into a gap, extends through an opening after the fabric shrinks. The insert element 2000 is inserted into fabric 200, which comprises first and second layers 201, 202. Layers 201, 202 form a gap 210 between them to receive the insert element 2000. The gap also includes a small opening 220 on its side, through which the insert element 2000 can extend partially. After the gap is closed during knitting and after the fabric shrinks, the shrunken fabric 200' tightly wraps around the insert element 2000, such that a portion of the insert element 2000 extends through the opening 220. More specifically, when the insert element 2000 is introduced between the first and second layers 201, 202, the width of the gap 210 is preferably greater than the total width of the insert element 2000. After the first and second layers 201, 202 are knitted together to close the gap 210 and the knitted fabric has been shrunk, the width of the gap is reduced and the insertion element 2000 extends through the opening 220.

[0094] The first and second fabric layers 201, 202 form a gap 210 with a small opening 220. The insert element 2000 is placed into the gap. After the knitting process is completed and, for example, heat is applied to shrink the fabric 200, the shrunken fabric 200' tightens around the insert element 2000, ensuring a tight fit. The shrinking process allows the insert element 2000 to partially extend through the opening.

[0095] Figure 4 A schematic diagram illustrates a trapezoidal insert element within a fabric. Fabric 300 comprises first and second layers 301, 302, forming a gap 310 to receive the trapezoidal insert element 3000. The trapezoidal insert element 3000 is inserted into the gap 310 during knitting. After knitting, the fabric is shrunk to wrap around the insert element 3000, thereby taking the shape of the insert element.

[0096] The first and second fabric layers 301, 302 create a gap 310 that accommodates a trapezoidal insert element 3000, such as a cushioning pad. During the knitting process, the insert element 3000 is inserted into the gap, and then the fabric 300 undergoes a shrinking step to tightly conform around the trapezoidal insert element 3000. This tight fit ensures that the insert element 3000 is firmly held in place and provides, for example, protection and support. The trapezoidal shape is an example of a shape that can be inserted into the gap according to the invention; such shapes include not only parallel sides but also other shapes, including irregular shapes. The use of shrinkable yarn and the addition of a shrinking step after the knitting process allows the knitted material to conform to the shape of the insert element, even an irregular shape, without creating a complex knitting procedure. The trapezoidal or similar shape of the insert element can be used, for example, to create a padding element in the heel area of ​​footwear, providing optimized coverage and comfort.

[0097] Figure 5 A concave insert element is schematically depicted within a stretchable fabric. The insert element 5000 is located within a void 510, which is formed between first and second layers 501, 502 of the fabric 500. An elastic yarn 530 (which is part of the first layer 501) forces the insert element 5000 to bend into a concave shape, thereby creating a void volume between the first layer 501 (which is stretched by the elastic yarn 530) and the concave insert element 5000. More specifically, when this method is performed on a flat knitting machine, the insert element 5000 is made of a deformable material—suitable for bending under the action of the elastic yarn 530—such as deformable foam or foil.

[0098] Fabric layers 501 and 502 form a gap 510 that accommodates a concave insert element 5000, for example, to form padding in the heel area of ​​a shoe. The elastic yarn 530 in the first layer 501 forces the insert element into a concave shape, ensuring a close fit to the body while creating small empty volumes 532, for example, for further comfort. This design can also enhance support and fit in, for example, sports bras, providing better shape and coverage. The concave shape of the insert element improves comfort by reducing pressure points and allowing better airflow, making sportswear suitable for a variety of activities. For bras, this approach can be achieved when the insert element is softly padded. Similarly, this solution can be applied to other products, such as shin guards or the visor of a hat, where the insert element would be made of a more rigid but still elastically deformable material.

[0099] Figure 6 The schematic diagram shows the insert element visible through a hole created in the first or second layer of fabric. Fabric 600 includes a gap 610 that accommodates the insert element 6000. The insert element is visible due to a through-hole 640 in fabric 600.

[0100] The fabric layers form gaps 610 to accommodate the insert element 6000. Through-holes 640 in the fabric allow the insert element 6000 to be visible and partially exposed. This design not only provides aesthetic appeal but also enhances breathability and flexibility. The visibility through the holes can also serve functional purposes, such as indicating the correct position of the insert or providing additional grip. This approach combines protection, comfort, and design innovation in sportswear.

[0101] Figure 7The diagrams illustrate fabrics with two insert elements in two gaps and fabrics with three insert elements in three gaps. A first fabric 710 includes first and second gaps 711 and 712, which accommodate first and second insert elements 7001 and 7002. Thus, a stacked assembly is formed by the layers of fabric 710 and the insert elements 7001 and 7002, thereby forming a sandwich structure. A second fabric 720 includes first, second, and third gaps 721, 722, and 723, which accommodate first, second, and third insert elements 7001, 7002, and 7003. Thus, a stacked assembly is formed by the layers of fabric 720 and the insert elements 7001, 7002, and 7003, thereby forming a sandwich structure.

[0102] A first fabric 710, with two gaps 711, 712 and insert elements 7001, 7002, can be used, for example, as a shin guard, where each insert provides targeted protection and cushioning. A second fabric 720, with three gaps 721, 722, 723 and insert elements 7001, 7002, 7003, can be used in more complex sports articles, where multiple layers can provide enhanced shock absorption and coverage. The sandwich structure ensures that each insert element is firmly held between the fabric layers, providing a robust, durable, and effective protective solution. This allows for customizable levels of protection—by varying the number and type of insert elements used. Each insert element can provide a different function, and for this purpose, it can be made from different materials.

[0103] Figure 8 The diagram illustrates a fabric with three insert elements as a footwear component. The fabric 800 is formed as part of the upper. The insert element 8003 on the front of the fabric 800 serves as a toe reinforcement, while the insert elements 8001 and 8002 serve as eyelet reinforcements.

[0104] The fabric 800 used for the upper includes three strategically placed insert elements 8001, 8002, and 8003. The toe reinforcement 8003 provides additional protection and durability to the forefoot. The eyelet reinforcements 8001 and 8002 ensure stronger and more abrasion-resistant lacing areas. This design improves the overall performance, lifespan, and comfort of the shoe, making it suitable for demanding athletic activities. The integration of these insert elements within the fabric ensures a seamless, lightweight, and aesthetically pleasing shoe construction.

[0105] Figure 9 The diagram illustrates a fabric containing four insert elements—as Figure 8 The corresponding counter-component. Fabric 900 is formed as... Figure 8Corresponding parts of the upper component. Insert elements 9001 and 9002 of the fabric can be used as lacing reinforcements. Insert element 9004 in the upper part of fabric 900 can be used as a heel foam cushioning component. Insert element 9005 in the lower part of fabric 900 can be used as a heel reinforcement.

[0106] As Figure 8 The fabric 900 of the corresponding components includes four strategically placed insert elements 9001, 9002, 9004, and 9005 to enhance functionality. Lacing reinforcements 9001 and 9002 ensure a durable and secure lacing area, improving fit and stability. Heel foam cushioning 9004 adds comfort and shock absorption to the heel area, while heel reinforcement 9005 provides additional structural support and protection. This enhances the overall performance, comfort, and durability of the shoe, making it ideal for strenuous athletic activities. The integration of these elements within the fabric ensures an integrated, lightweight, and efficient shoe design.

[0107] Figure 10 The image shows a photograph of manually inserting the insert element 10000 into a knitting machine (especially a flat knitting machine).

[0108] Figure 11 Showing Figure 10 A close-up photo of the insertion element 10000 inserted into a knitting machine.

[0109] Figure 12 Shown as a side view Figure 10 A photograph of the insertion element 10000 inserted into a knitting machine. As can be seen, the insertion element is placed between the needle beds.

[0110] Figure 13 Depicting Figure 9 The photograph shows the back of fabric 900, which has insert elements 9001, 9002, 9004, and 9005. The surface shown corresponds to the back of the footwear element; however, from a technical point of view, it represents the front of the knitted material—when it comes out of the knitting machine.

[0111] Figure 14 Showing Figure 9 A front view of fabric 900 with insert elements 9001, 9002, 9004, and 9005. The surface shown forms the inside of the footwear element; however, it corresponds to the back of the knitted material—when it comes out of the knitting machine.

[0112] Figure 15 Showing Figure 8 A front view of fabric 800 with insert elements 8001, 8002, and 8003.

[0113] Figure 16 Showing Figure 8 A close-up photograph of fabric 800, which has insert elements 8001, 8002, and 8003.

[0114] Figure 17 A photograph depicts a fabric with insert element 17000 serving as a reinforcement for the shoe tongue.

[0115] Figure 18 Showing Figure 17 A close-up photograph of a fabric with 17,000 insert elements.

[0116] List of reference numerals in the attached diagram: 100, 200, 300, 500, 600, 710, 720, 800, 900: Fabric 101, 201, 301, 501: First Floor 102, 202, 302, 502: Second floor 110, 210, 310, 510, 610, 711, 712, 721, 722, 723: Gaps 150: Knitting needles 200', 300': Shrinkage of the fabric 220: Opening 530: Stretch yarn 532: Empty volume 640: Hole 1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000: Inserted components 8001, 8002, 9001, 9002: Lace-up reinforcement 8003: Toe reinforcement 9004: Heel foam cushioning 9005: Heel reinforcement 17000: Shoe tongue reinforcement.

[0117] Further examples are described below to aid in understanding the invention.

[0118] 1. A method for manufacturing sporting goods, the method comprising a knitting process, the knitting process including the following steps: a) Provide a knitting machine, yarn for knitting, and at least one insert element; b) Knitting a fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) such that the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) includes at least one open gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) between at least two layers of the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900); c) While the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) is held within the knitting machine, at least one insertion element is inserted into the at least one opening (110, 210, 310, 510, 610, 711, 712, 721, 722, 723); and d) Further knit the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) such that by connecting the at least two layers, the at least one gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is at least partially closed around the insert element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000).

[0119] 2. The method according to Example 1, wherein the method does not include creating the opening gaps (110, 210, 310, 510, 600, 710, 720, 800, 900) by cutting the knitted fabric (100, 200, 300, 500, 600, 710, 712, 721, 722, 723).

[0120] 3. The method according to Example 1 or Example 2, wherein during steps b)-d), the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) is continuously held on the knitting machine.

[0121] 4. The method according to any one of the foregoing embodiments, wherein the insertion of the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is performed automatically, preferably by supplying the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) from the storage area.

[0122] 5. In the method according to any one of the foregoing embodiments, the insertion of the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is performed manually by an operator.

[0123] 6. The method according to any one of the foregoing embodiments, wherein the knitting machine size is a maximum of 18.

[0124] 7. The method according to any one of the foregoing embodiments, wherein after step b), the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises two or more layers and includes two or more gaps defined between the layers, such that after the insertion element is inserted, the insertion element and the layers are stacked alternately.

[0125] 8. The method according to any one of the foregoing embodiments, wherein the height of the gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is greater than the height of the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), and / or the width of the gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is greater than the width of the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000).

[0126] 9. The method according to any one of the foregoing embodiments, wherein the at least one insertion element is fixed in the gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) by a yarn extending through the insertion element.

[0127] 10. The method according to any one of the foregoing embodiments, wherein the yarn comprises a shrinkable yarn, and the method includes a shrinking step such that the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) surrounding the gap follows the contour of the insert element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), wherein the shrinking is preferably achieved by applying heat.

[0128] 11. The method according to any one of the foregoing embodiments, wherein the layers comprise different yarns, and wherein preferably one layer of the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises elastic and / or shrinkable yarns, while another layer comprises inelastic and / or non-shrinkable yarns.

[0129] 12. The method according to any one of the foregoing embodiments, wherein the yarn comprises an elastic and / or shrinkable yarn.

[0130] 13. The method according to any one of the foregoing embodiments, wherein one of the layers comprises a molten yarn adapted to form a connection with the insert element upon melting.

[0131] 14. The method according to Example 13, wherein the melt yarn is also a shrinkable yarn.

[0132] 15. The method according to any one of the foregoing embodiments, wherein the yarn comprises: an inelastic and / or non-shrinkable yarn comprising polyester.

[0133] 16. The method according to any one of the foregoing embodiments, wherein the yarn comprises a shrinkable yarn, and the gap has one or more openings (220) smaller than the insertion elements (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), and the method includes a shrinking step such that after shrinking the yarn, the insertion elements (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) partially extend through the openings (220).

[0134] 17. The method according to any one of the foregoing embodiments, wherein the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) includes a reinforcing device and / or a cushioning device.

[0135] 18. The method according to any one of the foregoing embodiments, wherein the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprises a magnet.

[0136] 19. The method according to any one of the foregoing embodiments, wherein the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprises one or more electronic components, preferably a microchip.

[0137] 20. The method according to any one of the foregoing embodiments, wherein the sporting article is a shoe.

[0138] 21. The method according to any one of the foregoing embodiments, wherein the sports article is clothing.

[0139] 22. A sporting article obtained by the method according to any one of the foregoing embodiments.

Claims

1. A method for manufacturing sporting goods, the method comprising a knitting process, the knitting process including the following steps: a) Provide a knitting machine, yarn for knitting, and at least one insert element; b) Knitting a fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) such that the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) includes at least one open gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) between at least two layers of the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900); c) While the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) is held within the knitting machine, at least one insertion element is inserted into the at least one opening (110, 210, 310, 510, 610, 711, 712, 721, 722, 723); and d) Further knit the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) such that by connecting the at least two layers, the at least one gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is at least partially closed around the insert element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000).

2. The method of claim 1, wherein the method does not include creating the opening gaps (110, 210, 310, 510, 600, 710, 720, 800, 900) by cutting the knitted fabric (100, 200, 300, 500, 600, 710, 712, 721, 722, 723).

3. The method according to claim 1 or claim 2, wherein during steps b)-d), the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) is continuously held on the knitting machine.

4. The method according to any one of the preceding claims, wherein the insertion of the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is performed automatically, preferably by supplying the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) from a storage area.

5. The method according to any one of the preceding claims, wherein the insertion of the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is performed manually by an operator.

6. The method according to any one of the preceding claims, wherein the knitting machine size is a maximum of 18.

7. The method according to any one of the preceding claims, wherein after step b), the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises two or more layers and includes two or more gaps defined between the layers, such that after the insertion element is inserted, the insertion element and the layers are stacked alternately.

8. The method according to any one of the preceding claims, wherein, The height of the gaps (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is greater than the height of the insert elements (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), and / or the width of the gaps (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is greater than the width of the insert elements (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000).

9. The method according to any one of the preceding claims, wherein the at least one insertion element is secured in the gap (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) by a yarn extending through the insertion element.

10. The method according to any one of the preceding claims, wherein, The yarn comprises a shrinkable yarn, and the method includes a shrinking step such that the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) around the gap follows the contour of the insert element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), wherein the shrinking is preferably achieved by applying heat.

11. The method according to any one of the preceding claims, wherein the layers comprise different yarns, and wherein preferably one layer of the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises elastic and / or shrinkable yarns, while another layer comprises inelastic and / or non-shrinkable yarns.

12. The method according to any one of the preceding claims, wherein the yarn comprises an elastic and / or shrinkable yarn.

13. The method according to any one of the preceding claims, wherein, One of the layers comprises molten yarn adapted to form a connection with the insert element upon melting.

14. The method of claim 13, wherein the melted yarn is also a shrinkable yarn.

15. The method according to any one of the preceding claims, wherein the yarn comprises: an inelastic and / or non-shrinkable yarn comprising polyester.

16. The method according to any one of the preceding claims, wherein, The yarn comprises a shrinkable yarn, and the gap has one or more openings (220) smaller than the insertion elements (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), and the method includes a shrinking step such that after the yarn is shrunk, the insertion elements (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) partially extend through the openings (220).

17. The method according to any one of the preceding claims, wherein the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprises a reinforcing device and / or a cushioning device.

18. The method according to any one of the preceding claims, wherein the insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprises a magnet.

19. The method according to any one of the preceding claims, wherein, The insertion element (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) contains one or more electronic components, preferably microchips.

20. The method according to any one of the preceding claims, wherein the sporting article is a shoe.

21. The method according to any one of the preceding claims, wherein the sporting article is clothing.

22. A sporting article obtained by the method according to any one of the preceding claims.

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