Multilayer footwear and methods of making thereof

Abstract

Provided herein are knitted footwear garments comprising a first layer, a second layer, a third layer, a midsole, and an outsole, wherein the first layer is configured to contact the foot of the garment wearer, wherein the third layer is coupled to and in contact with the first layer and the second layer, wherein the midsole is disposed between the second layer and the third layer, and wherein the outsole is coupled to an outer surface of the third layer.

Description

MULTILAYER FOOTWEAR AND METHODS OF MAKING THEREOFCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority benefit to U.S. Provisional Patent Application No. 63 / 516,477, filed July 28, 2023, which is entitled “Multilayer Footwear and Methods of Making Thereof,” and which is incorporated by reference herein in its entirety and for all purposes.BACKGROUND

[0002] Existing technologies for manufacturing outer footwear have relied on a labor- intensive process of fabricating and assembling multiple layers. In many cases, a single layer of an article of outer footwear can require fabrication and assembly of multiple separate components, using existing technologies. Separately, many types of outer footwear are intended to be used with a separate article of clothing (e.g., a sock or stocking), which can add to overall cost to consumers and can increase the overall cost and logistical complexity of manufacturing the end footwear system.SUMMARY

[0003] In various embodiments, a footwear garment comprises: a first layer comprising a first knit fabric; a second layer comprising a second knit fabric; a third layer comprising a third knit fabric; and a midsole in direct contact with an inner surface of the second layer and at least a portion of an outer surface of the third layer, wherein the first layer is fabricated on at least a portion of an inner surface of the third layer, and wherein an inner surface of the first layer is configured to contact at least a portion of a foot of a wearer of the footwear garment. In various embodiments, a footwear garment comprises: an inner first layer comprising a first knit fabric; an outer second layer comprising a second knit fabric; a middle third layer comprising a third knit fabric; a space between an outer surface of the third layer and an inner surface of the second layer configured to receive a midsole; and a space bounded an inner surface of the first layer and, optionally, an inner surface of the third layer, wherein the space is configured to receive a foot of a wearer of the footwear garment such that at least a portion of the first layer contacts at least a portion of the foot. In some embodiments, the midsole is in direct contact with the second layer and the third layer. In some embodiments, the footwear garment further comprises an outsole. In some embodiments, the outsole is in contact with an outer surface of the second layer. In some embodiments, the first layer comprises a hydrophilic fiber or a semi-hydrophilic fiber. In some embodiments, the third layer comprises a hydrophilic fiber. In some embodiments, thehydrophilic fiber of the third layer is more hydrophilic than the hydrophilic fiber of the first layer. In some embodiments, the footwear garment is manufactured using circular knitting technology. In some embodiments, one or more of the first layer, the second layer, the third layer, and the midsole are recyclable materials. In some embodiments, the midsole is made of recycled materials from one or more of a first layer material, a second layer material, or a third layer material. In some embodiments, the footwear garment does not comprise an insole. In some embodiments, the outsole is fabricated from a durable material, optionally wherein the outsole is fabricated from a material comprising a natural rubber or a synthetic rubber. In some embodiments, the footwear garment further comprises a cuff directly coupled to a proximal end of the third layer and directly coupled to a distal end of the second layer. In some embodiments, the cuff comprises a ribbed knitted fabric. In some embodiments, the first layer and third layer are fabricated together using a double-knitting technique. In some embodiments, the first layer, second layer, or the third layer comprises at least two portions having different textures. In some embodiments, the at least two portions having different textures comprise a plurality of bumps fabricated in the respective layer.

[0004] In various embodiments, a footwear garment comprises: a first layer comprising a first knit fabric; a second layer comprising a second knit fabric; a third layer In various embodiments, a method of manufacturing a knitted footwear garment, comprising: knitting a tube-shaped structure comprising a first layer, a second layer, and a third layer, the first layer and third layer being concentric with one another around a longitudinal axis of the structure, and the second layer being concentric around the longitudinal axis but not concentric with the first layer or third layer, wherein a distal end of the second layer is coupled to a proximal end of the third layer at a first end or to a cuff that is coupled directly to a distal end of the second layer; sealing a distal opening of the tube-shaped structure at the distal end of the third layer; folding the second layer over an outer surface of the third layer; inserting a midsole through a proximal opening of the tube-shaped structure; and coupling an outsole to an outer surface of the second layer. In some embodiments, the distal end of the second layer is coupled to a proximal end of the first layer. In some embodiments, the cuff is coupled directly to the distal end of the first layer. In some embodiments, the first layer comprises a hydrophilic fiber or a semi-hydrophilic fiber. In some embodiments, the third layer comprises a hydrophilic fiber. In some embodiments, the hydrophilic fiber of the third layer is more hydrophilic than the hydrophilic fiber of the first layer. In some embodiments, the footwear garment is manufactured using circular knitting technology. In some embodiments, one or more of the first layer, the second layer, the third layer, and the midsoleare recyclable materials. In some embodiments, the midsole is made of recycled materials from one or more of a first layer material, a second layer material, or a third layer material. In some embodiments, the footwear garment does not comprise an insole. In some embodiments, the outsole is fabricated from a durable material, optionally wherein the outsole is fabricated from a material comprising a natural rubber or a synthetic rubber.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations .

[0006] FIG. 1 shows a footwear garment comprising an inner first layer, an outer second layer, a middle third layer, a midsole, and an outsole, in accordance with embodiments.

[0007] FIG. 2 shows method steps in the manufacture of a footwear garment described herein, in accordance with embodiments.

[0008] FIG. 3A shows a knitted tube-shaped structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, a third layer, and a cuff, in accordance with embodiments. FIG. 3B shows a see-through view of the knitted tube-shaped structure shown in FIG. 3A, in accordance with embodiments.

[0009] FIG. 4A shows a knitted tube-shaped structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, and a third layer, in accordance with embodiments. FIG. 4B shows a see-through view of the knitted tube-shaped structure shown in FIG. 4 A, in accordance with embodiments.

[0010] FIG. 5A shows a knitted tube-shaped structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, and a third layer, wherein the first layer is configured to contact a portion but not all of the foot, in accordance with embodiments. FIG. 5B shows a different embodiment of a knitted tube-shaped structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, and a third layer, wherein the first layer is configured to contact a portion but not all of the foot, in accordance with embodiments.

[0011] FIG. 6A shows a knitted tube-shaped structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, a third layer, and a cuff, wherein the first layer is configured to contact a portion but not all of the foot, in accordance with embodiments. FIG. 6B shows a different embodiment of a knitted tube-shaped structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, athird layer, and a cuff, wherein the first layer is configured to contact a portion but not all of the foot, in accordance with embodiments.

[0012] FIGs. 7A, 7B, and 7C show views of a knitted tube-shaped structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, a third layer, and a cuff, in accordance with embodiments. FIG. 7B shows a perspective view of the side of the knitted tube-shaped structure, in accordance with embodiments. FIG. 7A shows a perspective view of a distal end of the knitted tube-shaped structure, viewed in parallel with the longitudinal axis of the knitted tube-shaped structure shown in FTG. 7B, in accordance with embodiment. FIG. 7C shows a perspective view of a proximal end of the knitted tube-shaped structure, viewed in parallel with the longitudinal axis of the knitted tube-shaped structure shown in FIG. 7B, in accordance with embodiments.

[0013] FIGs. 8A, 8B, and 8C show views of the knitted structure useful in the manufacture of a footwear garment comprising a first layer, a second layer, a third layer, and a cuff shown in FIGs. 7A, 7B, and 7C, respectively, wherein the distal end of the knitted tube-shaped structure has been sealed with a seam, in accordance with embodiments. FIG. 8B shows a perspective view of the side of the knitted tube-shaped structure, in accordance with embodiments. FIG. 8A shows a perspective view of a distal end of the knitted tube-shaped structure, viewed in parallel with the longitudinal axis of the knitted tube-shaped structure shown in FIG. 8B, in accordance with embodiment. FIG. 8C shows a perspective view of a proximal end of the knitted tube-shaped structure, viewed in parallel with the longitudinal axis of the knitted tube-shaped structure shown in FIG. 8B, in accordance with embodiments.

[0014] FIGs. 9A, 9B, and 9C show views of the knitted structure of FIG. 8B during a method of manufacturing of a footwear garment described herein, in accordance with embodiments. FIG. 9A shows a perspective view of the side of the knitted structure, in accordance with embodiments. FIG. 9B shows the knitted structure of FIG. 9A, wherein the proximal end of the knitted structure has been folded over a portion of the knitted structure, in accordance with embodiment. FIG. 9C shows the knitted structure of FIG. 9B, wherein the proximal end of the knitted structure has been further folded over a portion of the outer surface of the third layer of the knitted structure, in accordance with embodiment.

[0015] FIGs. 10A, 10B, and 10C show views of a knitted structure during a method of manufacturing of a footwear garment described herein, in accordance with embodiments. FIG. 10A shows a second layer folded over an outer surface of a third layer, in accordance with embodiments. FIG. 10B shows the knitted structure of FIG. 10 A, wherein the second layer has been folded further over the outer surface of the third layer of the knitted structure,in accordance with embodiment. FIG. IOC shows the knitted structure of FIG. 10B, wherein the second layer has been folded completely over the outer surface of the third layer of the knitted structure, creating a space between the outer surface of the third layer of the knitted structure and the inner surface of the second layer configured to receive a midsole, in accordance with embodiment.

[0016] FIG. 11 shows a midsole being inserted through a proximal opening of the knitted footwear garment of FIG. 10C and into a space between the outer surface of the third layer and an inner surface of the second layer, in accordance with embodiments.

[0017] FIG. 12A shows the knitted footwear garment of FIG. 11 being coupled to an outsole, in accordance with embodiments. FIG. 12B shows the knitted footwear garment of FIG. 12A after an outsole has been coupled to an outer surface of the second layer of the knitted footwear garment, in accordance with embodiments.

[0018] FIG. 13A shows the knitted footwear garment of FIG. 11 being coupled to an outsole, in accordance with embodiments. FIG. 13B shows the knitted footwear garment of FIG. 13 A after the proximal opening of the knitted footwear garment has been sealed, in accordance with embodiments. FIG. 13C shows the knitted footwear garment of FIG. 13B being coupled to an outsole, in accordance with embodiments. FIG. 13D shows the knitted footwear garment of FIG. 13C after an outsole has been coupled to an outer surface of the second layer of the knitted footwear garment, in accordance with embodiments.

[0019] FIG. 14A shows an exterior view of the knitted footwear garment of FIG. 13C being coupled to an outsole, in accordance with embodiments. FIG. 14B shows the knitted footwear garment of FIG. 14 A after the outsole has been coupled to an outer surface of the second layer of the knitted footwear garment, in accordance with embodiments.

[0020] FIGs. 15A and 15B show images of knitted footwear garments, in accordance with embodiments.

[0021] FIGs. 16A and 16B show a knitted footwear garment and a sideview of the knitted tube-like structure useful in fabricating the knitted footwear garment, respectively, in accordance with embodiments.

[0022] FIGs. 17A and 17B show a knitted footwear garment and a sideview of the knitted tube-like structure useful in fabricating the knitted footwear garment, respectively, in accordance with embodiments.

[0023] FIGs. 18A and 18B show a knitted footwear garment and a sideview of the knitted tube-like structure useful in fabricating the knitted footwear garment, respectively, in accordance with embodiments.

[0024] FIGs. 19A and 19B show a knitted footwear garment and a sideview of the knitted tube-like structure useful in fabricating the knitted footwear garment, respectively, in accordance with embodiments.

[0025] FIG. 20A shows a photograph of a knitted tube-like structure comprising a first layer, a second layer, a third layer, and a cuff, in accordance with embodiments. FIG. 20B shows a photograph of the knitted tube-like structure of FIG. 20A after the outer second layer has been folded over the outer surface of the third layer, in accordance with embodiments. FIG. 20C shows a photograph of the knitted tube-like structure of FIG. 20B after the outer second layer has been folded further over the outer surface of the third layer, in accordance with embodiments. FIG. 20D shows a photograph of the knitted tube-like structure of FIG. 20C after a midsole has been inserted between the outer surface of the third layer and the inner surface of the outer second layer, in accordance with embodiments. FIG. 20E shows a photograph of the knitted tube-like structure of FIG. 20D after the outer second layer has been folded completely over the outer surface of the third layer, following insertion of the midsole, in accordance with embodiments.

[0026] FIG. 21A shows a perspective view of a midsole useful in footwear garments or portions described herein, in accordance with embodiments. FIG. 21B shows a bottom view of a midsole useful in footwear garments or portions thereof described herein, in accordance with embodiments.

[0027] FIG. 22A shows a perspective view of a midsole cover useful in footwear garments or portions described herein, in accordance with embodiments. FIG. 22B shows a bottom view of a midsole cover useful in footwear garments or portions thereof described herein, in accordance with embodiments.

[0028] FIG. 23 shows a method of assembling a midsole hammock, in accordance with embodiments.

[0029] FIG. 24A shows a perspective view of a midsole as shown in FIG. 21 A and midsole cover as shown in FIG. 22A, assembled into a midsole hammock useful in footwear garments or portions described herein, in accordance with embodiments. FIG. 24B shows a bottom view of a midsole as shown in FIG. 2 IB and a midsole cover as shown in FIG. 22B, assembled into a midsole hammock useful in footwear garments or portions thereof described herein, in accordance with embodiments.DETAILED DESCRIPTION

[0030] Described herein are methods, systems, and articles of manufacture related to articles of attire, including footwear garments 100 (e.g., a “unified shoe system”) comprisinga plurality of fabric layers (e.g., a plurality of knitted fabric layers). For example, triple-layer footwear garments 100 can be selected or engineered as described herein to offer moisture management through selection and configuration of the constituent layers comprising the garments while also offering a comfortable and flexible fit and durable foot protection. In some cases, a footwear garment 100 described herein can comprise a first layer 110, (e.g., inner first layer 110); a second layer 120, (e.g., outer second layer 120); and a third layer 130, (e.g., middle third layer 130), wherein at least a portion of the first layer (and, optionally, at least a portion of the third layer) is configured to be in contact with at least a portion of a wearer’s foot and / or leg 101, for example, as shown in FIG. 1.

[0031] As described herein, a footwear garment 100 comprising a plurality of fabric layers (e.g., including a first layer 110, (e.g., inner first layer 110); a second layer 120, (e.g., outer second layer 120), and a third layer 130, (e.g., middle third layer 130)) can be fabricated as a single piece of knitted fabric (e.g., a single knitted structure, not counting midsole or outsole, if present in the final footwear garment). For example, FIG. 3A - FIG. 20E show footwear garments or portions thereof comprising a plurality of fabric layers. In some cases, a footwear garment can comprise no more than two fabric layers (e.g., an inner first layer 110 and an outer second layer 120). In some cases, a footwear garment can comprise no more than three fabric layers (e.g., an inner first layer 110, and outer second layer 120, and a middle third layer 130). In some cases, two or more layers of a footwear garment can be fabricated (e.g., knitted) together as a single fabric (e.g., a fabric having a first fabric layer (e.g., first layer 1 10) and a second fabric layer (e.g., third layer 130)), for example, using double-knitting techniques or the like. In some cases, a footwear garment 100 fabricated as a single piece of knitted fabric can be seamless, which can improve comfort and / or aesthetic appeal of the footwear garment. As described herein, a footwear garment 100 comprising a single piece of knitted fabric (e.g., a single tube-like fabric structure) can reduce time, logistical complexity, and cost of fabrication.

[0032] As described herein, a footwear garment 100 comprising a single piece of knitted fabric can be fabricated using circular knitting technology (e.g., using a circular knitting machine). In some cases, the use of a programmable circular knitting machine can further increase efficiency of manufacturing some footwear garments 100 described herein, for example, by pre-programming the programmable circular knitting machine to execute one or more steps of a method for manufacturing a footwear garment 100 described herein, such as step 202 of method 200 shown in FIG. 2. Circular knitting technology can be especially well- suited for fabricating tube-shaped fabric structures disclosed herein. For instance, a “tube-shaped” fabric structure (e.g., as shown in FIGs. 3A-7C or 20A) can be used to fabricate a footwear garment 100 described herein. As will be understood from the disclosures herein by a person of skill in the art, a “tube-shaped” fabric structure can be cylindrical in shape or non- cylindrical in shape (e.g., “banana-shaped”). For example, the fabric structure fabricated using cylindrical knitting technology can have a bend (e.g., wherein the bend is formed by knitting additional material around some but not all of the circumference of the “tube” structure for at least a portion of the length of longitudinal axis of the “tube” shape, between the proximal end and distal end of the fabric structure, e.g., to accommodate the shape of the heel of the foot. Accordingly, a longitudinal axis 170 of a “tube-shaped” or “tube- like” fabric structure described herein can be a straight line or a curved line (e.g., wherein the curved line represents an axis of concentricity for the fabric structure and / or one or more layers thereof, including the first layer, the third layer, and / or the second layer). In some cases, cylindrical knitting technology can be used to create a fabric structure having a non-cylindrical (e.g., curved tube) shape that is useful in the fabrication of a footwear garment 100 described herein. In some cases, a fabric structure can be fabricated with one or more gore lines 172 (e.g., as shown in FIG. 15A, 15B, and 18A-19B), for example, to introduce a curve to the fabric structure (e.g., “tube-shaped,” or “banana-shaped”), which can aid in forming a comfortably shaped footwear garment 100 structured to accommodate the heel of a wearer. In some cases, gore lines (and / or a curved or non-cylindrical shape to a “tube-shaped” fabric structure) can be introduced during the cylindrical process. This can be advantageous, as “tube-shaped” fabric structures described herein (e.g., comprising one, two, three, or more than three layers) can be fabricated efficiently in the knitting process, without the need to join separate pieces of fabric to form a non-cylindrical “tube-shaped” fabric structure (e.g., having gore lines 172). In some cases, a fabric structure created using cylindrical knitting technology can have one gore line 172. In some cases, a fabric structure created using cylindrical knitting technology can have a plurality of gore lines 172. In some cases, gore lines 172 can be created in more than one layer of a fabric structure described herein using cylindrical knitting, for example, at a corresponding position along a longitudinal axis of the fabric structure in each layer.

[0033] One or more components of a footwear garment 100 described herein can be recyclable (e.g., made of recyclable materials, preferably wherein the footwear garment comprises one or more components made entirely of recyclable materials). In many cases, all components of a footwear garment 100 (e.g., first (e.g., inner) layer 110, second (e.g., outer) layer 120, third (e.g., middle) layer 130, midsole 140, and outsole 150, and, optionally, cuff160) can be recyclable (e.g., made of recyclable materials, preferably wherein each component is made entirely of recyclable materials). In many cases, one or more of the fabric layers of footwear garment 100 and preferably all fabric layers of footwear garment 100 can be recycled to produce a midsole 140 or portion thereof, useful in the construction of a footwear garment 100).

[0034] Advantageously, footwear garments 100 described herein can be constructed without the need for an insole. In some cases, selection of fabrics (and, in some cases, yarns comprising the fabrics) for use in footwear garments 100 can provide effective water management properties to the footwear garments 100 (e.g., as described herein) and can eliminate the need for absorptive properties of an insole. Furthermore, the water management properties of footwear garments 100 described herein (e.g., water management properties, including wicking and water absorption, of the system of multiple fabric layers of footwear garments described herein) can allow for faster and more complete drying of footwear garments described herein as compared to articles of footwear comprising an insole, which can reduce the risk or extent of odor. In some cases, a fabric layer (e.g., a first layer, or a third layer) or a midsole of a footwear garment 100 described herein can comprise an anti-bacterial material (for instance, a yarn with antibacterial or antibiotic properties, e.g., an antibacterial polymer such as antibacterial polyester), which can further reduce the risk or extent of odor in footwear garments 100 described herein. In some cases, one or more yams of a fabric layer (e.g., a first layer, a third layer, or a midsole cover) can comprise one or more of a bamboo fiber, a wool fiber, a copper thread, and / or a jade thread. For example, one or more yams used to create a fabric layer of a footwear garment or portion thereof (e.g., a first layer, a second layer, a third layer, or a midsole cover) can comprise 1% to 25%, 25% to 35%, 35% to 50%, 50% to 75%, or more than 75% of a bamboo fiber, a wool fiber, a copper thread, or a jade thread, for instance to confer an antibacterial / antimicrobial benefit or an aesthetic or tactile benefit on the footwear garment. The provision of a midsole 140 (e.g., a shaped midsole) can provide sufficient structural support to footwear garments 100 described herein as to obviate the need for structural support provided by an insole. By avoiding the need for an insole, footwear garments 100 described herein can have increased flexibility and comfort compared to an article footwear comprising an insole.

[0035] Preferably, footwear garments 100 described herein can be constructed without using hot melt technology (e.g., hot melt yarns). In some embodiments, hot melt yarns can be used to construct a portion of a footwear garment 100 (for instance, one or more layers of a footwear garment 100 can comprise one or more hot melt yarns, in some cases), but it ispreferable to use only fabric (e.g., knitted fabric) construction without for producing first layer 110 fabric and third layer 130 fabric of footwear garments 100 described herein, as footwear garments can exhibit greater flexibility and comfort without the use of hot melt technology to construct the footwear garment. As described herein, hot melt yams can be useful in the fabrication of a knitted midsole cover 142, e.g., for the construction of a midsole hammock 148.Footwear Garment Construction

[0036] Footwear garments 100 can comprise a plurality of fabric layers (e.g., a plurality of knitted fabric layers). In some cases, a footwear garment 100 can consist or consist essentially of knitted fabric (e.g., two, three, or more than three knitted fabric layers (e.g., comprising a first layer, a second layer, and a third layer disclosed herein), and, optionally, a knitted cuff 160). In some cases, a footwear garment 100 can consist or consist essentially of knitted fabric (e.g., two, three, or more than three knitted fabric layers (e.g., comprising a first layer, a second layer, and a third layer disclosed herein), and, optionally, a knitted cuff 160) and a non-knitted midsole 140. A midsole 140 can provide mechanical structure to the footwear garment 100 and can provide an advantageous shape to the footwear garment 100 (e.g., a desired aesthetic shape and / or a comfortable and / or orthopedic fit, which can be a personalized fit based on a specific individual’s foot shape). In some cases, a footwear garment 100 can consist or consist essentially of knitted fabric (e.g., two, three, or more than three knitted fabric layers (e.g., comprising a first layer, a second layer, and a third layer disclosed herein), and, optionally, a knitted cuff 160), a non-knitted midsole 140, and a nonknitted outsole 150. An outsole 150 can provide a footwear garment 150 with increased durability, increased comfort for a wearer on uncomfortable or injurious walking surfaces, and additional structural shape or aesthetic appeal. In some cases, a footwear garment 100 can comprise an additional shaping device (e.g., comprising a cardboard or plastic insert) installed within a space (e.g., a chamber, such as in the heel region of the footwear garment) of the footwear garment 100, for example, to provide additional structural support to the footwear garment 100. In some cases, a melting yarn can be used to provide structure in the heel region of the footwear garment 100; however, use of melting yarn is preferably avoided (e.g., such that no melting yarn is present in the footwear garment 100) in many embodiments, for example, to increase flexibility and comfort of the footwear garment. In some embodiments, a footwear garment can comprise a cuff 160 (e.g., a true ribbed-knit cuff 160), which can aid in maintaining the shape and / or comfortable fit of footwear garments 100 described herein.

[0037] In some cases, one or more fabric materials or fabric layers of a footwear garment 100 described herein can comprise one or more types of threads, fibers, or microfilaments. In some cases, inclusion of micro filaments in a fabric or fabric layer of a footwear garment 100 can increase the surface area of the threads or yarns in the fabric or fabric layer, which can affect the hydrophobicity and / or water management properties (e.g., wicking and / or water absorption) of the fabric or fabric layer. In some cases, a microfilament can have a weight of approximately 100 denier per 120 microfilaments.

[0038] A first layer 1 10 (e.g., a first layer 110) of a footwear garment 100 can be in contact with all or a portion of a wearer’s foot and / or leg 101. In some cases, a footwear garment 100 can be constructed such that a first layer 110 is shaped, sized, and positioned in the footwear garment 100 so that the first layer 110 contacts one or more of: the sole (or a portion thereof); one, two, three, four, or five of the toes (or a portion of one or more toes); the instep (or a portion thereof); the heel (or a portion thereof); the ankle (or a portion thereof); the top of the foot (or a portion thereof); or the leg (or a portion thereof). In some cases, a footwear garment 100 described herein can be fabricated such that a first layer 110 of the footwear garment is configured to contact only the bottom (sole) of a wearer’ s foot and heel and the bottoms of the wearer’s toes (and optionally the instep) but not the top of the foot or toes or the ankle, e.g., so that only one or two layers of fabric (e.g., second layer and / or third layer) are configured to contact the upper portions of the wearer’s foot and ankle (and, optionally, leg), which can provide improved airflow, breathability, and comfort to the wearer compared to a footwear garment having three layers of fabric surrounding the upper portions of the wearer’s foot (and ankle and, optionally, leg).

[0039] A first layer 110 of a footwear garment 100 can consist of or consist essentially of a knitted material (e.g., a knitted fabric). A first layer (e.g., a first layer 110) can comprise a hydrophilic or semi-hydrophilic fabric (e.g., a knitted material comprising one or more hydrophilic or semi-hydrophilic fibers). In some cases, a hydrophilic material or a semi- hydrophilic fiber can be more comfortable against the skin of a wearer than a hydrophobic fiber. In some embodiments, it can be preferable to use a fabric that is hydrophilic (e.g., a knitted material comprising one or more hydrophilic or semi -hydrophilic fibers) but is less hydrophilic than a portion of a third layer 130 in contact with the first layer 110, for example, to encourage movement of water (e.g., from sweat) from the first layer to the more hydrophilic third layer.

[0040] In some cases, a first layer 110 can be fabricated as a layer physically separate from any other layer (e.g., third layer 130 and second layer 120) of a footwear garment 100. Insome cases, a first layer 110 can be fabricated as an inner aspect or inner surface of a different layer. In some embodiments, a first layer 110 can be fabricated as an inner aspect or inner surface of a third layer 130, for example, by using a double- knitting technique to fabricate a first layer 1 10 section on the third layer 130 (e.g., wherein the third layer 130 comprises yarns with higher hydrophilicity than the yams of first layer 110, optionally, wherein the first layer 110 comprises semi-hydrophilic or hydrophilic yarns). FIGs. 5 A and 5B shows examples of a “tube-shaped” fabric structure useful in fabricating a footwear garment 100, wherein a portion of the third layer 130 has been fabricated using a doubleknitting technique to create a first layer 110 integrated with the third layer 130. In this fashion, a first layer 110 can be created on all or a portion of an inner surface 130a of the third layer 130, e.g., to improve comfort and / or water management of the footwear garment 100.

[0041] In some cases, the fabric of a first layer 110 can comprise two or more portions having different textures or thicknesses. For example, a first layer 110 can comprise shaped regions of increased thickness, increased hardness, and / or increased density in the fabric, e.g., by using double-knitting and / or incorporation of hot melt yams along with selective application of heat to the hot melt yarns. In some cases, a region of a first layer 1 10 having increased fabric thickness (e.g., as a result of double-knitting) can be further increased in firmness or density (e.g., by fabricating the first layer 110 using hot melt yarns and selectively heating the regions of increased thickness). Regions of increased thickness, hardness, and / or density in a first layer 110 can appear as bumps in the fabric and can feel like bumps against the foot of a wearer. In some cases, the presence of and / or configuration of regions of increased thickness, hardness, or density (e.g., bumps) in a first layer 110 can improve traction for a wearer. In some cases, such regions may improve blood flow in the foot or leg of a wearer and / or improve recovery from exercise or injury.

[0042] A third layer 130 (e.g., a middle layer 130) of a footwear garment 100 can consist of or consist essentially of a knitted material (e.g., a knitted fabric). In some cases, third layer 130 can comprise a material (e.g., a knitted material) that is not present in first layer 110. In some cases, third layer 130 can comprise a material (e.g., a knitted material) that is not present in second layer 120. In some cases, third layer 130 can consist of or consist essentially of a material (e.g., a knitted material) that is not present in first layer 110. In some cases, third layer 130 can consist of or consist essentially of a material (e.g., a knitted material) that is not present in second layer 120. A third layer 130 can comprise a hydrophilic fabric (e.g., a knitted material comprising one or more hydrophilic fibers). In someembodiments, it can be preferable to use a fabric or filament in at least a portion of the third layer 130 that is more hydrophilic than a portion of the first layer 110 in contact with, adjacent to, or in close proximity to the portion of the third layer 130, for example, to encourage movement of water (e.g., sweat) from the first layer to the more hydrophilic third layer 130.

[0043] In some cases, the fabric of a third layer 130 can comprise two or more portions having different textures or thicknesses. For example, a third layer 130 can comprise shaped regions of increased thickness, increased hardness, and / or increased density in the fabric, e.g., by using double-knitting and / or incorporation of hot melt yams along with selective application of heat to the hot melt yarns. In some cases, a region of a third layer 130 having increased fabric thickness (e.g., as a result of double-knitting) can be further increased in firmness or density (e.g., by fabricating the third layer 130 using hot melt yarns and selectively heating the regions of increased thickness). Regions of increased thickness, hardness, and / or density in a third layer 130 can appear as bumps in the fabric and can feel like bumps against the foot of a wearer. In some cases, the presence of and / or configuration of regions of increased thickness, hardness, or density (e.g., bumps) in a third layer 130 can improve traction for a wearer. In some cases, such regions may improve blood flow in the foot or leg of a wearer and / or improve recovery from exercise or injury.

[0044] A second layer 110 (e.g., an outer second layer 120) of a footwear garment 100 can consist of or consist essentially of a knitted material (e.g., a knitted fabric). A second layer 120 (e.g., outer second layer 120) can comprise a hydrophobic fabric (e.g., a knitted material comprising one or more hydrophobic fibers). In some cases, second layer 120 can comprise fibers that are more hydrophobic than fibers of first layer 110 and / or more hydrophobic of third layer 130 (e.g., to prevent or reduce the likelihood of water or another liquid penetrating the second (e.g., outer) layer 120 from outside of the footwear garment 100 to contact the first layer 110 and or the third layer 130). In some embodiments, it can be preferable to use a fabric that has desirable aesthetic qualities (e.g., texture, color, luster, or reflectivity) for the second (e.g., outer) layer 120 (or, in some cases, for the outer surface 120b of the outer, second layer). In some embodiments, it can be preferable to use a fabric that has desirable mechanical or structural properties (which can be achieved, for example, by altering the angle of the yams, increasing or decreasing yam or filament count, and / or increasing or decreasing the elasticity or diameter of the yarns or microfilaments) for the second layer 120. In some cases, second layer 120 can comprise a material (e.g., a knitted material) that is not present in first layer 1 10. In some cases, second layer 120 can comprise a material (e.g., a knittedmaterial) that is not present in third layer 130. In some cases, second layer 120 can consist of or consist essentially of a material (e.g., a knitted material) that is not present in first layer 110. In some cases, second layer 120 can consist of or consist essentially of a material (e.g., a knitted material) that is not present in third layer 130. In some cases, second layer 120 can be fabricated to comprise multiple sections of different materials (e.g., having different textures, colors, or other optical or tactile properties or having different structural properties), for example, as shown in FIGs. 16A-16B, 17A-17B, 18A-18B, and 19A-19B. In some cases, one or more portions 126 of a second layer 120 (and / or a third layer 130 and / or a first layer 1 10) can be fabricated (e.g., using circular knitting) to comprise one or more holes (e.g., as shown in FIG. 15B). In some cases, including one or more holes in a layer (e.g., a second layer 120 and / or a third layer 130 of a footwear garment) can improve air circulation to the foot and comfort for the wearer.

[0045] In some cases, a first layer 110 (or a portion thereof), third layer 130 (or a portion thereof), second layer 120 (or a portion thereof), and / or cuff 160 (or a portion thereof) can be a double-layer of fabric. In some cases, a first layer 110 can be part of a double-layer of fabric, e.g., wherein the other layer of the double-layer of fabric is a third layer 130, for example, as shown in FIG. 3A-FIG. 13D. In some cases, first portion 102 of a double-layer of fabric (e.g., of a knitted fabric structure, such as tube-like knitted fabric structure shown in FIG. 3A-7C) can comprise a first layer 110 and / or a third layer 130. In some cases, second portion 104 of a double-layer of fabric (e.g., of a knitted fabric structure, such as tube-like knitted fabric structure shown in FIG. 3A-7C) can comprise a second layer 120. In some cases, a first layer 110 and / or a third layer 130 can be coupled (e.g., at a proximal end of the first layer 110 and / or a proximal end 132 of the third layer 130) directly to the second layer 120 (e.g., at a distal end 124 of the second layer 120), for example, as shown in FIG. 3A and FIG. 3B or to a cuff 160 (e.g., a knitted cuff 160) at an interface 190 (e.g., as shown in FIG. 4A and FIG. 4B). In some cases, an interface 190 can be created during a manufacturing process, e.g., by changing the yams, threads, or microfilaments used in the knitting process (e.g., circular knitting process) and / or the knitting pattern being employed, to change from fabricating one layer (e.g., second layer 120 or cuff 160) to another layer (e.g., first layer 110 and / or third layer 130). Thus, interface 190 can be a seamless transition from a first material, filament combination, or layer to a second material, filament combination, or layer. Using such seamless transitions, it can be possible to fabricate the entirety of the tube-like knitted structure as a single knitted component (e.g., rather than stitching together or gluing together individually fabricated sections of material), which can result in a more durable, morecomfortable, and or more efficiently assembled footwear garment 100. In some cases, interface 190 can comprise a stitched seam. In some cases, first layer 110 does not completely encircle the circumference of the knitted fabric structure (e.g., tube-like knitted fabric structure), for example, as shown in FIGs. 5 A-6B. In some cases, first layer 110 encircles a portion of the circumference of the knitted fabric structure (e.g., tube-like knitted fabric structure) and the remainder of the circumference of the same layer of the knitted fabric structure is formed by third layer material, for example, as shown in FIG. 5A-FIG. 6B. In some cases, regions of the tube-like knitted structure denoted in FIGs. 3B, 4B, 5A, 5B, 6A, and 6B with dotted lines can be seamless interfaces between fabrics, filaments, or layers (e.g., end-to-end knitted interfaces or double-knitted interfaces between layers forming a thickness of the tube- like sock structure) In some cases, first layer 110 does not extend completely from a proximal end of the first portion of the knitted fabric structure (e.g., tube-like knitted fabric structure) to a distal end of the first portion of the knitted fabric structure. In some cases, first layer 110 comprises only a portion of the axial length of the first portion of the knitted fabric structure (e.g., wherein the first layer 110 is formed using double-knitting on the third layer 130), for example, wherein the remainder of the axial length of the first portion comprises third layer material, for example, as shown in FIG. 5B and FIG. 6B. The amount of the circumference of the knitted fabric structure and the axial length of the first portion comprised by first layer material can be selected based on which portions of the footwear garment are intended to comprise first layer material. For example, a tube-like knitted fabric structure comprising first layer material only at the distal end of the first portion of the fabric structure and only around an subsection (e.g., less than 10 degrees, from 10 degrees to 30 degrees, from 30 degrees to 45 degrees, from 45 degrees to 60 degrees, from 60 degrees to 90 degrees, from 90 degrees to 135 degrees, or from 135 degrees to 180 degrees) of the circumference of the tube-like knitted fabric structure may be used to produce a footwear garment wherein the first layer only contacts the foot of the wearer on the sole, heel, and toes (but not ankles or leg) of the wearer, in some embodiments.

[0046] In some cases, a knitted fabric structure (e.g., tube-like knitted fabric structure) can be fabricated such that an outer surface 110b of the first layer 110 is in direct contact with at least a portion of the inner surface 130a of third layer 130 (e.g., as formed using doubleknitting techniques). In such an orientation, using yams in the third layer 130 that are more hydrophilic than those used in the first layer 110, it is possible to create water management in the footwear garment 100 wherein water is drawn away from the foot and into the third (e.g., middle) layer, which can increase comfort by decreasing moisture residence near the foot.

[0047] In some cases, lumen of the first portion 102 of the knitted fabric structure can be formed into a first space 106 (e.g., cavity or chamber) of the footwear garment. In some cases, the first space (e.g., cavity or chamber) 106 will provide a space into which the foot of the wearer is inserted during use (e.g., as shown in FIGs. 10A-10C). In some cases, a distal opening 182 of the knitted fabric structure (e.g., tube-like knitted fabric structure) can be closed (e.g., sewn closed), e.g., as shown in FIGs. 7A-8C, to help create the first space 106. It is contemplated that distal opening 182 may be left unsewn (e.g., wherein a portion of surface 130b is folded under the foot or glued to midsole 140 and / or to surface 120a). In some cases, distal opening 182 is not closed, and the distal end (e.g., toe-end) of the footwear garment 100 is formed by folding the second layer 120 over the outer surface 130b of the first portion 102 and inserting the midsole through proximal opening 180 of the knitted fabric structure, for example, as shown in FIGs. 9A-9C, 10A-10C, 11, and 12A. In some cases, a footwear garment 100 can be fabricated using all or some of the steps shown in FIGs. 10A-12B. For example, a fabricated tube-like knitted fabric structure such as is shown in FIG. 5B (which may include a cuff 160 between the distal first portion 102 and the proximal second portion 104) can be formed into a footwear garment 100 using some or all of the steps shown in FIGs. 10A-12B. In some cases, fabrication of a footwear garment 100 using all or a portion of the steps shown in FIGs. 10A-12B can include sewing or otherwise sealing shut a distal end of a tube-like knitted footwear structure (e.g., as shown in FIGs. 8A-8C).

[0048] Folding the second layer 120 down over the outer surface 130b of the third layer 130 can create a second space (e.g., cavity or chamber) 108, which can be used to house the midsole 140, for example, as shown in FIGs. 9A-9C, 10A-10C, 11, 12A-12B, and 13A-13D. Accordingly, a footwear garment 100 can comprise at least two separate cavities or spaces (e.g., for separately housing the midsole 140 and the foot of the wearer 101). Because the second space (or cavity or chamber) 108 is separate from the first space (or cavity or chamber) 106 and can be bounded by the outer surface 130b of the third layer and the inner surface 120a of the second layer 120, the friction of the fabric layers against the midsole material can keep the midsole in place relative to the fabric of the footwear garment without requiring additional securing of the fabric to the midsole (note also that the inner surface 120a of the second layer can be considered to be on the exterior of the tube-like knitted fabric structure and the outer surface of the second layer 120 can be considered to be facing the lumen of the second portion 104 of the tube-like knitted fabric structure, for example, because the second layer 120 can be folded down over the first portion 102, inverting the orientation of the second portion 104 relative to the lumen of the first portion, e.g., as shownin FIG. 7C), The midsole 140 can be inserted through the proximal opening 180 of the knitted fabric structure, for example, after the second portion 104 of the knitted fabric structure has been folded down over the first portion 102, for example, as shown in FIG. 11.

[0049] In some cases, an outsole 150 can be coupled (e.g., via application of heat molding, application of adhesive, by stitching, or another means of securing outsole 150 to layer 120) to the outer surface of the second layer 120 (e.g., as shown in FIGs. 12A and 12B, in FIGs. 13C and 13D, and in FIGs. 14A and 14B, which show an exterior view of FIGs. 13C and 13D). In some cases, proximal opening 180 can be left open until the outsole 150 is coupled to the bottom of the footwear garment 100 (e.g., as shown in FIG. 12A and 12B), which can effectively seal proximal opening 180 closed. In such cases, an outsole made of material(s) that have water proof or water resistant material properties can protect from water intrusion through proximal opening 180. The footwear garment 100 is shown in FIG. 14 after insertion of the midsole 140. In some cases, proximal opening 180 can be sealed (e.g., sewn closed or closed by the application of a sealant patch) prior to coupling of the outsole to the outer surface 120b of the second layer. It is contemplated that, in some embodiments, a footwear garment 100 may not include an outsole 150 (e.g., wherein the footwear garment 100 is intended for use indoors or on surfaces that may not be suitable for an outsole structure more rigid than the material of layer 120). In such cases, proximal opening 180 may be left open, sewn shut, or patched over with a suitable material, as the intended use dictates. FIG. 15A and FIG. 15B show two possible finished footwear garments 100 as described herein. In some cases, an outsole 150 may be added to the footwear garments 100 shown in FIG. 15A and / or FIG. 15B.

[0050] FIG. 16A shows a side view of an embodiment of a footwear garment 100 comprising a cuff 160 and a single continuous outer second layer material 120 (comprising surfaces 120a and 120b). FIG. 16B shows a schematic of a tube-like knitted structure useful in fabricating the footwear garment of FIG. 16 A. FIG. 17A shows a side view of an embodiment of a footwear garment 100 without a cuff 160 and a single continuous outer second layer material 120 (comprising surfaces 120a and 120b). FIG. 17B shows a schematic of a tube-like knitted structure useful in fabricating the footwear garment of FIG. 17 A. FIG. 18 A shows a side view of an embodiment of a footwear garment 100 without a cuff 160 and with an outer second layer 120 that is subdivided into a plurality of sections by the presence of one or more gore lines 172. The subdivision of second layer 120 into a plurality of sections can be advantageous for the provision of additional fabric to create a shape for a heel of the footwear garment 100 or for separation of different second layer materials (e.g., comprisingdifferent filament or fiber combinations, which can introduce functional benefits such as greater tensile force around at least a portion of the middle of the foot for a better fit and / or for aesthetic variation of material texture, pattern, luster, or color). FIG. 18B shows a schematic of a tube-like knitted structure useful in fabricating the footwear garment of FIG. 18 A. FIG. 19 A shows a side view of an embodiment of a footwear garment 100 with a cuff 160 and with an outer second layer 120 that is subdivided into a plurality of sections by the presence of one or more gore lines 172. FIG. 19B shows a schematic of a tube- like knitted structure useful in fabricating the footwear garment of FIG. 19A. While not shown in FIGs. 16A-19B, it is contemplated that first layer 110 and / or third layer 130 can also comprise gore lines 172, e.g., for the same or similar purposes as the gore lines 172 described above.

[0051] In some cases, a footwear garment 100 can comprise one or more additional layers in addition to the first layer; the second layer; and the third layer. In some embodiments, a footwear garment 100 can comprise 4, 5, 6, 7, 8, 9, 10, or more than 10 layers. For example, a portion of a wearer’s foot 101 can be covered by 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 layers of fabric of the footwear garment 100 (e.g., not counting midsole or outsole), in some embodiments. In some cases, the one or more additional layers can comprise one or more additional inner layers (e.g., additional first layers) having properties and / or construction the same as or similar in function to the first layer described herein. For example, a footwear garment 100 can comprise one or more additional inner layers comprising yarns that are hydrophilic or semi-hydrophilic. In some cases, one or more additional inner layers can have different stretch characteristics, different aesthetic characteristics (e.g., including a different softness or thickness), and / or different water management properties (e.g., wicking or absorption capacity), which can be imparted by material properties of the yams used, the number of yarns used, or the degree of alignment of the yams in the layer, as compared to the first layer described herein.

[0052] In some cases, the one or more additional layers can comprise one or more additional third layers (e.g., one or more additional middle layers) having properties and / or construction the same as or similar in function to the third layer described herein. For example, a footwear garment 100 can comprise one or more additional third layers (e.g., one or more additional middle layers) comprising yams that are hydrophilic (e.g., highly hydrophilic). In some cases, one or more additional third layers (e.g., one or more additional middle layers) can have different stretch characteristics, different aesthetic characteristics (e.g., including a different softness or thickness), and / or different water management properties (e.g., wicking or absorption capacity), which can be imparted by materialproperties of the yams used, the number of yarns used, or the degree of alignment of the yams in the layer, as compared to the third layer described herein.

[0053] In some cases, the one or more additional layers can comprise one or more additional second layers (e.g., one or more additional outer layers) having properties and / or construction the same as or similar in function to the second layer described herein. For example, a footwear garment 100 can comprise one or more additional second layers 120 (e.g., one or more additional outer layers 120) comprising yarns that are hydrophobic (e.g., highly hydrophobic and / or hydrophobic relative to a layer between the one or more additional second layers (e.g., one or more additional outer layers) and the foot / leg of the wearer). In some cases, one or more additional second layers (e.g., one or more additional outer layers) can have different stretch characteristics, different aesthetic characteristics (e.g., including a different reflectivity, different luster or sheen, different natural coloration, and / or different texture), and / or different water management properties (e.g., inhibition of water wicking, absorption, or permeability), which can be imparted by material properties of the yarns used, the number of yarns used, or the degree of alignment of the yarns in the layer, as compared to the second layer described herein.

[0054] A footwear garment 100 can be shaped, sized, and configured to contact a wearer’s foot 101 and / or leg to various extents. For example, a footwear garment 100 can be designed and manufactured for “over-the-calf’ length, “boot” length, “crew” length, “mid-crew” length, “quarter” length, “low-cut” length, or “extra low” length. “Over-the-calf’ length can mean that the garment 100 extends to contact the wearer’s leg at the middle of the calf muscle or higher on the leg (e.g., contacting the leg up to 1 inch above and no higher than the calf muscle, up to 1 inch below the knee and no higher, up to the middle of the knee and no higher, or above the knee (e.g., up to 1 inch above the knee; up to the mid-thigh; or up to the upper thigh) and lower on the leg / foot. In some cases, “over-the-calf” length can mean at least 15 inches in length (e.g., as measured along the longest dimension of the inner surface of the garment when worn on the foot / leg or when placed on a shoemakers’ last). “Boot” length can mean that the garment 100 extends to contact the wearer’s leg below the middle of the calf and is from 11 to 15 inches or from 13 to 15 inches in length (e.g., as measured along the longest dimension of the inner surface of the garment when worn on the foot / leg or when placed on a shoemakers’ last). “Crew” length can mean that the garment 100 extends to contact the wearer’s leg above the ankle and below the mid-calf and is from 9 to 12 inches in length (e.g., as measured along the longest dimension of the garment when worn on the foot / leg or when placed on a shoemakers’ last). “Mid-crew” length can mean that the innersurface of the garment 100 extends to contact the wearer’s leg above the ankle and below the middle of the calf and is from 6 to 8 inches in length (e.g., as measured along the longest dimension of the garment when worn on the foot / leg or when placed on a shoemakers’ last). “Quarter” length can mean that the garment 100 extends to contact the wearer’s leg at or above the ankle and is from 4 to 5 inches in length (e.g., as measured along the longest dimension of the inner surface of the garment when worn on the foot / leg or when placed on a shoemakers’ last). “Low-cut” length can mean that the garment 100 extends to contact the wearer’s leg below the ankle and is at least 3 inches and less than 4 inches in length (e.g., as measured along the longest dimension of the inner surface of the garment when worn on the foot / leg or when placed on a shoemakers’ last). “Extra low” length can mean that the garment 100 extends to contact the wearer’s leg below the ankle and is less than 3 inches in length (e.g., as measured along the longest dimension of the inner surface of the garment when worn on the foot / leg or when placed on a shoemakers’ last).Midsole Embodiments

[0055] A midsole 140 described herein can be useful in providing structure and / or shape to a footwear garment described herein. In some cases, a midsole can be inserted into a space between a third layer 130 and a second layer 120 of a footwear garment 100 (e.g., through a proximal opening 108 of a knitted structure shown in any one of FIGs. 3A-9C), for example, as shown in FIGs. 11-13D. A midsole 140 can be fabricated from recycled materials (e.g., recycled materials, e.g., from one or more of a first layer 110, a second layer 120, a third layer 130, a midsole 140, or a midsole cover 180). In some cases, a midsole 140 can comprise a thermoplastic polyurethane (TPU).

[0056] In some cases, a midsole 140 can be used with a midsole cover 142 to create a midsole hammock 148. A midsole hammock 148 can improve comfort, function, and / or aesthetic appeal of a footwear garment 100. A midsole hammock 148 can comprise a midsole 140 as described herein. For example, FIGs. 21A and 21B show views of a midsole 140 that can be used in a midsole hammock 148 of a footwear garment 100. A midsole 140 of a footwear garment can be fabricated from a material that retains its shape when unloaded but which can also compress or deform when loaded (e.g., by the weight of a wearer applied by the wearer’s foot to the midsole 140 or to one or more layers of fabric disposed between the wearer’s foot and the midsole 140). In some cases, a midsole 140 can rebound after being compressed to retain its original shape when a compressive force is removed from the midsole 140. The materials and proportions of materials used to fabricate a midsole 140 can be selected to provide the midsole 140 with a desired yield strength, compressibility, and / orresilience. In some cases, a midsole 140 can be shaped with a curved (e.g., concave) upper aspect or surface, for example, to conform to a wearer’s foot 101. In some cases, the shape of the upper portion (e.g., upper surface or upper aspect) of the midsole can be designed to conform to a specific wearer’ s foot and / or to provide specific structural or orthopedic benefit (e.g., specific arch support), for instance, based on one or more measurements of the wearer’s foot (e.g., height, width, length, arch shape, etc.). In some cases, a midsole 140 can have a higher lip or upper edge 147 at the heel of the midsole 140. In some cases, a midsole 140 with a higher lip or upper edge 147 at the heel of the midsole can reduce slipping of the foot inside the footwear garment 100. In some cases, a rigid or semi-rigid heel insert can be added to an interior space 106 or 108, e.g., to add shape to the footwear garment and / or to reduce slipping of the foot inside the footwear garment 100.

[0057] A midsole hammock 148 can comprise a midsole cover 142 (e.g., a midsole sleeve). A midsole cover 142 can be a knitted structure, preferably a knitted structure fabricated using a circular knitting technique (e.g., using an automated circular knitting machine). A midsole cover 142 comprising a knitted structure can have a tube-like structure. In some cases, a midsole cover 142 can have a first, proximal opening 144 at a first end of the midsole cover tube-like structure and a second, distal opening 146 at an opposing second end of the midsole cover tube-like structure. In some cases, the second, distal opening 146 of the midsole cover can be stitched closed (e.g., as shown in FIGs. 22A and 22B), for example, to create an interior space or pocket into which a midsole 140 can be inserted. A midsole cover 148 can be fabricated using one or more types or combinations of yams used to fabricate a different layer of a footwear garment described herein (e.g., a first layer 110, a third layer 130, and / or a second layer 120). In some cases, a diameter of a midsole cover tube-like structure can be less than the diameter of one or more of a first layer 110, a third layer 130, or a second layer 120 of a footwear garment 100 when the first layer, third layer, and second layer are fabricated into a tube-like structure for fabrication of the footwear garment. In some cases, the smaller diameter of the midsole cover 142 can assist in restricting the height, width, and / or length of the midsole 140, which can be useful in inserting the midsole hammock 148 into the proximal opening 180 of the footwear garment 100 during assembly of the footwear garment 100, e.g., as shown herein with respect to an uncovered midsole 140, for instance in FIG. 11. In some cases, a midsole cover 142 can comprise one or more hot melt yams. In some cases, a midsole cover 142 can comprise zero hot melt yarns. In some cases, a midsole cover 142 comprising one or more hot melt yarns can allow the midsole hammock 148 to be secured within the space 108 between the third layer 130 and the second layer 120. In somecases, the one or more hot melt yams can be used to affix the midsole cover 142 to the midsole 140. In some cases, a midsole cover 142 comprising one or more hot melt yarns can add rigidity to the structure of the midsole 140 and / or the midsole hammock 148, which can be advantageous for maintaining the shape of the footwear garment 100 (e.g., in loaded or unloaded conditions). In some cases, a midsole cover 142 can comprise two or more portions having different textures or thicknesses. For example, a midsole cover 142 can comprise shaped regions of increased thickness, increased hardness, and / or increased density in the fabric, e.g., by using double-knitting and / or incorporation of hot melt yarns along with selective application of heat to the hot melt yams. In some cases, a region of a midsole cover having increased fabric thickness (e.g., as a result of double-knitting) can be further increased in firmness or density (e.g., by fabricating the midsole cover 142 using hot melt yams and selectively heating the regions of increased thickness). Regions of increased thickness, hardness, and / or density in a midsole cover 142 can appear as bumps in the fabric and can feel like bumps against the foot of a wearer. In some cases, the presence of and / or configuration of regions of increased thickness, hardness, or density (e.g., bumps) in a midsole cover 142 can improve traction for a wearer. In some cases, such regions may improve blood flow in the foot or leg of a wearer and / or improve recovery from exercise or injury.

[0058] In some cases, a midsole 140 can be inserted into a proximal opening 144 of a midsole cover 142, for example as shown in FIG. 23, to create a midsole hammock 148 (e.g., such as shown in FIG. 24A and 24B). As shown in FIG. 23 and FIGs. 24A and FIG. 24B, the midsole cover 142 can be stretched around (e.g., and in contact with) a basal, lateral, and / or basolateral side of the midsole 140. In some cases, a midsole 140 can have a concave or hollowed shape (e.g., as shown in FIG. 21A), for instance, to receive and / or cushion the foot of a user. In some cases, the midsole 140 can have an upper edge 147 surrounding all or a portion of the perimeter of the midsole. In some cases, the midsole cover 142 can be stretched across the upper portion of the midsole 140 between the upper edges 147 of the midsole 140. In some cases, the midsole cover 142 does not contact an upper or interior (e.g., concave or hollowed) surface of the midsole 140. For instance, the midsole cover 142 can be suspended above the upper or interior (e.g., concave or hollowed) surface of the midsole by virtue of being stretched between the upper edges 147 of the midsole 140 (e.g., a “hammock” configuration). In some cases, the “hammock” configuration of a midsole hammock 148 (e.g., when the midsole hammock 148 is installed in a space 108 between a third layer 130 and second layer 120 of a footwear garment 100) can provide benefits to the function of thefootwear garment 100. For instance, the hammock-like structure can provide additional support to the arch of the foot of the wearer and / or can distribute weight more evenly across the foot, which may reduce strain on the foot arch and / or promote proper foot alignment. In some cases, the configuration of the midsole hammock 148 can act as a cushioning layer, can absorb impact, and / or can reduce pressure on the foot, for instance, by resisting downward force of the wearer’s foot on the midsole 140, e.g., via stretching of the midsole cover 142 material. In some cases, this can be especially useful during activities involving repetitive movements and / or high impact. In some cases, the midsole hammock 148 configuration can enhance overall comfort of the footwear garment 100, for example, by providing a supportive and / or snug fit. In some cases, the “hammock” configuration can stabilize the foot within the footwear garment, which may reduce the likelihood of slippage or discomfort. In some cases, the “hammock” configuration can reduce foot fatigue, for instance in extended periods of standing or walking, which can cause additional strain on the foot. In some cases, a midsole hammock can be configured (e.g., with respect to dimensions and / or materials used) to promote proper foot alignment, which can reduce likelihood of injury and can promote a healthier gait. In some cases, the shape, dimensions, and / or materials of a midsole hammock 148 can be selected based on one or more dimensions of a foot of a wearer, e.g., to provide a more personalized and / or more comfortable fit. In some cases, the shape, dimensions, and / or materials of a midsole hammock 148 can be selected to provide targeted support and / or assistance to the health of a wearer’s foot or leg. For instance, the shape, dimensions, and / or materials of midsole hammock 148 can be selected as part of a treatment regimen for improving the health of a wearer’s foot or leg (e.g., as part of a rehabilitation regimen to treat a specific injury or risk of injury). In some cases, midsole hammock 148 can be inserted into a traditional footwear garment fabricated using previously known techniques, for instance, to improve comfort and / or performance of the traditional footwear garment.Methods

[0059] Footwear garments 100 described herein (or portions thereof) can be produced using a circular knitting technique. Circular knitting, which can comprise a knitting stitch performed continuously in the round, is fundamentally different than a flat knitting technique, which comprises knitting back and forth in two dimensions. By utilizing a circular knitting technique to produce garments or portions thereof described herein, garments or portions thereof comprising complex stitching and / or fabric combinations (for example, including garments and portions thereof as described herein) can be created as a single piece, which can allow for greater efficiency in fabrication, greater durability of final products, and / or greatercomfort or aesthetically appeal (for instance, as seamless or a reduced number of seams are required to create the garment or portion thereof), as compared to flat knitting techniques, which may employ a flatbed knitting machine. For instance, a first layer 110 can be coupled (e.g., knitted) directly to a third layer 130 during the fabric creation portion of the footwear garment fabrication process, using circular knitting technology. Use of a circular knitting machine (e.g., a programmable circular knitting machine) in the fabrication of garments and portions thereof can be advantageous as well, for instance, as hand-knitting (e.g., manual) techniques, such as use of a manual circular knitting spool, a manual circular knitting frame, or circular needle, can be time consuming, difficult to scale to higher production runs, and technically challenging. Programmable circular knitting machines can be particularly advantageous, as complex changes to the yarn type(s) and ratios can be realized with preprogrammed protocols. For instance, some embodiments of garments or portions thereof described herein comprising an inner layer (e.g., which may comprise a first layer) that contacts some but not all of the foot or leg of the wearer contacted by the garment or portion thereof (other than that contacted by the cuff, if present) can be produced far more easily using a programmable circular knitting machine compared to manual knitting techniques or even circular knitting machines not equipped with computer programmable control. In some cases, an inner layer (e.g., a layer in contact with all or part of a wearer’s foot) can comprise a first layer material. In some cases, some but not all of an inner layer (e.g., a layer in contact with all or a part of a wearer’s foot) can comprise a first layer material. FIGs. 6A and 6B show a footwear garment 100 wherein some but not all of an inner layer comprises a first layer 100 material. It is contemplated that any portion of the inner layer can comprise first layer material (e.g., such that only the sole of a wearer’s foot contacts the first layer material, such that only the sole and toes of a wearer’ s foot contact the first layer material, such that only the portion of a wearer’s foot from ankle to toes contacts the first layer material, or such that the first layer material contacts only a subset of the surface area of a wearer’s foot).

[0060] As described herein, a method for manufacturing a footwear garment can comprise fabricating a fabric structure (e.g., a knitted fabric structure, such as a tube-shaped fabric structure described herein) comprising a plurality of fabric layers (for example, a first layer 1 10; a second layer 120; and a third layer 130, e.g., as described herein), optionally, including a cuff 160 (e.g., a knitted cuff, such as a ribbed cuff). In some cases, a method of manufacturing a footwear garment 100 can comprise one or more steps of method 200 shown in FIG. 2. For example, a method of manufacturing a footwear garment 100 can comprise a step 202 fabricating (e.g., knitting) a fabric structure (e.g., a tube-shaped fabric structure)comprising a first layer 110 (e.g., first layer 110), a second layer (e.g., second layer 120), and a third layer (e.g., third layer 130), the first layer 110 and the third layer 130 being concentric with one another around a longitudinal axis 170 of the structure, and the second layer 120 being concentric around the longitudinal axis 170 but not concentric with the first layer 110 or third layer 130 (e.g., wherein the second layer 120 is translated axially along the longitudinal axis 170 such that no part of the second layer 120 is concentric with the first 110 or third layers 130 in the initial, unfolded tube-like fabric structure), wherein a distal end 124 of the second layer 120 is coupled to a proximal end 132 of the third layer 130 (and, optionally, a proximal end of the first layer) at a first end or to a cuff 160 that is coupled to a distal end 124 of the second layer (and, optionally, to the first layer 110). In some cases, a method of manufacturing can comprise a step 204, wherein a distal end of the third layer can be optionally sealed closed, e.g., by sewing the distal opening 182 of the tube-like fabric structure (e.g., the open end of the middle and / or first layers of the tube-like fabric structure) closed. In some cases, a method of manufacturing can comprise a step 206, wherein the second layer 120 (e.g., the inner surface 120a of the second layer 120, which can be on an exterior surface of the tube-like knitted fabric structure) can be folded out, over the outer surface 130b of the third layer 1 0. In some cases, a method of manufacturing a footwear garment 100 can comprise a step 208, wherein a midsole 140 can be inserted through the proximal opening 180 of the folded tube- like knitted structure, e.g., between the outer surface 130b of the third layer 130 and the inner surface 120a of the second layer 120. In some cases, a method of manufacturing a footwear garment 100 can comprise a step 210, wherein an outsole can be coupled to the outer surface 120a of the second layer 120.

[0061] FIGs. 20A-20E shown images of steps in a process for manufacturing a footwear garment 100 described herein. FIG. 20A shows a tube-like knitted fabric structure comprising a third layer 130 coupled to a cuff 160 at a first interface 190 and the cuff 160 coupled to the second layer 120 at a second interface 190. FIG. 20B shows the tube- like knitted fabric structure after the second layer 120 and cuff 160 have been folded over the third layer 130 such that proximal opening 180 is near the distal end 132 of the tube-like knitted fabric structure. FIG. 20C shows another view of second layer 120 of the tube-like knitted fabric structure folded over the third layer 130. FIG. 20D shows a step of inserting midsole 140 in a space 108 between third layer 130 and second layer 120 (the space to be occupied by the wearer’s foot is shown in this image as a last inserted into the space bounded by the first layer 110 (not shown). In some cases, inserting the midsole is more easily accomplished with a last in the space to be occupied by the wearer’s foot. FIG. 20E shows the second layer 120 foldeddown over the toe of the midsole 140, prior to coupling of the outsole 150 to the sole of the second layer 120.

[0062] In some cases, a method of manufacturing a footwear garment 100 described herein can comprise measuring a foot and / or leg of an intended wearer of the footwear garment 100, e.g., to provide a (e.g., customized or tailored) fit allowing improved comfort for that individual wearer. In some cases, measuring a foot and / or leg of a wearer can comprise measuring a length, a width, instep height, circumference, and / or a shape of the foot and / or leg. In some cases, measurements can be taken manually or using computer- assisted methods, such as optical scanning (e.g., 2D or 3D laser scanning) and / or computer assisted gait or pressure analysis. In some cases, a measuring step can incorporate preferred or required dimensional or shape parameters based on a medical analysis, e.g., for orthopedic benefit. Data obtained from a measuring step or process can be used to design and / or manufacture a midsole 140 of a footwear garment 100 described herein. In some cases, data obtained from a measuring step or process can be used to determine a length, width, circumference, instep height, or shape of a footwear garment 100.

[0063] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof that are not in the prior art, which would occur to persons skilled in the art upon reading the foregoing description.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A footwear garment comprising: a first layer comprising a first knit fabric; a second layer comprising a second knit fabric; a third layer comprising a third knit fabric; and a midsole in direct contact with an inner surface of the second layer and at least a portion of an outer surface of the third layer, wherein the first layer is fabricated on at least a portion of an inner surface of the third layer, and wherein an inner surface of the first layer is configured to contact at least a portion of a foot of a wearer of the footwear garment.

2. A footwear garment comprising: an inner first layer comprising a first knit fabric; an outer second layer comprising a second knit fabric; a middle third layer comprising a third knit fabric; a space between an outer surface of the third layer and an inner surface of the second layer configured to receive a midsole; and a space bounded an inner surface of the first layer and, optionally, an inner surface of the third layer, wherein the space is configured to receive a foot of a wearer of the footwear garment such that at least a portion of the first layer contacts at least a portion of the foot.

3. The footwear garment of claim 1 or claim 2, wherein the midsole is in direct contact with the second layer and the third layer.

4. The footwear garment of one of the preceding claims, further comprising an outsole.

5. The footwear garment of claim 4, wherein the outsole is in contact with an outer surface of the second layer.

6. The footwear garment of any one of the preceding claims, wherein the first layer comprises a hydrophilic fiber or a semi-hydrophilic fiber.

7. The footwear garment of any one of the preceding claims, wherein the third layer comprises a hydrophilic fiber.

8. The footwear garment of claim 7, wherein the hydrophilic fiber of the third layer is more hydrophilic than the hydrophilic fiber of the first layer.

9. The footwear garment of any of the preceding claims, wherein the footwear garment is manufactured using circular knitting technology.

10. The footwear garment of any one of the preceding claims, wherein one or more of the first layer, the second layer, the third layer, and the midsole are recyclable materials.

11. The footwear garment of any one of the preceding claims, wherein the midsole is made of recycled materials from one or more of a first layer material, a second layer material, or a third layer material.

12. The footwear garment of any one of the preceding claims, wherein the footwear garment does not comprise an insole.

13. The footwear garment of any one of the preceding claims, wherein the outsole is fabricated from a durable material, optionally wherein the outsole is fabricated from a material comprising a natural rubber or a synthetic rubber.

14. The footwear garment of any one of the preceding claims, further comprising a cuff directly coupled to a proximal end of the third layer and directly coupled to a distal end of the second layer.

15. The footwear garment of claim 14, wherein the cuff comprises a ribbed knitted fabric.

16. The footwear garment of any one of the preceding claims, wherein the first layer and third layer are fabricated together using a double-knitting technique.

17. The footwear garment of any one of the preceding claims, wherein the first layer, second layer, or the third layer comprises at least two portions having different textures.

18. The footwear garment of claim 17, wherein the at least two portions having different textures comprise a plurality of bumps fabricated in the respective layer.

19. A method of manufacturing a knitted footwear garment, comprising: knitting a tube-shaped structure comprising a first layer, a second layer, and a third layer, the first layer and third layer being concentric with one another around a longitudinal axis of the structure, and the second layer being concentric around the longitudinal axis but not concentric with the first layer or third layer, wherein a distal end of the second layer is coupled to a proximal end of the third layer at a first end or to a cuff that is coupled directly to a distal end of the second layer; sealing a distal opening of the tube-shaped structure at the distal end of the third layer; folding the second layer over an outer surface of the third layer; inserting a midsole through a proximal opening of the tube-shaped structure; and coupling an outsole to an outer surface of the second layer.

20. The method of claim 19, wherein the distal end of the second layer is coupled to a proximal end of the first layer.

21. The method of claim 19 or claim 20, wherein the cuff is coupled directly to the distal end of the first layer.

22. The method of any one of claims 19-21, wherein the first layer comprises a hydrophilic fiber or a semi-hydrophilic fiber.

23. The method of any one of claims 19-22, wherein the third layer comprises a hydrophilic fiber.

24. The method of claim 23, wherein the hydrophilic fiber of the third layer is more hydrophilic than the hydrophilic fiber of the first layer.

25. The method of any one of claims 19-24, wherein the footwear garment is manufactured using circular knitting technology.

26. The method of any one of claims 19-25, wherein one or more of the first layer, the second layer, the third layer, and the midsole are recyclable materials.

27. The method of any one of claims 19-26, wherein the midsole is made of recycled materials from one or more of a first layer material, a second layer material, or a third layer material.

28. The method of any one of claims 19-27, wherein the footwear garment does not comprise an insole.

29. The method of any one of claims 19-28, wherein the outsole is fabricated from a durable material, optionally wherein the outsole is fabricated from a material comprising a natural rubber or a synthetic rubber.

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