KNITTED BAG WITH INSERTED ELEMENT

Abstract

The present invention relates to a method for manufacturing a sporting goods article, comprising a knitting process, wherein the knitting process comprises the following steps: a) providing a knitting machine, yarn for knitting, and at least one insert element; b) knitting a fabric such that the fabric comprises at least one open cavity between at least two layers of the fabric; c) inserting at least one insert element into the at least one open cavity while the fabric remains in the knitting machine; and d) further knitting the fabric such that the at least one cavity is at least partially closed around the insert element(s) by joining the at least two layers. The invention further relates to a sporting goods article.

Description

1. Field of the invention

[0001] This invention relates to a method for manufacturing a sporting goods article, comprising a knitting process, and to a sporting goods article. 2. Background

[0002] The invention relates to the field of manufacturing sporting goods using knitting processes. Conventional manufacturing methods for sporting goods, such as shoes and clothing, often involve several steps, including cutting, sewing, and gluing, to integrate various functional elements such as reinforcements and / or padding into the fabric. These processes can be labor-intensive, prone to inconsistencies, and can compromise the structural integrity and flexibility of the final product.

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

[0004] The disadvantage here is that the fabric has to be cut to place inserts into pockets formed in the fabric. Therefore, there is a need for a manufacturing process that does not require a cutting step to place insert elements.

[0005] The primary problem addressed by the invention is the need for an efficient, consistent, and seamless method for integrating various functional elements into sportswear during the knitting process itself. Conventional methods for attaching elements, such as padding or reinforcements, to fabrics often result in weaker connections, added bulk, and potential user discomfort. Furthermore, these methods can be inefficient and costly due to the multiple steps and associated manual labor. The invention provides a method for seamlessly integrating functional elements into sportswear during the knitting process.By creating cavities within the knitted fabric and inserting elements such as reinforcing pads, padding, magnets, or electronic components while the fabric is still on the knitting machine, the process ensures the secure and precise placement of these elements. The use of shrinkable or meltable yarns can further enhance integration by tightly enclosing the elements within the fabric, eliminating the need for additional cutting or gluing steps.

[0006] In light of the above, there is a need for an improved manufacturing process for knitted sporting goods. It is therefore an object of the present invention to overcome some or all of the shortcomings of the prior art. 3. Summary

[0007] The above problems are at least partially solved by the subject matter of independent claim 1. Preferred embodiments are the subject matter of the dependent claims, and the person skilled in the art will find references to other suitable aspects of the present invention in the overall disclosure of the present application.

[0008] One aspect of the invention relates to a method for manufacturing a sporting goods article, comprising a knitting process, wherein the knitting process comprises the following steps: a) providing a knitting machine, yarn for knitting, and at least one insert element; b) knitting a fabric such that the fabric comprises at least one open cavity between at least two layers of the fabric; c) inserting at least one insert element into the at least one open cavity while the fabric remains in the knitting machine; and d) further knitting the fabric such that the at least one cavity is at least partially closed around the insert element(s) by joining the at least two layers. In particular, the cavity is accessible during knitting step b) through an opening, which is then closed in step d).

[0009] Such a process can be used, for example, to create a sports shoe with enhanced support. The insert element could be a padded pad or a reinforcing strip. By inserting the element, such as a pad, into the cavity within the knitted layers and then knitting further to secure it, the sportswear gains additional structural support and comfort without the need for external seams or adhesives. This approach ensures a more seamless design, reduces manufacturing steps, and improves the durability and performance of the sportswear.

[0010] The process can be further improved if it does not involve cutting the knitted fabric to create the open cavity.

[0011] With this method, the open cavity is created directly during the knitting process by manipulating the yarn and machine settings to leave a gap or cavity between layers of fabric. This technique eliminates the need for cutting, which is common in prior art, thus preserving the integrity and strength of the fabric. For example, when creating a seamless sportswear garment, this method allows for the strategic placement of a breathable or reinforced section without weakening the material. This results in a more durable and comfortable product, as the fabric retains its original strength and flexibility.

[0012] A further improvement is achieved in particular if the fabric is continuously held on the knitting machine during steps b.)-d.).

[0013] With this method, the fabric remains on the knitting machine throughout the entire process of creating the open cavity, inserting the element, and knitting to close the cavity. For example, in the production of a sporting goods item such as a shoe or glove, this continuous process ensures the precise placement and secure integration of padding or support elements. This method improves production efficiency by reducing handling and potential errors associated with moving the fabric between machines. Additionally, it improves the alignment and consistency of the final product, resulting in higher quality and reduced production time.This means that the knitted fabric is not removed from the knitting machine during these steps and is held on the machine's needles, although the specific needles holding the fabric may change over time during the manufacturing process.

[0014] A further improvement is achieved if the insertion of the insert element(s) is carried out automatically, preferably by feeding the insert element(s) from a storage area.

[0015] With this method, insert elements, such as padding pads or reinforcing strips, are automatically inserted into the fabric using a mechanism that retrieves these elements from a designated storage area. For example, in the production of a sporting goods item, this automated insertion ensures the precise and consistent placement of protective and / or padding elements without manual intervention. The automatic insertion can be achieved using a robotic arm integrated into and / or attached to the knitting machine. This configuration not only ensures precise positioning of the insert but also facilitates its maneuverability within the machine's limited space, such as the area between the needle beds.This automation improves production speed and accuracy while reducing labor costs, resulting in a more efficient manufacturing process and higher-quality products with consistently placed components. A storage area, for example, could be a magazine for storing and feeding components.

[0016] An alternative improvement is achieved if the insertion of the insert element(s) is carried out manually by an operator.

[0017] With this method, the insertion of insert elements, such as padding pads or reinforcing strips, is performed manually by an operator. For example, when creating custom sporting goods, an operator can precisely position and adjust each insert element according to specific design requirements. This manual insertion allows for greater flexibility and customization, ensuring that each product meets exact specifications and caters to individual needs. This method can be advantageous for limited production runs or specialized items where precision and customization are prioritized over automation.

[0018] A further improvement can be achieved if the knitting machine count is a maximum of 14.

[0019] With this method, the knitting machine used in the process has a maximum gauge of 18, meaning it can produce a relatively fine and detailed fabric. For example, using a machine with a gauge of 18 in the production of sporting goods allows for the creation of a lightweight and delicate fabric. As the gauge increases, the material becomes finer; however, this also reduces the spacing between the needle beds, making it more difficult to insert an insert between them. A configuration with a gauge of 18 offers a balance that is fine enough to produce delicate material while still maintaining sufficient spacing between the needle beds to allow the insertion of elements between them and into the knitted fabric.

[0020] A further improvement is achieved if the opening through which the cavity is accessed has a width greater than the maximum width of the insert element(s). This allows the insert element to be fully inserted into the cavity in step c) without deforming it. This may require designing the knitted fabric and the knitting program in a suitable way to allow for the placement of the insert element(s) during the knitting process.

[0021] A further improvement is achieved if the maximum thickness of the insert element(s) is less than the distance between the layers of fabric that define the cavity while held in the knitting machine. This allows the insert element to be fully inserted into the cavity in step c) without deformation. Alternatively, the maximum thickness of the insert element(s) could be greater than the distance between the layers of fabric while held in the knitting machine, and the insert element(s) could be made of an elastically deformable material so that they can be compressed in step c) to be inserted into the cavity. In particular, the distance between the layers of fabric is determined by the distance between the needle beds.

[0022] A further improvement is achieved when the fabric is knitted as a double, triple, or quadruple layer, with the at least two layers of the fabric being bonded together by the knitting process, and the open cavity defined in a selected area of ​​the fabric where the at least two layers are separated and overlap. For example, the fabric could be a double-layered fabric where, in selected areas, the two layers are separated (i.e., not bonded between them) and overlap to define the cavity.

[0023] A further improvement is achieved if, after step b.), the material comprises more than two layers and two or more cavities defined between them, so that after the insertion of the insert elements, the insert elements and the layers are stacked alternately.

[0024] This process results in a multi-layered fabric with multiple cavities for insert elements. For example, in the manufacture of high-performance sporting goods, this technique allows for the insertion of both padding and structural supports within the same fabric. By stacking insert elements such as structural and padding layers alternately with the fabric layers, the sporting goods can offer improved cushioning, breathability, and structural integrity. This multi-layered construction enhances the functionality and comfort of the sporting goods and provides tailored performance benefits for various athletic activities. This process can be implemented on knitting machines that incorporate two needle beds, using alternating needles in a 1x1 technique.Alternatively, it can be done on knitting machines with additional needle beds, such as those with four needle beds, which simplifies the process and allows knitting on all needles.

[0025] A further improvement is achieved if the height of the cavity is greater than the height of the insert element(s) and / or the width of the cavity is greater than the width of the insert element(s).

[0026] This method creates cavities larger than the inserts to ensure easy insertion and movement within the cavity. This design improves comfort and adaptability, as the inserts can adjust within the cavity to provide optimal support and reduce pressure points. This flexibility can also simplify the manufacturing process by accommodating variations in insert sizes. This is particularly advantageous when non-elastic yarns are used in the knit fabric. When elastic yarns are used, the cavity dimensions could actually be smaller than those of the insert, as the elastic yarn allows for stretching to compensate for the difference in dimensions.

[0027] A further improvement is achieved if at least one insert element is fixed in the cavity by the yarn that extends through the insert element.

[0028] This method secures the insert within the cavity by knitting the yarn through the insert itself. For example, when creating protective sports equipment, such as knee pads, the padding element can be securely anchored in place by threading the yarn through holes or loops in the pad. This ensures the insert remains firmly in position, providing consistent protection and support during use. This method improves the durability and stability of the sports product and prevents the insert elements from shifting or coming loose during intense physical activity.

[0029] This method can be carried out in particular with insert elements that are not made of a rigid material, such as padding elements made of foams, reinforcing films, or fabrics, simply by using needles to punch through the insert elements. This method can also be carried out with insert elements made of a rigid material, provided that holes or loops are provided in the insert elements for this purpose.

[0030] A further improvement is achieved if the insert element has a shape adapted to fit between the needle beds of the knitting machine. For example, if a flat knitting machine with flat needle beds is used, the insert element should advantageously have a flat shape to allow for easy insertion between the needle beds. If a different shape is desired, the insert element could be given the desired shape and made of an elastically deformable material to be deformed during insertion step c). Alternatively, the insert element could initially be given a flat shape and made of a plastically deformable material to be shaped into the desired form after the knitting process, for example, by means of a hot pressing step.

[0031] In other words, if a circular knitting machine is used which has a round needle cylinder and a circular knitting wheel, the insert should have a curved shape adapted to fit between the needle cylinder and the circular knitting wheel, or it should be made of a flexible material that can be conveniently bent to fit around the circumference.

[0032] A further improvement is achieved if the yarn comprises a shrinkable yarn and the process includes a shrinking step, so that the fabric around the cavity adapts to the contour of the insert element(s), with the shrinking preferably being achieved by applying heat.

[0033] In this process, the fabric is knitted with shrinkable yarn, and after the insert(s) are placed, the fabric undergoes a shrinking process. For example, when manufacturing a custom-made sporting goods item, heat can be applied to the fabric, causing the shrinkable yarn to contract and conform tightly to the padding or support elements. This ensures a snug and precise fit, improving the functionality and comfort of the sporting goods. The heat shrinking step ensures that the inserts remain securely in place, preventing them from shifting within the cavity, and perfectly contours the fabric to the desired shape, providing enhanced performance.The knitted products can incorporate numerous different yarns, and a shrinkable yarn could be knitted together with other different yarns or used only in a specific area where it is needed, and not elsewhere. Heat can be applied, for example, by steaming, ironing, autoclaving, using an oven, or similar methods.

[0034] A further improvement is achieved when the layers comprise different yarns, and preferably one layer of the fabric comprises an elastic and / or shrinkable yarn, and another layer comprises a non-elastic and / or non-shrinkable yarn.

[0035] In this type of process, the fabric contains layers made from different types of yarn. For example, when creating a sports compression garment, the inner layer might be made from an elastic and shrinkable yarn to provide a snug, fitted look, while the outer layer is made from a non-elastic, durable yarn to offer support and protection.

[0036] This combination allows the garment to stretch and adapt to the wearer's body while maintaining structural integrity and durability. This double-layered construction can improve the comfort, performance, and longevity of the sporting goods, providing targeted support and flexibility when needed.

[0037] A further improvement is achieved if the yarn includes an elastic and / or shrinkable yarn.

[0038] In this type of process, the knitting process uses yarn that is elastic and / or shrinkable. For example, the use of elastic yarn in the manufacture of sporting goods ensures that the fabric can stretch and adapt to the movements of the foot, providing a comfortable and flexible fit. Additionally, shrinkable yarn can be used to further improve the fit and shape retention of the garment after heat treatment. This use of specialized yarns enhances the overall performance, durability, and comfort of the sporting goods, making them ideal for dynamic, high-intensity activities. If the yarn includes an elastic / shrinkable component, the insert can fit better into the cavity thanks to the fabric layers that conform to the insert's shape. An elastic or shrinkable yarn could include an elastomer and / or thermoplastic polyurethane (TPU).

[0039] A further improvement is achieved if one of the layers includes a melt yarn that is adapted to form a bond with the insert element(s) when fused.

[0040] In this type of process, the fabric layer incorporates a fusible yarn that, when heat is applied, is at least partially fused to the insert elements. For example, in the manufacture of athletic shoes, a fusible yarn can be used in the inner layer of the shoe padding. When heat is applied, this yarn melts and bonds to the insert elements, such as shock-absorbing pads, creating a secure and integrated structure. This process improves the durability and stability of the padding and ensures that it remains firmly in place during use. The melting process also simplifies the manufacturing steps and eliminates the need for additional adhesives, resulting in more streamlined and efficient production.

[0041] This process can be further improved if the melt yarn is also a shrinkable yarn.

[0042] In this type of process, the melt yarn used in the fabric layer is also shrinkable. When heat is applied, these yarns not only fuse, at least partially, to the insert elements by bonding, but also shrink to conform closely to them. This dual function ensures a secure bond and a precise fit, improving the support and stability of the sporting goods. The combination of melting and shrinking properties simplifies the manufacturing process and enhances the overall effectiveness and comfort of the product. A melt yarn that is also shrinkable could, for example, be a hybrid or twisted yarn.

[0043] This process, which uses a yarn that is both meltable and shrinkable, is particularly advantageous in the manufacture of footwear when, for example, the insert elements placed in the knitted material are rigid and require precise placement, such as support stays.

[0044] A further improvement can be achieved if the yarn includes a non-elastic and / or non-shrinkable yarn containing polyester.

[0045] In this type of process, the fabric incorporates a non-elastic and non-shrinkable polyester yarn. For example, using polyester yarn in the manufacture of sporting goods such as footwear or sports bags provides durability and resistance to stretching, ensuring that the footwear or bag retains its shape and can withstand heavy use. Polyester's inherent strength and resistance to environmental factors such as moisture and UV light make it an ideal choice for outdoor sports equipment. This use of polyester yarn enhances the longevity, structural integrity, and reliability of the sporting goods, making them suitable for demanding applications.

[0046] A further improvement is achieved if the yarn comprises a shrinkable yarn and the cavity has one or more openings smaller than the insert element(s), and the process includes a shrinking step such that, after the yarn shrinks, the insert element(s) partially extends through the opening(s). In particular, the one or more openings could be independent of the opening through which the insert element(s) is placed in the cavity, or could be created by only partially closing the opening.

[0047] In this type of process, the fabric uses shrinkable yarn and has openings smaller than the insert(s). For example, when creating sporting goods, after the insert(s) are placed in the fabric, heat is applied to shrink the yarn. This causes the fabric to tighten, and the insert(s) to partially protrude through the openings. This design ensures that the insert(s) remain securely in place while allowing a portion of it to be accessible. This is particularly advantageous, for instance, if the insert is an electrical component and part of it needs to be accessible to allow for electrical charging or data transmission.The shrinkage step ensures a precise and snug fit around the insert elements, improving both the performance and aesthetics of the sporting goods. The opening of the cavity is preferably not the one providing access to the open cavity for inserting the insert elements, but rather a separate opening to give the sporting goods additional functionality, for example, by allowing the insert element to extend through this additional opening.

[0048] A further improvement is achieved when the knitted fabric includes one or more holes, and in particular through-holes, connected to the cavity, and the insert element(s) is / are partially visible through the holes. This design improves breathability and ensures that the insert element(s) remain securely in place while allowing additional airflow.

[0049] A further improvement is achieved if the insert element(s) includes reinforcement material and / or padding material.

[0050] Using this method, the reinforcement elements provide reinforcement and / or padding. For example, in the manufacture of athletic shoes, the reinforcement elements could be stiffeners for additional support or padded cushions for comfort. Reinforcing elements can improve the structural integrity and durability of the shoes, making them more resistant to wear and tear. Examples of such reinforcing elements include: instep reinforcements or toe boxes to strengthen the toe and forefoot areas of the shoes; heel counters to provide the necessary stiffness to the heel area and more support for the wearer's foot; or eyelet reinforcements to strengthen the lacing areas. Other reinforcing elements can be provided to improve shoe performance.Examples of such reinforcement elements include stiffening elements, such as plates or rods, which are placed in the sole area of ​​the shoe to increase sole rigidity, thus enabling better power transfer from the ankle to the ground. Cushioning elements improve comfort by absorbing shocks and reducing pressure on the feet. Examples of cushioning elements include heel or tongue padding. This combination ensures that the sporting goods meet the specific performance needs of athletes, providing both firmness and comfort. Such cushioning can be made, for example, from a foam or from pellet or particle foam.

[0051] A further improvement is achieved if the insert element(s) include magnets.

[0052] For example, by integrating magnets directly into the fabric, the garment can be used to create a detachable fastener that can replace a zipper or hook-and-loop closure. This method improves the functionality of the sporting goods and allows for a clean design. A further improvement is achieved if the insert(s) include one or more electronic components, preferably microchips.

[0053] Using such a method, the integrated components can include electronic elements, such as microchips. For example, in the production of smart sportswear, microchips can be integrated into the fabric to monitor and collect data on the wearer's performance, such as heart rate, position, movement, speed, ball impact force, and temperature. These electronic components can connect to a mobile app, for instance, providing the user with real-time feedback and analysis. This integration of electronics enhances the functionality of the sportswear, transforming it into a high-tech garment that offers both performance monitoring and improved training results.

[0054] In one embodiment, the insert element(s) includes an RFID tag, for example for identification or tracking purposes. A further improvement is achieved when the sporting goods item is a shoe.

[0055] For example, the process can be used to create shoe uppers with integrated padding or reinforcement elements for enhanced comfort or support. Alternatively or additionally, the process can be used to create insoles, Strobel boards, or other sole components of 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, the inclusion of features such as shrinkable yarns and electronic components, like microchips, can provide a customized fit and performance tracking. This process enhances the overall quality, functionality, and innovation of the athletic shoe, making it ideal for a variety of sporting activities.

[0056] In another embodiment, the sporting goods item is a clothing item.

[0057] For example, the process can be used to create garments with integrated padding or support elements for enhanced performance, comfort, or safety. Knitting technology allows for the strategic placement of these elements within the fabric, resulting in a seamless and ergonomic design. Additionally, the use of elastic or shrinkable yarns can provide a snug, adaptive fit, while electronic components, such as microchips, can offer advanced features like performance monitoring. This process improves the functionality, comfort, and innovation of sportswear, making it suitable for a wide range of athletic activities.

[0058] Examples of sportswear items include: an upper body garment for motorsport, where the insert element could be safety padding or reinforcement; a sock, where the insert element is shin protection, intended for use in, for example, playing football, baseball or hockey; cycling shorts or tights with seat padding; protective compression sportswear, including integrated protective pads; and lower body garments with moisture-wicking and leak-proof padding.

[0059] Another embodiment of the invention is a sporting goods item obtained by the method described above.

[0060] For example, the sporting item could be a sports accessory, such as knee or elbow protection, for example for playing volleyball or skating, a ball, and the knitted material could be the carcass of the ball, while the insert element could be, for example, a sensor, a bag or a backpack, and the insert element could be a reinforcement or a padding element.

[0061] For example, a sports shoe manufactured using this process could feature integrated cushioning, reinforcement elements, and potentially 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, sportswear manufactured using this process could include compression garments with strategically placed support and padding, offering enhanced performance and comfort. 4. Brief description of the characters

[0062] Preferred embodiments of the disclosure are revealed below with reference to the accompanying figures. Fig. Figure 1 illustrates the insertion of an insert element into an open cavity in a material in a schematic view. Fig. Figure 2 shows the insert element within the cavity between two layers in a cross-sectional view. Fig. Figure 3 illustrates in a schematic view the insertion of an insert element into an open cavity in a fabric and the insert element extending through an opening after the fabric has shrunk. Fig. Figure 4 illustrates in a schematic view the insertion of a trapezoidal insert element into an open cavity in a fabric and the insert element within the fabric. Fig. 5: Illustrates in a schematic view a concave insert element within a stretchable fabric. Fig. Figure 6 shows a schematic view of an insert element visible through holes in the fabric. Fig. Figure 7 illustrates in a schematic view a fabric with two insert elements within two cavities and a fabric with three insert elements within three cavities. Fig. Figure 8: illustrates in a schematic view a fabric with three insert elements as a component for a shoe. Fig. 9: Illustrates in a schematic view a material with four incorporating elements as a counter-component to Fig. 8. Fig. Figure 10 shows a photograph of a manual insertion of an insert element between the needle beds of a knitting machine. Fig. 11: shows a close-up photograph of the insertion of the insert element from Fig. 10 between the needle beds of a knitting machine. Fig. 12: shows a side view photograph of the insertion of the insert element from Fig. 10 into a knitting machine. Fig. 13: illustrates a reverse side photograph of the fabric with insert elements made of Fig. 9. Fig. 14: shows a front view photograph of the fabric with insert elements made of Fig. 9. Fig. 15: shows a front view photograph of the fabric with insert elements made of Fig. 8. Fig. 16: shows a close-up of the fabric made of Fig. 15. Fig. 17: illustrates a photograph of a fabric with an insert element as a shoe tongue. Fig. 18: illustrates a close-up of the fabric from Fig. 17. 5. Detailed description of the figures

[0063] The following sections provide a detailed description of the invention, with reference to the accompanying figures for clarity. The descriptions are examples only and are not intended to limit the scope of the invention. Identical reference numerals in the figures and in the text denote the same components. The figures may not be true to size or scale; their dimensions, proportions, and representations of elements may have been enhanced for better understanding and visual convenience.

[0064] Fig. Figure 1 illustrates, in a schematic view, the insertion of an insert element into an open cavity in a fabric. The fabric 100 is suspended from the 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 open cavity 110, configured to receive the insert element 1000. The cavity 110 is accessible, in particular, through an opening 103.

[0065] The fabric 100 remains on the knitting machine needles 150 throughout the entire process, ensuring that the first layer 101 and the second layer 102 are kept spaced apart by their respective needles and that the opening 103 remains open, allowing for the precise placement of the insert element 1000. This method improves the structural integrity and comfort of the sporting goods by securely integrating the insert element, such as a padding insert, within the fabric layers 101 and 102. This technique results in a seamless, durable sporting goods product.

[0066] Fig. Figure 2 shows the insert element within the cavity between two layers in a cross-sectional view. The material 100 comprises a first and a second layer 101, 102 and a cavity 110 between the layers. The insert element 1000 sits in the cavity and is enclosed by layers 101 and 102.

[0067] The first and second layers 101, 102 of the fabric 100 create a cavity 110 in which an insert element 1000 is placed. This cross-sectional view illustrates how the insert element 1000 is securely enclosed within the fabric layers 101, 102, ensuring that it remains in place during use. This method offers improved protection and comfort, as the insert element, in the form of, for example, reinforcement or padding, can absorb impacts, while the fabric layers retain flexibility and durability.

[0068] Fig. Figure 3 illustrates a schematic view of an insert element as it is inserted into the cavity and then extends through an opening after the fabric has shrunk. The insert element 2000 is inserted into the fabric 200, which comprises a first and a second layer 201, 202. The layers 201, 202 form a cavity 210 between them to accommodate the insert element 2000. The cavity also includes a small opening 220 on the side through which the insert element 2000 can partially extend. After the cavity closes during the knitting process and after the fabric has shrunk, the shrunk fabric 200' tightly encloses the insert element 2000, so that parts of the insert element 2000 extend through the opening 220.More precisely, the width of the cavity 210 is preferably larger than the overall width of the insert element 2000 when the insert element 2000 is inserted between the first and second layers 201, 202. After the first and second layers 201, 202 have been knitted together to close the cavity 210, and the knitted fabric has undergone a shrinkage post-treatment, the width of the cavity is reduced and the insert element 2000 protrudes through the opening 220.

[0069] The first and second fabric layers 201, 202 form a cavity 210 with a small opening 220. The insert element 2000 is placed in the cavity. After completion of the knitting process and the application of, for example, heat to shrink the fabric 200, the shrunken fabric 200' contracts around the insert element 2000, ensuring a secure fit. The shrinking process allows the insert element 2000 to extend partially through the opening.

[0070] Fig. Figure 4 illustrates a trapezoidal insert element within a fabric in a schematic view. The fabric 300 comprises a first and a second layer 301, 302, which form a cavity 310 to accommodate the trapezoidal insert element 3000. The trapezoidal insert element 3000 is inserted into the cavity 310 during the knitting process. After knitting, the fabric is shrunk so that it encloses the insert element 3000, thus taking on the shape of the insert element.

[0071] The first and second layers of fabric 301, 302 create a cavity 310 that holds a trapezoidal insert element 3000, for example, a padding insert. During the knitting process, the insert element 3000 is placed into the cavity, and then the fabric 300 undergoes a shrinkage step that closely conforms to the trapezoidal insert element 3000. This precise fit ensures that the insert element 3000 remains securely in place, providing, for example, protection and support. The trapezoidal shape is an example of a form that not only includes parallel sides that can be inserted into a cavity according to the invention, but other shapes, including irregular ones, could also be used.The use of shrinkable yarns and the addition of a shrinkage step after knitting allows the knitted material to conform to the shape of the insert element, even if it is irregular, without the need for complex knitting programs. Trapezoidal or similar shapes of insert element(s) could, for example, be used to create padding element(s) on the heel area of ​​a footwear item, providing optimized coverage and comfort.

[0072] Fig. Figure 5 illustrates a concave insert element within a stretchable fabric in a schematic view. The insert element 5000 sits within the cavity 510, which is formed between the first and second layers 501, 502 of the fabric 500. The stretch yarn 530, which is part of the first layer 510, forces the insert element 5000 to bend into a concave shape, thus creating an empty volume between the first layer 510, which is stretched by the stretch yarn 530, and the concave insert element 5000. More precisely, if the process is carried out on a flat knitting machine, the insert element 5000 is made of a deformable material, such as a deformable foam or film, which is adapted to bend under the action of the stretch yarn 530.

[0073] The fabric layers 501 and 502 form a cavity 510 that holds a concave insert element 5000, for example, to create padding in the heel area of ​​a shoe. The stretch yarn 530 in the first layer 501 forces the insert element to bend into a concave shape, ensuring a snug fit against the body while creating a small empty volume 532, for example, for added comfort. This design could also improve the support and fit of, for example, a sports bra, providing better shape and coverage. The concave shape of the insert enhances comfort by reducing pressure points and allowing for better airflow, making the sportswear suitable for various activities. For a bra, this process could be implemented if the insert element is a soft padding.This solution can also be applied to other products, such as shin guards or the visor of a cap, where the insert element would consist of a more rigid, yet elastically deformable material.

[0074] Fig. Figure 6 shows a schematic view of an insert element visible through holes created in the first or second layer of the fabric. The fabric 600 includes a cavity 610 that holds the insert element 6000. The insert element is visible due to through-holes 640 in the fabric 600.

[0075] The fabric layers form a cavity 610 to hold 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 offers aesthetic appeal but also improves breathability and flexibility. The visibility through the holes can also serve functional purposes, such as indicating the correct positioning of the insert or providing additional grip. This method combines protection, comfort, and design innovation in the sporting goods product.

[0076] Fig. Figure 7 illustrates a schematic view of a fabric with two insert elements within two cavities and a fabric with three insert elements within three cavities. The first fabric 710 comprises a first and a second cavity 711, 712, which hold a first and a second insert element 7001, 7002. In this way, a stacked arrangement is formed by the layers of fabric 710 and the insert elements 7001, 7002, thus creating a sandwich structure. The second fabric 720 comprises a first, a second, and a third cavity 721, 722, 723, which hold a first, a second, and a third insert element 7001, 7002, 7003. In this way, a stacked arrangement is formed by the layers of fabric 720 and the insert elements 7001, 7002, 7003, thus creating a sandwich structure.

[0077] The first fabric, 710, with two cavities (711, 712) and insert elements (7001, 7002), can be used, for example, for shin guards, with each insert providing targeted protection and cushioning. The second fabric, 720, with three cavities (721, 722, 723) and insert elements (7001, 7002, 7003), can be used for more complex sporting goods, with multiple layers offering enhanced shock absorption and coverage. The sandwich structure ensures that each insert element is securely held between the fabric layers, providing a robust, durable, and effective protective solution. This allows for customized levels of protection by varying the number and type of insert elements used. Each insert element can provide different functionality and can be made from different materials for this purpose.

[0078] Fig. Figure 8 illustrates a schematic view of a fabric with three insert elements as a component for a shoe. The fabric 800 is designed as part of a shoe upper. The insert element 8003 on the front part of the fabric 800 serves as a toe reinforcement, and the insert elements 8001 and 8002 serve as eyelet reinforcement.

[0079] The 800 fabric used for the upper incorporates three strategically placed inserts: 8001, 8002, and 8003. The 8003 toe reinforcement provides added protection and durability to the front of the shoe. The 8001 and 8002 eyelet reinforcements ensure that the lacing areas are stronger and more resistant to wear. This design enhances the overall performance, durability, and comfort of the shoe, making it suitable for rigorous athletic use. The integration of these inserts within the fabric ensures a seamless, lightweight, and aesthetically pleasing shoe construction.

[0080] Fig. Figure 9 illustrates in a schematic view a material with four incorporating elements as a counter-component to Fig. 8. Fabric 900 is designed as a counterpart to the upper shoe component made of Fig. 8. The insert elements 9001 and 9002 of the fabric can serve as a lacing reinforcement. The insert element 9004 on the middle and upper part of the fabric 900 can serve as a heel foam padding. The insert element 9005 on the middle and lower part of the fabric 900 can serve as a heel reinforcement.

[0081] The fabric 900 is the counterpart to the fabric made of Fig. The 9 incorporates four insert elements—9001, 9002, 9004, and 9005—strategically placed for enhanced functionality. Lace reinforcements 9001 and 9002 ensure durable and secure lacing areas, improving fit and stability. Heel foam padding 9004 adds comfort and shock absorption to the heel area, while heel reinforcement 9005 provides additional structural support and protection. This improves the overall performance, comfort, and durability of the shoe, making it ideal for intense athletic activities. The integration of these elements within the fabric ensures a streamlined, lightweight, and efficient shoe design.

[0082] Fig. Figure 10 shows a photograph of the manual insertion of an insert element 10000 into a knitting machine, in particular a flat knitting machine.

[0083] Fig. Figure 11 shows a close-up photograph of the insertion of the insert element 10000 from Fig. 10 into a knitting machine.

[0084] Fig. Figure 12 shows a side view photograph of the insertion of the 10000 insert element. Fig. 10 into a knitting machine. As can be seen, the insert element is placed between the needle beds.

[0085] Fig. Figure 13 illustrates a reverse side photograph of fabric 900 with the insert elements 9001, 9002, 9004, 9005 from Fig. 9. The surface shown corresponds to the reverse side of the footwear element; however, from a technical perspective, it represents the front side of the knitted material as produced by the knitting machine.

[0086] Fig. Figure 14 shows a front view photograph of fabric 900 with the insert elements 9001, 9002, 9004, 9005 made of Fig. 9. The surface shown represents the inside of the footwear element; however, it corresponds to the reverse side of the knitted material as it emerges from the knitting machine.

[0087] Fig. Figure 15 shows a front view photograph of fabric 800 with insert elements 8001, 8002, 8003 made of Fig. 8.

[0088] Fig. Figure 16 shows a close-up of fabric 800 with insert elements 8001, 8002, 8003 made of Fig. 8.

[0089] Fig. Figure 17 illustrates a photograph of a fabric with an insert element 17000 as a tongue reinforcement of a shoe tongue.

[0090] Fig. Figure 18 shows a close-up of the fabric with the insert element 17000 made of Fig. 17. Reference symbol list: 100, 200, 300, 500, 600, 710, 720, 800, 900 fabric 101, 201, 301, 501 first shift 102, 202, 302, 502 second shift 110, 210, 310, 510, 610, 711, 712, 721, 722, 723 cavity 150 needles 200', 300' shrunken fabric 220 Opening 530 stretch yarn 532 empty volume 640 holes 1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000 insert element 8001, 8002, 9001, 9002 Lace reinforcement 8003 Toe reinforcement 9004 Heel foam padding 9005 Heel reinforcement 17000 tongue amplification QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 9 538 803 B2

[0003]

Claims

A method for manufacturing a sporting goods article comprising a knitting process, wherein the knitting process comprises the following steps: a.) providing 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) has at least one open cavity (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.) Inserting at least one insert element into the at least one open cavity (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) while the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) remains in the knitting machine; and d.) further knitting of the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) such that the at least one cavity (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is at least partially closed around the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) by joining the at least two layers. Method according to claim 1, wherein the method does not include cutting the knitted fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) to create the open cavity (110, 210, 310, 510, 610, 711, 712, 721, 722, 723). Method according to claim 1 or claim 2, wherein the material (100, 200, 300, 500, 600, 710, 720, 800, 900) is continuously held on the knitting machine during steps b.)-d.). Method according to one of the preceding claims, wherein the insertion of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is carried out automatically, preferably by feeding the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) from a storage area. Method according to one of the preceding claims, wherein the insertion of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is carried out manually by an operator. Method according to one of the preceding claims, wherein the knitting machine count is a maximum of 18. Method according to one of the preceding claims, wherein after step b.) the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises more than two layers and two or more cavities defined between them, such that after the insertion of the insert elements the insert elements and the layers are stacked alternately. A method according to any of the preceding claims, wherein the height of the cavity (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is greater than the height of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) and / or the width of the cavity (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is greater than the width of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000). Method according to one of the preceding claims, wherein at least one insert element is fixed in the cavity (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) by the yarn extending through the insert element. Method according to one of the preceding claims, wherein the yarn comprises a shrinkable yarn and the method comprises a shrinking step, such that the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) adapts around the cavity to the contour of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), wherein the shrinking is preferably achieved by applying heat. Method according to 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 an elastic and / or shrinkable yarn and another layer comprises a non-elastic and / or non-shrinkable yarn. Method according to any of the preceding claims, wherein the yarn comprises an elastic and / or shrinkable yarn. Method according to one of the preceding claims, wherein one of the layers comprises a melt yarn adapted to form a bond with the insert element(s) when fused. Method according to claim 13, wherein the melt yarn is also a shrinkable yarn. Method according to any of the preceding claims, wherein the yarn comprises a non-elastic and / or non-shrinkable yarn comprising polyester. A method according to any of the preceding claims, wherein the yarn comprises a shrinkable yarn and the cavity has one or more opening(s) (220) that is / are smaller than the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), and the method comprises a shrinking step such that, after shrinking the yarn, the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) extends / extend partially through the opening(s) (220). Method according to any of the preceding claims, wherein the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprises / comprise reinforcing means and / or damping means. Method according to one of the preceding claims, wherein the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprises (or comprises) magnets. Method according to one of the preceding claims, wherein the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprises one or more electronic components, preferably microchips. A method according to any of the preceding claims, wherein the sporting goods are a shoe. Method according to one of the preceding claims, wherein the sporting goods are clothing. Sporting goods obtained by a process according to any of the preceding claims.

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