HK40006710B - Article of footwear with multiple layers, retention system for an article of footwear, and methods of manufacture - Google Patents

Description

Article of footwear having multiple layers, retention system for article of footwear, and method of manufacture

Related applications

This application claims the benefit of priority to U.S. Provisional Application No. 62/491,898, filed April 28, 2017, which is incorporated herein by reference in its entirety. This application also claims the benefit of priority to U.S. Provisional Application No. 62/365,114, filed July 21, 2016, which is incorporated herein by reference in its entirety.

background

Conventional footwear typically includes two main components: an upper and a sole structure. The upper is secured to the sole structure and forms a cavity within the footwear for comfortably and securely receiving the foot. The sole structure is secured to the lower surface of the upper so as to be positioned between the upper and the ground. In some footwear, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to reduce stress on the foot and leg during walking, running, and other ambulatory movements. The outsole may be secured to the lower surface of the midsole and forms the ground-engaging portion of the sole structure, which is formed from a durable and wear-resistant material.

The upper of an article of footwear typically extends over the instep and toe area of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. An ankle opening in the heel area typically provides access to the interior cavity of the upper. A lacing system is typically incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the cavity within the upper. The upper may include a tongue that extends below the lacing system to enhance the adjustability of the footwear, and the upper may include a heel counter to limit movement of the heel.

Overview

One aspect of the present disclosure provides a knitted component that forms an overfoot portion and an underfoot portion of an article of footwear. The knitted component may include a first layer that defines a cavity and a second layer that at least partially surrounds the first layer. The second layer may form an outer surface on the overfoot portion and the underfoot portion, and a portion of the first layer may be continuous with a portion of the second layer in the ankle region of the knitted component. An interstitial space may be formed between the first layer and the second layer, and a component may be disposed between the first layer and the second layer.

In some embodiments, the first layer and the second layer can be formed on a circular knitting machine, and the second layer can be flipped relative to the first layer. A seam can be formed in at least the second layer in the toe area of the knitted component. The seam can connect the first layer to the second layer. The tension of the second layer can hold the component in the underfoot area of the gap space. The gap space can be substantially free of adhesive. The component can be a midsole. The knitted component can also include a retention system formed in the second layer, the retention system having a plurality of first yarns and a plurality of second yarns, wherein the first yarns and the second yarns at least partially form the second layer of the knitted component, wherein the second yarns bias the retention system to a first state, and wherein the retention system applies tension in the second state.

In another aspect, the present disclosure provides an upper having a first layer and a second layer, wherein the second layer at least partially surrounds the first layer, wherein a portion of the first layer is continuous with a portion of the second layer, and wherein the first layer is continuous with the second layer in at least a portion of an ankle region of the upper. A component may be disposed between the first layer and the second layer, wherein the component comprises a material having different properties than the first layer and the second layer.

In some embodiments, the component can have a greater stiffness than the first and second layers. The component can have the shape of a bootie that is coextensive with at least the forefoot region and the midfoot region of the upper. The bootie can be coextensive with a portion of the heel region. The component can have a greater stretch resistance than the first and second layers. The first and second layers can be formed from knitted components. A pocket can be provided between the first and second layers, wherein the pocket receives the component. A seam can be included that connects the first layer to the second layer in the toe region of the upper.

In another aspect, the present disclosure includes a method of manufacturing an article of footwear. The method may include pulling an open toe area of an element toward a primary fold line disposed between a first portion of the element and a second portion of the element such that an inner surface of the first portion of the element is exposed during the pulling operation; pulling the open toe area past the primary fold line and onto the second portion such that the first portion substantially surrounds the second portion and forms a fold in an ankle region of the article of footwear; aligning the open toe area of the element with a closed toe area of the second portion of the element; and forming a seam to connect the open toe area with the closed toe area.

In some embodiments, the element can be a knitted component, and the method can further include forming the knitted component on a knitting machine. A gap space can be formed between the first portion and the second portion. The method can further include inserting the component into the gap space between the first portion and the second portion.

Another aspect of the present disclosure provides a knitted component having a knitted layer formed at least in part from a plurality of first yarns and a retention system formed in the knitted layer. The retention system may include a plurality of floating portions of the first yarn, wherein the retention system is movable from a first state to a second state. In the first state, the floating portions of the first yarn may exhibit a relaxed state, wherein the floating length of the first yarn is greater than a size of the retention system.

In some embodiments, in the second state, the float portion of the first yarn can be generally taut. When the retention system is in the second state, the first yarn can be subjected to tension. The retention system may also include a plurality of second yarns, wherein the second yarns have an elasticity greater than that of the first yarn. The second yarns can be generally taut when the retention system is in the first state and when the retention system is in the second state. The retention system may also include a plurality of third yarns that at least partially form a knitted layer, wherein a plurality of knitted structures formed by the third yarns cover the outer surface of the first yarn. Optionally, the first retention area can be separated from the second retention area by a portion of the knitted layer, and the portion of the knitted layer can include stitches formed by the first yarn. The knitted layer can at least partially surround the inner layer and the inner layer can define a cavity, wherein the knitted layer forms an outer surface on the upper and lower parts of the knitted component, and wherein a portion of the inner layer is continuous with a portion of the knitted layer in the ankle area of the knitted component. The knitted component may include: a gap space formed between the inner layer and the knitted layer; and a component that can be arranged between the inner layer and the knitted layer.

In another aspect of the present disclosure, an article of footwear may include a knitted component having a retention system, the retention system comprising a plurality of first yarns. Each first yarn may include a first float portion located in a first region of the knitted component, the first region being located on at least one of a medial side and a lateral side of the article of footwear. The retention system may be moved from a first state, wherein the float portions of the first yarns have slack in the first state, to a second state.

In some embodiments, the retention system further comprises a plurality of second yarns located in the first zone, the second yarns biasing the retention system toward the first state. The retention system may further comprise a plurality of third yarns at least partially covering the first float portions of the first yarns. Each first yarn may comprise a second float portion located in a second zone of the knitted component, the second zone being separated from the first zone by a stitch formed by the first yarn. The first float portion may be subject to tension in the second state. The first float portion may have an orientation approximately perpendicular to the sole structure. In the first state, the knitted component may assume a soft state. The retention system may be formed on a circular knitting machine.

In another aspect of the present disclosure, a method of knitting a knitted component is provided. The method may include forming a knitted layer at least partially from a plurality of first yarns, and forming a plurality of float portions of the first yarns in a holding region, the holding region including a plurality of second yarns. The holding region is movable from a first state to a second state, wherein the float portions of the first yarns have slack in the first state, and wherein the second yarns bias the holding region toward the first state.

In some embodiments, forming the plurality of float portions of the first yarn may include forming the plurality of float portions at least partially on a circular knitting machine. The method may additionally or alternatively include forming a plurality of third yarns in a holding zone, wherein the third yarns at least partially overlap the first yarn.

BRIEF DESCRIPTION OF THE DRAWINGS

The various embodiments of the present disclosure may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily drawn to scale, but rather emphasis is placed on illustrating certain principles. In addition, in the drawings, like reference numerals represent corresponding parts throughout the different views.

1 is a perspective side view of an embodiment of an article of footwear having a multi-layer upper with components disposed between layers of the upper.

FIG2 is an exploded view of the embodiment of the article of footwear of FIG1 ;

3 is a cross-sectional view of the forefoot region of the embodiment of the article of footwear of FIG. 1 , with the cross-section taken along line 3 - 3 .

4A is a cross-sectional view of the heel region of the embodiment of the article of footwear of FIG. 1 , with the cross-section taken along line 4 - 4 .

4B is a cross-sectional view of a heel region of another embodiment of an article of footwear.

5 is an embodiment of an unfolded knit element that may be used to form a multi-layer knit upper.

6 depicts an embodiment of a first step in forming a multi-layer knit upper from the unfolded knit elements shown in FIG. 5 .

7A depicts an embodiment of a second step in forming a multi-layer knit upper from the unfolded knit elements shown in FIG. 5 .

7B depicts an embodiment of a third step in forming a multi-layer knit upper from the unfolded knit elements shown in FIG. 5 .

FIG. 8 depicts an embodiment of a completed multi-layer knit upper formed from the unfolded knit elements shown in FIG. 5 .

9 depicts a perspective side view of an embodiment of an article of footwear having a multi-layer upper with various regional pockets and inserts.

10 is a cross-sectional view of the forefoot region of the embodiment of the article of footwear shown in FIG. 9 , with the cross-section taken along line 10 - 10 .

11 is a partial cross-sectional view of an embodiment of an upper of the article of footwear shown in FIG. 9 , illustrating an exterior surface of an interior layer of the upper.

FIG12 depicts an embodiment of a regional bag.

13 is a cross-sectional view of an embodiment of a regional bag, wherein the cross-section is taken along line 13-13 of FIG. 12. FIG.

14 is a perspective side view of another embodiment of an article of footwear having a multi-layer upper with various regional pockets and inserts.

15 is a partially exploded view of the article of footwear of FIG. 14 , illustrating various regional inserts.

16 is an embodiment of an upper for an article of footwear in which the upper includes various zones having distinctly different colors and a visible bite line.

17 is an embodiment of a knit element having knit-in zones and a bite line, wherein the knit element can be used to form a multi-layer upper with a visible bite line.

18 illustrates the steps of attaching an embodiment of an upper having a visible bite line to an embodiment of a sole structure.

19 is an embodiment of an article of footwear having a visible bite line, wherein an embodiment of the sole structure is attached to the upper proximate the visible bite line.

20A is an embodiment of an article of footwear having a retention system in a first state.

20B is the embodiment of the article of footwear shown in FIG. 20A , wherein the retention system is shown in a second condition.

Detailed description

With reference to Fig. 1, there is shown a first embodiment of an article of, for example, article of footwear 100. Article of footwear 100 comprises an embodiment with upper 101 and optional sole structure 103, wherein components are sandwiched between two layers. Article of footwear 100 is disclosed as having an overall structure suitable for walking or running. The concept associated with footwear (comprising upper 101) can also be applied to a variety of other sports footwear types, including but not limited to baseball shoes, basketball shoes, cross-training shoes, cycling shoes, rugby shoes, soccer shoes, sprinting shoes, tennis shoes and hiking boots. This concept can also be applied to footwear types that are generally considered to be non-sports, including dress shoes, loafers, sandals and work boots. Therefore, the concept disclosed herein is applicable to a variety of footwear types. In addition, the concept disclosed herein can be applicable to articles beyond footwear, such as accessories or clothing.

In the embodiment of Figure 1, upper 101 generally provides comfortable and safe coverage for the foot. Upper 101 may include an upper foot region 160 and an optional lower foot region 162 surrounding cavity 119. Thus, the wearer's foot may be positioned within cavity 119 to effectively secure the foot within article of footwear 100 or otherwise unite the foot and article of footwear 100. In addition, sole structure 103 may be secured to a lower region (e.g., lower foot region 162) of upper 101, or may be partially or completely within a portion (e.g., a gap space as described below) of upper 101 and may be positioned between the foot and the ground to attenuate ground reaction forces (e.g., cushion the foot), provide traction, enhance stability, and/or influence the motion of the foot.

For reference purposes, upper 101 of article of footwear 100 can be generally divided into three general areas along a longitudinal axis (heel to toe): forefoot area 109, midfoot area 110, and heel area 111. Forefoot area 109 generally includes the portion of article of footwear 100 corresponding to the toes and the joints connecting the metatarsal bones to the phalanges. Midfoot area 110 generally includes the portion of article of footwear 100 corresponding to the arch area of the foot. Heel area 111 generally corresponds to the rear portion of the foot, including the calcaneus. Article of footwear 100 also includes lateral side 107 and medial side 105, which extend through each of forefoot area 109, midfoot area 110, and heel area 111 and correspond to opposite sides of article of footwear 100. More specifically, lateral side 107 corresponds to the lateral area of the foot (i.e., the surface facing away from the other foot), and medial side 105 corresponds to the medial area of the foot (i.e., the surface facing the other foot). Forefoot region 109, midfoot region 110, heel region 111, lateral side 107, and medial side 105 are not intended to delineate precise areas of article of footwear 100. Rather, forefoot region 109, midfoot region 110, heel region 111, lateral side 107, and medial side 105 are intended to represent general areas of article of footwear 100 to assist in the following discussion.

In some embodiments, the sole structure 103 can generally include a midsole 106 and/or an outsole 108. The midsole 106 can be fixed to the lower surface of the upper 101, or can be positioned in the interstitial space 129 between the outer knitted layer 120 and the inner knitted layer 122, as described below. When the midsole 106 occupies the interstitial space 129, the tension in the outer knitted layer 120 can keep the midsole 106 in a position under the foot between the inner knitted layer 122 and the outer knitted layer 120. The midsole 106 can be located in the interstitial space 129 with or without additional elements, and the additional elements are used to keep the midsole 106 in the underfoot area, such as adhesives, stitches, thermal bonding, RF welding or sonic welding. The lack of adhesive that keeps the midsole 106 in the interstitial space 129 can advantageously contribute to a more compliant and more flexible wearing feel. However, the outsole 108 may additionally or alternatively be secured to the lower surface of the upper 101 using adhesives or other suitable mechanical or chemical mechanisms or devices. The midsole 106 may be formed from a compressible polymer foam element (e.g., polyurethane or ethylene vinyl acetate foam) that attenuates ground reaction forces (e.g., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. Additionally or alternatively, the midsole 106 may include plates, modulators, fluid-filled chambers, lasting elements, and/or motion control members that further attenuate forces, enhance stability, or influence the motion of the foot.

In some embodiments, outsole 108 having a ground engaging surface may be disposed at a lower surface of midsole 106 or a lower surface of upper 101. Outsole 108 may be at least partially formed of a textured, wear-resistant rubber material, providing tread elements 112 to impart traction.

While the depicted configuration of sole structure 103 provides an example of a sole structure that may be used in conjunction with upper 101, a variety of other configurations for sole structure 103 may alternatively be used. In some embodiments, for example, external sole structure 103 may be omitted, and portions of upper 101 may be treated or otherwise configured to provide a suitable ground-engaging surface.

As depicted, upper 101 includes a first or outer knit layer 120 and a second or inner knit layer 122. In some embodiments, outer knit layer 120 substantially surrounds inner knit layer 122, and outer knit layer 120 can form outer surface 121 (shown in Figures 4A-4B) of upper 101. In some embodiments, such as the embodiment shown in Figure 1, outer knit layer 120 completely covers inner knit layer 122, such that inner knit layer 122 is not visible when viewed from an external perspective after assembly. In another embodiment, outer knit layer 120 only covers a portion of inner knit layer 122, such that another portion of inner knit layer 122 is visible when viewed from an external perspective after assembly.

In some embodiments, the outer knit layer 120 and the inner knit layer 122 are arranged or otherwise configured to create a gap space 129 (e.g., a void) between the outer knit layer 120 and the inner knit layer 122. One or more components 124 can be located in the gap space 129 between the outer layer 120 and the inner layer 122. The component 124 can be a bootie, a midsole, a cleat plate, a waterproof membrane, or any other suitable device. Thus, as shown in FIG1 , a three-layer upper can be provided with an outer knit layer 120, an inner knit layer 122, and a component 124 located between the outer knit layer 120 and the inner knit layer 122.

In some embodiments, component 124 disposed in interstitial space 129 can be constructed or otherwise configured to provide a particular shape to upper 101 so that upper 101 can maintain the particular shape when a foot is not positioned within upper 101 (e.g., when other layers of upper 101 lack structural features that would maintain a desired three-dimensional shape on their own). For example, in some embodiments, such as the embodiment shown in FIG1 , component 124 can advantageously facilitate the article of footwear maintaining a typical athletic footwear shape with or without a foot being received within the void.

In some embodiments, such as those shown in Figures 1-4A, component 124 is a bootie. Component 124, as best shown in Figure 2, can have the general construction of an athletic shoe upper. Component 124 can be constructed (e.g., sized and shaped) to receive and/or substantially cover the user's foot when the foot is inserted into upper 101. Component 124 can be made of a material having sufficient rigidity and/or hardness to maintain its established three-dimensional shape, and can include a material having greater rigidity or hardness than outer knit layer 120 and inner knit layer 122. In some embodiments, component 124 can be a single layer of material. Additionally or alternatively, component 124 can be made of a non-woven fabric (and note that knitted fabric is different from non-woven fabric). In some embodiments, component 124 can include a thermoplastic portion or a thermosetting portion so that component 124 can be heat-set to maintain a specific shape.

In some embodiments, such as the embodiment shown in Figure 4B, component 124 is the midsole 106 positioned in the gap space 129. For example, the tension in the outer layer 120 can keep the midsole 106 in the foot position between the inner layer 122 and the outer layer 120. The midsole 106 can be located in the gap space 129 with or without additional elements, and the additional elements are used to keep the midsole 106 in the foot area, such as adhesive or stitching. In the embodiment in which the midsole 106 is located in the gap space 129 when there is no additional element to fix it to the outer knitted layer 120 or the inner knitted layer 122, owing to eliminating at least one adhesive layer that reduces flexibility, the midsole 106 can better conform to the wearer's foot during walking activities. In addition, the removal of the adhesive can advantageously reduce the demand for some materials and/or manufacturing steps, which can improve manufacturing efficiency and reduce the total cost of footwear. As described above, midsole 106 may be formed of one or more materials that provide cushioning when compressed between the foot and the ground during walking, running, or other ambulatory activities. Midsole 106 may additionally (or alternatively) include other elements that further attenuate forces, improve stability, or influence the motion of the foot.

Component 124 can be made of multiple layers of material. Optionally, component 124 can include features for cushioning, such as relatively thick portions, expandable portions, foam portions, etc. Additionally or alternatively, component 124 can include features for protection, such as thicker portions, rigid portions (e.g., plates), reinforced portions, etc. In some embodiments, component 124 can have holes or can otherwise include discontinuities, such that component 124 essentially provides a scaffold that maintains breathability and flexibility while establishing a three-dimensional shape.

As shown in FIG3 , component 124 can establish the shape of interior cavity 119, which is the opening within upper 101 into which a user's foot is inserted for use. Inner surface 123 of inner knit layer 122 can define and form the surface of interior cavity 119. When inner knit layer 122 is formed from a relatively flexible knit fabric, it can be difficult for inner knit layer 122 to maintain a specific three-dimensional shape, such as the shape shown in FIG3 . Therefore, component 124 can interface with inner knit layer 122 to establish and maintain the desired shape of interior cavity 119.

Component 124 may be coextensive with outer knit layer 120 and/or inner knit layer 122 at least in some locations, while not coextensive with outer knit layer 120 and/or inner knit layer 122 at other locations. Referring to FIG4A , which shows a cross-section of upper 101 taken along line 4-4 in heel region 111, component 124 is coextensive with outer knit layer 120 and inner knit layer 122 at the bottom portion of article of footwear 100. The upper or top edge of component 124 terminates within ankle region 102 of upper 101, while outer knit layer 120 and inner knit layer 122 extend past component 124 to form ankle region 102. Specifically, component 124 extends from lateral inner bootie top edge 131 on lateral side 107 to medial inner bootie top edge 130 on medial side 105. The outer knit layer 120 and the inner knit layer 122 extend beyond the lateral inner bootie top edge 131 and the medial inner bootie top edge 130 to form the ankle region 102 and are connected at the medial fold 126 and the lateral fold 128. As shown in FIG4A , in the ankle region 102, the medial gap space 125 and the lateral gap space 127 are empty, allowing the ankle region 102 to behave more like a traditional sock and/or have properties more like a traditional sock. For example, the ankle region 102 can be flexible to conform to the wearer's ankle during use and/or have suitable stretchability to accommodate the insertion and removal of the wearer's foot.

In some embodiments, the outer knit layer 120 and the inner knit layer 122 are made from a common knit element 118 that is folded to form layers 120 and 122. In the embodiment shown in FIG1 , the knit element 118 has been folded in half to form two layers. One embodiment of such an unfolded knit element 138 is shown in FIG5 . Making both layers of the knit element 118 of the upper 101 from a common unfolded knit element 138 can reduce costs, not only in terms of knitting time and waste, but also because folding the unfolded element 138 into the knit element 118 in a folded orientation can take less time and labor than aligning two separate pieces of material and joining them together.

5-8 illustrate an embodiment in which an unfolded element 138 is flipped over to form a double-layer knitted element (e.g., knitted element 118). FIG. 5 illustrates an embodiment of an unfolded element 138 in which the unfolded element 138 has a generally tubular, sock-like configuration. The unfolded element 138 comprises two portions: a first portion 141 and a second portion 143. The first portion 141 and the second portion 143 may be nearly identical in shape, albeit mirror-image portions and/or generally symmetrical portions oriented in opposite directions. In some embodiments, the first portion 141 and the second portion 143 may have a foot-like shape, with a toe portion (e.g., a first toe portion 140 and a second toe portion 142) and a shaped heel portion (e.g., a first heel portion 145 and a second heel portion 146).

5 , the first portion 141 includes a first or open toe 140 so that a portion of the inner surface 144 of the unfolded element 138 is visible. In contrast, the second portion 143 can have a second or closed toe 142 that is closed by connecting the edges together during the post-knitting process, during knitting (e.g., edges connected by the knit structure of the knit element 118 formed on the knitting machine), or closed in other ways by a desired or acceptable method. Alternatively, the closed toe 142 can be at least initially open, for example, in a manner similar to the open toe 140. In such an embodiment, the closed toe 142 can ultimately be closed to form a seam, as discussed below in forming the seam connecting the open toe 140 to the inner knit layer 122.

Unfolded element 138 can use suitable knitting process to manufacture.In some embodiments, unfolded element 138 can be manufactured on circular knitting machine.In some embodiments, first portion 141 and second portion 143 are made by the same type of yarn and the same type of knitting stitches (knit stitches).In other embodiments, first portion 141 and second portion 143 can be made by dissimilar yarns, different knitting stitches and/or other knitting structures, and/or have different knitting stitch densities.Similarly, in each part, first portion 141 and second portion 143 can be made by the same type of yarn and the same type of knitting stitches or other knitting structures.In other embodiments, in first portion 141, first portion 141 can include dissimilar yarns, different knitting stitches or other knitting structures and/or different knitting stitch densities.Similarly, in second portion 143, second portion 143 can include dissimilar yarns, different knitting stitches or other knitting structures and/or different knitting stitch densities.

First portion 141 and second portion 143 can be considered to be separated by a primary fold line 135. Primary fold line 135 can be an imaginary line that divides unfolded element 138 into first portion 141 and second portion 143. In some embodiments, primary fold line 135 can approximately divide unfolded element 138 in half. In other embodiments, first portion 141 can be slightly larger than second portion 143, which can be advantageous when first portion 141 is to be folded over second portion 143, although it is also contemplated that second portion 143 can be larger. In some embodiments, first portion 141 can surround or substantially surround second portion 143 to form outer knit layer 120. Thus, while first portion 141 is not significantly larger than second portion 143, first portion 141 can have sufficient stretch to enclose second portion 143 and allow for interstitial space 129. In these embodiments, the tension in the yarns of first portion 141 can help maintain any components positioned within interstitial space 129 in the desired position.

As shown in FIG6 , the step of forming the knitted element 118 from the unfolded element 138 includes grasping the open toe 140 and essentially turning the open end of the first portion 141 inside out, such that the inner surface 144 becomes the outer surface and a first middle fold 150 is formed in the first portion 141. In some embodiments, in the final product, the inner surface 144 of the unfolded element 138 becomes the outer surface 121 (as shown in FIG3 ). After the first portion 141 is turned or turned inside out, the open toe end 140 is pulled in a first folding direction 151. The first folding direction 151 is in a direction toward the main fold line 135.

FIG7A shows a subsequent point in the folding process. As shown, the open toe portion 140 has been pulled past the first portion heel 145 shown in FIG6 , so that the first portion heel 145 is also turned inside out. The open toe portion 140 is also depicted as being pulled past the second portion heel 146 in a second folding direction 153. The open toe portion 140 is shown approaching the closed toe portion 142. At this stage, the inner surface 144 can form a majority of the outer surface of the illustrated element. The wearable orientation of the outer knitted layer 120 and the inner knitted layer 122 is now more clearly visible.

FIG7B illustrates another optional point in the folding process, wherein the open toe portion 140 is pulled past the closed toe portion 142 prior to the final step. By pulling the open toe portion 140 past the closed toe portion 142, the technical and/or aesthetic properties of the outer knit layer 120 can be extended to and connected to the closed toe portion 142. Furthermore, pulling the open toe portion 140 past the closed toe portion 142 at this stage can enable the toe seam 132 to be formed by an alternative post-processing method, described below.

FIG8 shows an embodiment of the final step in the folding process. In this step, the open toe 140 can be pulled into close proximity with the closed toe 142. In some embodiments, such as the embodiment shown, the open toe 140 is aligned with the closed toe 142. In other embodiments, the open toe 140 may not reach the closed toe 142 or may be pulled past the closed toe 142 (as shown in FIG7B ). In embodiments where the open toe 140 can be pulled past the closed toe 142, the outer knit layer 120 can be temporarily connected to the closed toe 142 before forming the toe seam 132. In addition, before or after forming the toe seam 132, the excess portion 141 of the outer knit layer 120 that extends over the closed toe 142 can be removed. The open toe 140 can be attached to the inner knit layer 122 to form the toe seam 132, which can be positioned in the upper toe area as well as in the underfoot area or other areas. The toe seam 132 can be formed by one or more steps, including but not limited to stitching, adhesive bonding, heat bonding (if the yarns of the outer knit layer 120 and the inner knit layer 122 include thermosetting or thermoplastic properties), welding (via RF welding or sonic welding processes), etc. Heat bonding, RF welding, and sonic welding can provide benefits over other types of joining processes by reducing labor costs and material waste, by enabling the toe seam 132 to be smaller in size and/or located below the bite line (e.g., in the underfoot area) where it is not visible, and/or by providing a seamless wearing feel to the user (e.g., by eliminating the "ears" on the medial and lateral portions of the toe area that are created by traditional toe closure steps (e.g., stitching). Any of the above-described methods of forming the toe seam 132 can be performed as a post-processing step, i.e., after the upper is removed from the knitting machine.

When the outer layer 120 and the inner layer 122 are in their wearable configuration, as shown in Figure 8, the knitted element 118 can extend from the toe seam 132 to the main fold line 135. Immediately adjacent to the main fold line 135 is the foot insertion opening 104. Also adjacent to the main fold line 135 is the main fold. As shown in Figures 4A-4B, the main fold is shown at the top of the ankle area 102 and includes a medial fold 126 and a lateral fold 128. The main fold can be continuous around the foot insertion opening 104. When the first portion 141 completely overlaps the second portion 143, the medial fold 126 and the lateral fold 128 can be formed. The main fold at the main fold line 135 (as shown in Figure 8) can be a bend in the knitted element 118 that maintains the properties (e.g., continuity) of the unfolded knitted element 138 while forming two distinct layers: the outer knitted layer 120 and the inner knitted layer 122.

In some embodiments, component 124 can be positioned on or between first portion 141 and/or second portion 143 before or during folding of unfolded element 138 into knitted element 118. In one particular example (e.g., when component 124 is a bootie as depicted), second portion 143 can be inserted into component 124 and then first portion 141 can be folded around component 124. In other embodiments, component 124 (and/or other components) can be inserted between first portion 141 and second portion 143 after portions 141 and 143 are generally folded or otherwise manipulated into their wearable orientation.

Figures 9-19 illustrate various embodiments of footwear articles with knitted elements, wherein different components and/or knitted structures are used in different areas of the footwear article to achieve different properties in different areas. For example, different parts or areas of the footwear article can benefit from different structural properties or performance characteristics. In some areas, such as in the forefoot area, breathability and flexibility are beneficial. In other areas, such as in the heel or toe, rigid support and protection can be beneficial.

In the embodiment shown in Figures 9-13, article of footwear 200 includes an upper 201 and an optional sole structure 203. In most respects, upper 201 is similar to upper 101, while secondary sole structure 203 is similar to sole structure 103, both of which were discussed above with reference to Figures 1-8. For example, second knit element 218 can optionally be made of the same material as knit element 118 discussed above and folded in the same manner as knit element 118 discussed above. In some embodiments, such as the embodiment shown in Figures 9-13, second knit element 218 can include at least one regional pocket configured to accommodate at least one regional insert.

Upper 201 may include regional pockets sandwiched between first knit layer 220 and second knit layer 222. Regional pockets and inserts may be provided to create different responses and characteristics in different portions of article of footwear 200. In the embodiment shown in FIG9 , three regional pockets are provided: a first regional pocket 230 disposed in second heel region 211, a second regional pocket 232 disposed on medial side 205 of second midfoot region 210, and a third regional pocket 234 disposed in the toe region of second forefoot region 209. As best shown in FIG11 , first regional pocket 230 is configured to receive a first regional insert 231 within a first pocket interior 236, second regional pocket 232 is configured to receive a second regional insert 233 within a second pocket interior 238, and third regional pocket 234 is configured to receive a third regional insert 235 within a third pocket interior 240.

In other embodiments, more or fewer regional pockets may be provided. In some embodiments, the number of regional pockets may exceed the number of regional inserts. For example, when a single design of knitted element 218 is provided for multiple different configurations, some pockets may remain empty in some configurations. In other embodiments, the number of regional pockets may be less than the number of regional inserts, such as when regional inserts may be provided in sets for interchangeability, or when more than one regional insert is intended to be positioned in a regional pocket in order to provide a finer degree of control over the properties contributed by the regional inserts.

10 , which is taken along line 10-10 of FIG9 and through second regional pocket 232, second regional pocket 232 is disposed in interstitial space 225 formed between outer knit layer 220 and inner knit layer 222 on medial side 205 of upper 201. Although second regional pocket 232 is discussed, the same principles of placement, construction, and execution may be equally applied to any of the regional pockets discussed with respect to this or any other embodiment.

As shown in FIG10 , the second pocket panel 239 extends within the gap space 225 between the outward-facing surface 224 and the inward-facing surface 226. In some embodiments, the second pocket panel 239 can be attached to the outward-facing surface 224, while in other embodiments, the pocket panel 239 can be attached to the inward-facing surface 226. In some embodiments, the second pocket panel 239 can be integrally formed (e.g., formed on a knitting machine using a common knitting structure) with at least one of the second outer knit layer 220 and/or the second inner knit layer 222. In other embodiments, the second pocket panel 239 can be formed separately and then sewn, adhered, heat-bonded, and/or welded to at least one of the outer knit layer 220 and the inner knit layer 222.

The second bag panel 239 can define a second bag interior 238. In the embodiment shown, the second bag interior 238 is defined by the second bag panel 239 and the outward-facing surface 224. In other embodiments, the second bag interior 238 can be defined by the second bag panel 239 and the inward-facing surface 226. Thus, one of the outer knit layer 220 and the inner knit layer 222 can form one wall of the bag, while the other wall of the bag can be formed by the second bag panel 239. In some embodiments, another bag panel can be included to define another wall of the second bag interior 238.

Second pocket interior 238 can be configured to receive second regional insert 233. In the embodiment shown, second regional insert 233 is positioned between second pocket panel 239 and outward-facing surface 224. In other embodiments, second regional insert 233 can be positioned between second pocket panel 239 and inward-facing surface 226. In other embodiments, second pocket panel 239 can be eliminated entirely, such that second regional insert 233 can be positioned in interstitial space 225. Pocket panel 239 generally serves to hold second regional insert 233 in a specific location within upper 201. In embodiments that do not utilize a pocket panel such as second pocket panel 239, a pocket can be formed by directly attaching a portion of second outer layer 220 to inner knit layer 222, such as by integral knitting, stitching, adhesive bonding, thermal bonding, and/or welding.

The structure of the bag, specifically the first regional bag 230, is shown in detail in Figures 12 and 13. As depicted, the first regional bag 230 is formed by associating a first bag panel 237 with an outward-facing surface 224. Thus, the outward-facing surface 224 forms a first wall of the first bag interior 236, while the first bag panel 237 forms an opposing wall of the first bag interior 236. The first bag panel 237 can be coupled to the outward-facing surface 224 on three edges, as indicated by panel attachment lines 244. The attachment of the first bag panel 237 is further illustrated in Figure 13, which is a cross-sectional view of Figure 12. First panel attachments 251 and second panel attachments 245 can attach opposing edges of the first bag panel 237 to the outward-facing surface 224. Attachment 245 can include sewing, adhesive bonding, thermal bonding, welding, or any other suitable means or method.

Attaching the first bag panel 237 to the outward-facing surface 224 can advantageously allow easy access to the first bag interior 236. As best shown in FIG12 , the bag lip 242 can be unattached to the outward-facing surface 224, and the bag lip 242 can be a free end of the first bag panel 237 that can be pulled away from the outward-facing surface 224 to allow access to the first bag interior 236. This can allow the manufacturer to slide the first regional insert 231 into the first bag interior 236. The same or similar structure as the first regional bag 230 can likewise apply to the second regional bag 232 and the third regional bag 234.

Regional inserts 231, 233, and 235 can be configured (e.g., sized, shaped, and formed from a material having specific properties) to provide specific properties to upper 201 proximate regional pockets 230, 232, and 234. In some embodiments, all of regional inserts 231, 233, and 235 can provide the same properties to upper 201. Alternatively, each regional insert can provide different properties depending on the location of the regional insert on upper 201. For example, first regional insert 231 can be sized, shaped, or otherwise configured to act as a heel counter, which can be rigid and stiff compared to the rest of upper 201. Second regional insert 233 can be sized, shaped, or otherwise configured to act as an arch support, so that second regional insert 233 can be sized, shaped, or otherwise configured to follow the contours of the arch while providing support and cushioning. The third regional insert 235 may be sized, shaped, or otherwise configured to serve as a toe cap that may be rigid and stiff compared to the rest of the upper 201, but may be made of a material that is more breathable than the material of the first regional insert 231. In some embodiments, more than one, or even all, of the regional inserts may have one or more regional properties in common, such as cushioning, while other properties vary between different regional inserts, such as stiffness and breathability.

Each of the regional inserts 231, 233, and 235 can optionally be made of the same material, or one or more of the regional inserts 231, 233, and 235 can be made of different materials. Exemplary materials can include natural or synthetic rubber, foam, polymer sheets or plates, cushioning bladders (which can be filled with foam, gas, and/or fluid), combinations of these materials, knitted or other fabrics, and/or other suitable materials and combinations.

9-13 illustrate that the regional inserts are arranged in layers of upper 201 such that the regional inserts are spaced apart/non-contact, while some portions of upper 201 do not contain any inserts. In other embodiments, such as the embodiment shown in Figures 14 and 15, substantially all of upper 301 may include regional inserts shaped to provide properties to various areas of upper 301.

The shoe upper 301 of Figures 14-15 is similar to the shoe upper 201 of Figures 9-13 in many aspects.For example, the shoe upper 301 is described as comprising a knitting element 318 folded to form an outer layer 320 and an inner layer 322 shown in Figure 15. Knitting element 318 can be similar to knitting element 218 (Figure 9) in terms of material and structure. However, the regional pockets formed in the gap space (which is formed between the outer layer 320 and the inner layer 322) and the regional inserts positioned in these pockets are different from the above-mentioned regional pockets. In the embodiment shown in the shoe upper 301, the regional pockets and the regional inserts are adjacent to each other and have the irregular edges that fit together like puzzle pieces. Covering the shoe upper 301 helps provide an upright structural shape to the shoe upper 301, and the shape of the bag and the insert is configured to follow the contour of the wearer's foot, so as to provide more specific regional support and characteristic to the various zones of the adjacent regional pockets of the shoe upper 301.

The depicted upper 301 includes a first irregular regional pocket 330, a second irregular regional pocket 332, a third irregular regional pocket 334, and a fourth irregular regional pocket 336. The first irregular regional pocket 330 and the first irregular regional insert 331 are disposed in the heel region 311. The first irregular regional insert 331 may generally have the configuration and properties of at least a portion of a heel counter. The first irregular regional pocket 330 is configured to receive the first irregular regional insert 331 and generally conform to the shape of the first irregular regional insert 331.

The second irregular regional pocket 332 and the second irregular regional insert 333 may be partially disposed in the heel region 311 and the ankle region 302, proximate the sole structure 303, spanning the third midfoot region, and terminating in the forefoot region 309. The second irregular regional insert 333 may have properties that provide flexibility and cushioning support to the portion of the upper proximate the second irregular regional insert 333. Additionally or alternatively, the second irregular regional pocket 332 may be configured to receive the second irregular regional insert 333 and may generally conform to the shape of the second irregular regional insert 333. As shown in FIG. 15 , the second irregular regional insert 333 may have a second thickness 343. The second thickness 343 may be uniform throughout the second irregular regional insert 333, or the second thickness 343 may vary throughout the second irregular regional insert 333. The variation in thickness may provide thinner portions of the irregular regional insert 333 for increased flexibility, or thicker portions for increased rigidity and support. The second irregular regional insert 333 may also include a second peripheral edge 342 shaped to extend portions of the second irregular regional insert 333 away from the sole structure 303 to provide cushioning along the sides of the upper 301 while also providing spacing between portions for increased flexibility. Similarly, the third irregular regional pocket 334 and the fourth irregular regional pocket 336 may be configured to receive a third regional insert 335 and a fourth regional insert 337, respectively, and each of these elements may include any of the features described above with respect to the second irregular regional pocket 332 and the second irregular regional insert 333. Any regional pocket of the upper 301 may be configured similarly to the regional pockets of the upper 201 (of FIG. 9 ), but the regional pockets of the upper 301 may have different shapes. Similarly, any regional insert of the upper 301 may optionally be made of a material similar to the regional inserts of the upper 201, but this is not required.

In some embodiments, such as the embodiment shown in Figures 16-19, the upper can be knitted to include visual cues and/or machine-detectable cues regarding the characteristics of the area, and/or can include a visible or machine-detectable bite line to similarly indicate to a technician or processing machine the intended placement of elements (such as a sole structure or throat opening support). In order to provide an article of footwear with desired aesthetic characteristics and effects, cues and/or bite lines can be included in addition or alternatively. The features illustrated by Figures 16-19 and described below can be used in combination with any other embodiment of the present disclosure.

16-19 can be similar in material and construction to knit element 218 (of FIG. 9 ). In some aspects, knit element 418 can be similar to upper 201 of article of footwear 200 and have many of the same features, structures, and performance characteristics as upper 201 of article of footwear 200.

While article 400 may include regional pockets and/or regional inserts, such as those described above, these regional pockets are not shown for clarity. Instead, article 400 may be provided with regional features or additional regional features based on the type of yarn used in a region, the type of knit stitches or other knit structures used in a region, and/or the knit density in a region. For the purposes of this discussion, knit density may be considered the number of stitches per unit length or area.

FIG16 shows several different zones on a knitted element 418: a first zone 430, a second zone 431, a third zone 433, a fourth zone 434, a fifth zone 435, a sixth zone 436, and a seventh zone 437. Each of these zones may have different structural, performance, and/or aesthetic properties. In addition to the type of yarn used in the zone, the type of knit stitches or other knit structures used in the zone, and/or the knit density in the zone, some of the different properties of the knitted element 418 may include stretch resistance, air permeability, and hardness.

In the embodiment of Figure 16, first district 430 spans from heel 416 to toe 414 along the lowest part of knitted element 418.First district 430 can be configured to (for example, with certain material and/or surface characteristics) in order to receive sole structure.In some embodiments, first district 430 can be harder than other districts, to form a stable surface for receiving sole structure.In some embodiments, first district 430 can be thicker than other districts, to form a surface that is more comfortable for foot.In some embodiments, first district 430 can comprise more thermoplastic polymer yarns than other districts, so that sole structure can be easily thermally bonded and/or welded to first district 430.In some embodiments, first district 430 can comprise the type of yarn that is more compatible with adhesive than other districts, so that first district 430 can be more easily adhesively bonded to sole structure.In some embodiments, first district 430 can be the combination of any characteristic in these characteristics.

Second district 431 extends from midfoot region 410 along the top of knitted element 418 and extends from the front portion of ankle region 402 to forefoot region 409. In some embodiments, second district 431 can be more elastic than other regions so that second district 431 can stretch to adapt to foot insertion and return to its original size to secure knitted element 418 to foot. In some embodiments, second district 431 can be configured to receive a lacing system reinforcement structure. When included, the lacing system can include eyelets, which can be perforated (e.g., knitted afterward) in second district 431, or can be directly knitted into second district 431. In embodiments with knitted eyelets, the eyelets can be formed by knitting float stitches (e.g., one-stitch float or two-stitch float on a circular knitting machine). Each eyelet can include an inlet and an outlet, and each of the inlet and outlet can include one or more yarns selected for durability and wear resistance. For example, the knitted eyelets may include high-tenacity yarns and/or thermoplastic yarns activated by a suitable post-processing step. In some embodiments, the second zone 431 may be thicker than the other zones to provide additional comfort for the top of the foot adjacent to the shoelaces. In some embodiments, the second zone 431 may include more thermoplastic yarns than the other zones, allowing the reinforcement structure to be easily thermally bonded and/or welded to the second zone 431. Alternatively, the second zone 431 may include a type of yarn that is more compatible with adhesives than the other zones, allowing the second zone 431 to be more easily adhesively bonded to the reinforcement structure. In some embodiments, the second zone 431 may include any combination of these characteristics.

The third zone 433 may be primarily located in the ankle region 402. The third zone 433 may be significantly more elastic and have greater recovery than the other zones (even than the second zone 431), such that the third zone 433 may stretch to accommodate foot insertion and return to its original size to secure the knit element 418 to the user's ankle.

The fourth district 434 can be positioned adjacent to the third district 433 and positioned between the first district 430 and the second district 431. The fourth district 434 can be positioned adjacent to the portion of the knitted element 418 that is designed to cover the ankle region of the user's foot. In some embodiments, the fourth district 434 can have stretch properties similar to those of the third district 433, but can also have cushioning properties or other protective properties to help protect the wearer's ankle. In some embodiments, the fourth district 434 can be harder and/or have less stretch than the third district 433 to suppress any possible lateral movement of the user's ankle. For example, the fourth district 434 can be selectively knitted with yarn having thermoplastic properties (e.g., hardening when activated by heat) to provide ankle support.

The fifth zone 435 can be positioned adjacent to the fourth zone 434 and between the first zone 430 and the second zone 431. In some embodiments, the fifth zone 435 can be stiffer than surrounding zones to provide stability to the knitted element 418. For example, the fifth zone 435 can be selectively knitted with yarn having thermoplastic properties (e.g., stiffening when activated by heat) to provide medial and lateral support.

The sixth zone 436 can be positioned adjacent to the fifth zone 435 and extend between the first zone 430 and the second zone 431. In some embodiments, the sixth zone 436 can be less stiff than surrounding zones to increase the flexibility of the knit element 418 proximate the user's toe joint.

Seventh zone 437 can be positioned in fourth forefoot region 409 and configured to cover the user's toes when the user's foot is within knitted element 418. In some embodiments, seventh zone 437 can be more breathable than surrounding zones. In other embodiments, seventh zone 437 can include a material that helps form toe seam 132, as described above, such as yarn comprising a thermoplastic polymer material.

FIG17 shows an embodiment of an unfolded element 518 that can be folded or otherwise manipulated into a double-layer knit element, such as knit element 418. The unfolded element 518 can include the same yarn pattern as shown in FIG16, or the unfolded element 518 can include a simplified pattern as shown, such that a first bite line 522 is positioned on a first portion of the unfolded element 518, and a second bite line 520 can be positioned between a first portion 543 and a second portion 541 of the unfolded element 518. The simplified pattern can include a first region 530 having a first regional characteristic, a second region 531 having a second regional characteristic, a third region 532 having a third regional characteristic, a fourth region 533 having a fourth regional characteristic, and a fifth region 534 having a fifth regional characteristic, etc. The regional characteristics can be any of the types of regional characteristics noted above with respect to knit element 418, or any other suitable type of regional characteristics. In this simplified embodiment, the second region 531 may have similar or substantially the same properties as the fifth region 534 , and the third region 532 may have similar or substantially the same properties as the fourth region 533 .

FIG17 shows an embodiment of an unfolded element 518 having a generally tubular, sock-like configuration. The first portion 543 and the second portion 541 are nearly identical in shape, albeit mirror images or opposite orientations. In some embodiments, the first portion 543 and the second portion 541 can have a foot-like shape similar to the unfolded element 138 discussed above.

In the embodiment shown, the first portion 543 includes an open toe 540, and the second portion 541 has a closed toe 542, wherein the edges of the tubular element have been knitted together or otherwise connected together. In some embodiments, the closed toe 542 can also be open. In such embodiments, the closed toe 542 can include a seam as discussed below.

5-8 . However, the unfolded element of FIG. 17 may additionally include a second bite line 520 that serves as a guide for the folding process, whereas the unfolded element 138 (of FIG. 5-8 ) does not show such a guide line. The folding machine may use a sensor, such as a laser detection system or a visual inspection system, that utilizes a captured image of the unfolded element 518 and the bite line 520 to detect where the primary fold should be, while the technician may use the bite line 520 as a simple visual guide for precise folding. Quality control inspection devices and inspectors may find that the second bite line 520 or other visual/detectable cue on the second unfolded element 518 may provide faster and more accurate inspections.

Figures 18 and 19 show an embodiment of how to use a bite line 420 to guide the sole structure 403 to be placed on the upper 401 including knitted elements 418. As shown in Figure 18, the sole structure may include a peripheral edge 423 that is constructed (e.g., sized and shaped) to follow the same profile as the bite line 420. Although shown as an irregular edge in the embodiment shown, the peripheral edge 423 may instead have a smooth edge or a different profile. The bite line 420 and the peripheral edge 423 may be aligned so that the peripheral edge 423 follows the profile of the bite line 420. Figure 19 shows article 400, in which the sole structure 403 is attached to the upper 401 so that the sole structure 403 covers the first zone 430 so that the peripheral edge 423 follows the first bite line 420. In other embodiments, when positioned on the upper 401, the peripheral edge 423 may cover a portion or all of the first bite line 420. Sole structure 403 may be attached to upper 401 using techniques including, but not limited to, stitching, adhesive bonding, heat bonding, and/or welding.

Figures 20A-20B show a knitted component 601, which includes an outer knitted layer 620 pulled onto an inner knitted layer (not shown), and further includes a sole structure 603, wherein the outer knitted layer 620 includes a retention system 640 for applying tension on the wearer's foot. The retention system 640 can be incorporated into a retention area 642, which can preferably be located on the medial and/or lateral portions of the outer knitted layer 620 and extend longitudinally along the knitted component 601. The retention system 640 can include one or more first yarns 650 (e.g., 650a, 650c, 650e, and 650g), which are configured to provide medial to lateral support (e.g., medial to lateral locking) when the wearer places the foot in the knitted component 601. The retention system 640 may additionally and optionally include one or more second yarns 660 (e.g., second yarns 660a, 660c, 660e, and 660g as depicted) for biasing the retention system 640 into the first state when the wearer's foot is not positioned within the knitted component 601. Furthermore, the retention system 640 may optionally include one or more third yarns 670 (e.g., third yarns 670a, 670c as depicted) that shield at least one first yarn 650 from abrasion, snagging, and other causes of damage while advantageously maintaining ventilation and visibility of the first yarn.

Still referring to Figures 20A-20B, first yarns 650a-650g can be knitted into intermeshed loops forming the outer knit layer 620, or can be inlaid within the intermeshed loops of the outer knit layer 620, and can generally have an orientation generally in the medial and lateral directions, in the heel and forefoot directions, or in other orientations. The first yarns 650a-650g can also include at least one inlaid first yarn 650 and a different looped first yarn 650. Optionally, when the retention system 640 includes a first yarn 650 having knitted loops, the first yarn 650 can include a float portion that floats (i.e., extends without looping) over a series of wales. When knitting a course during the knitting process, the float portion can be formed when the float portion of the first yarn 650 skips (i.e., extends through, without engaging) a series of consecutive needles on a needle bed. The needle bed can be a needle bed of a circular knitting machine. The length in the horizontal direction between the loops of each first yarn 650 that are closely adjacent to the end of the float portion can be referred to as the float length. When the first yarn 650 is taut, the float length can form a relatively straight dimension that can be parallel to and define the dimension of the holding area 642a-642b in the horizontal direction (i.e., the vertical dimension from the perspective of Figure 20A). When the first yarn 650 is not taut, the float length may not form a relatively straight dimension and may not define the dimension of the holding area 642a-642b in the horizontal direction. The number of consecutive float courses of the first yarn 650 can generally define the dimension of the holding area 642a-642b in the longitudinal direction (i.e., the horizontal dimension from the perspective of Figure 20A). This knitting structure allows each knitted first yarn 650 to be loosened from the rest of the knitted component within the holding area 642a-642b. Because the first yarn 650 has a nominal stitch length within the float length, and because the first yarn 650 can be constructed from a material having low stretch, the first yarn 650 can have very low stretch within the holding zone 642 along the horizontal direction (depicted as vertical) (at least when the first yarn 650 is taut).

More than one holding area 642 can be included. As shown in Figure 20A, for example, two holding areas 642a-642b can be included. Holding area 642a can be spaced apart from holding area 642b by part 643 of outer knitted layer 620 or otherwise separated. Part 643 of knitted layer can include a loop formed by first yarn 650a-650g. Advantageously, relative to including only one holding area 642, providing two (or more) holding areas 642a-642b can increase the amount that the retention system can shift between its first and second states. In addition, it is expected that machine limitations can limit the maximum float length of the first yarn 650a-650g, which is caused by the maximum number of needles that can be skipped without interrupting the knitting process (e.g., 8 needles, according to a test performed by the inventor). Therefore, in order to alleviate this limitation, part 643 of outer knitted layer 620 can include a loop formed by first yarn 650a-650g.

Suitable materials for the first yarn 650 include yarns formed with low-stretch/low-elasticity materials with relatively high tensile strength, such as cables, lines and ropes. Exemplary materials that can be used for the first yarn 650 can include strands or fibers with low elastic modulus and high tensile strength, such as the tensile strands of monofilament materials with a diameter of about 0.5 mm-2.0 mm, or fibers manufactured by Honeywell, Morristown, New Jersey, such as SPECTRA ^™ . Other suitable materials for the first yarn 650 include various filaments, fibers and yarns formed by rayon, nylon, polyester, polyacrylic acid, silk, cotton, carbon, glass, aramid (such as para-aramid fiber and meta-aramid fiber), ultra-high molecular weight polyethylene and liquid crystal polymers. Compared with the second yarn 660, the thickness of the first yarn 650 can be larger.

Still referring to Figure 20A-Figure 20B, the second yarn 660a-660g can be knitted into the mutually engaged loops forming the outer knitting layer 620, or can be embedded in the mutually engaged loops of the outer knitting layer 620, and can have mechanical properties (such as, specific elasticity and resilience), for when the knitted component 601 is not on the wearer's foot, the retention system 640 is biased to the first state. Exemplary materials for the second yarn 660a-660g can include yarns comprising elastic fibers, such as those yarns obtained from E.I.duPont de Nemours company with the LYCRA trade name. Such yarn can have the structure of covered LYCRA, such as yarn with a LYCRA core surrounded by a nylon sheath. Other fibers or silks showing elastic properties can also be adopted.

Still referring to Figure 20A, the third yarn 670 (as 670a-670c shown in Figure 20A and not shown in Figure 20B) can be knitted into the knitted structure of the mutually interlocking loops forming the outer knitted layer 620, or be inlaid in the mutually interlocking loops of the outer knitted layer 620. The third yarn 670 may include a yarn with suitable durability, such as a monofilament yarn or other yarn with high wear resistance and fracture resistance. In Figure 20A, the third yarn 670a-670c is schematically shown, and Figure 20A does not necessarily correspond to the orientation or stitch type of the third yarn 670a-670c. Typically, the third yarn 670 can be formed by a knit stitch, a tuck stitch or other suitable stitch or other knitted structure, and can be oriented to form a lattice structure, a covering or other protective knitted structure for the first yarn 650 as needed. In some embodiments, when the outer knit layer 620 is pulled over the inner knit layer 622, at least one of the first yarns 650 can be positioned behind at least one of the third yarns 670, such that an outer surface of the at least one of the first yarns 650 is covered by the at least one of the third yarns 670. In other words, in use, when the wearer's foot is placed within the knitted component 601, at least one of the first yarns 650 can be positioned between the wearer's foot and at least one of the third yarns 670, i.e., at least one of the third yarns 670 can be positioned over at least one of the first yarns 650.

Still referring to Figure 20 A, before the wearer places foot in knitted component 601, knitted component 601 can be in relatively soft sock-shaped state.The second yarn 660a-660g can bias knitted component 601 to a first state, wherein the second yarn 660a-660g can present a contracted state, and the first yarn 650a-650g can present a relaxed state, as shown in the figure, wherein the float length of the first yarn 650a-650g is greater than the corresponding size in the course direction of the retention system.By inserting foot into knitted component 601, as shown in Figure 20 B, the wearer stretches the second yarn 660a-660g to the second state, at which time, the second yarn 660a-660g stretches and provides a fitting wearing sensation by generating tension in the part of the bridge (bridge of the wearer ' s foot) of knitted component 601 around the wearer's foot. In addition, by inserting foot into knitted component 601, the wearer makes the first yarn 650a-650g become taut, as shown in Figure 20 B. Because the first yarn 650a-650g can be made of the material with relatively low stretchability and relatively high tensile strength, the first yarn 650a-650g can be subjected to tensile stress and tend to resist further elongation in the second state. This tends to remain on the wearer's foot with knitted component 601, without the need for extra steps (such as, lacing), and also the wearer's foot is remained on sole structure 603. In other words, the retention system applies tension (such as, the tension in the first yarn 650), to remain on the wearer's foot with knitted component 601. Tension force can also include the tension force present in the second yarn. In some embodiments, conventional elements such as tongue can be provided. However, in the embodiment shown, the sock-shaped property of knitted element can not need traditional tongue, because the ankle area can stretch to adapt to the insertion and retraction of foot, to fitly fix foot in knitted component. In some embodiments, the closure element can also be included for selectively fixing the knitted component to the wearer's foot. The closure element can be the element of any suitable type, for example a shoelace. In other embodiments, the closure element can also include one or more buckles, straps or other suitable tools for fixing the knitted component to the wearer's foot. Yet, in the illustrated embodiment, the knitted component can be constructed to be pulled onto the user's foot like a sock, and therefore can not include any additional closure element. When comprising the closure element, the closure element can operate together with the retention system 640 of Figure 20 A-20B, but, it can also be expected that the retention force provided by the retention system 640 can make the additional closure element unnecessary.

In other configurations, any of the knitted components disclosed above may include additional elements. For example, upper 101 (of FIG. 1 , or any other upper described herein) may include a toe guard formed of a wear-resistant material in the forefoot area. The upper may additionally include logos, trademarks, symbols, and a placard with care instructions and material information. It should be appreciated that any of the uppers disclosed above may include additional elements without departing from the scope of this disclosure.

The silk of non-woven layer, knitted material, parts or insert in any embodiment discussed above can comprise thermoplastic polymer material.In general, thermoplastic polymer material melts when heated, and returns to solid state when cooling.More specifically, thermoplastic polymer material is changed to softened state or liquid state from solid state when subjected to enough heat, and then thermoplastic polymer material is changed to solid state from softened state or liquid state when being cooled enough.Therefore, thermoplastic polymer material can be melted, moulded, cooled, melted again, moulded again and cooled again in multiple cycles.As will be described in more detail below, thermoplastic polymer material can also be combined with or fused to other fabric element, plate, sheet material, polymer foam element, thermoplastic polymer element, thermosetting polymer element or the multiple other element that is formed by various materials.Compared with thermoplastic polymer material, a lot of thermosetting polymer materials do not melt when heating, and just burn. While a wide variety of thermoplastic polymer materials can be used for nonwoven or knitted materials or filaments for inserts or components, some examples of suitable thermoplastic polymer materials include thermoplastic polyurethanes, polyamides, polyesters, polypropylenes, and polyolefins. While any of the aforementioned thermoplastic polymer materials can be used in the embodiments discussed above, the advantages of utilizing thermoplastic polyurethanes relate to thermal bonding and colorability. Compared to various other thermoplastic polymer materials (e.g., polyolefins), thermoplastic polyurethanes are relatively easy to bond to other components, as will be discussed in more detail below, and colorants can be added to thermoplastic polyurethanes through various conventional processes.

In some embodiments, the present invention relates to a nonwoven layer, a knitted material, a component and/or an insert. The nonwoven layer, a knitted material, a component and/or an insert may be formed entirely of a single thermoplastic polymer material. Some parts of the nonwoven layer, a knitted material, a component and/or an insert may also be formed, at least in part, of a plurality of polymer materials. As an example, a single filament in a nonwoven or knitted fabric may have a sheath-core structure, wherein the outer sheath of the single filament is formed of a first type of thermoplastic polymer material, and the inner core of the single filament is formed of a second type of thermoplastic polymer material. As a similar example, a single filament in a nonwoven or knitted fabric may have a bicomponent structure, wherein half of the single filament is formed of a first type of thermoplastic polymer material, and the relative other half of the single filament is formed of a second type of thermoplastic polymer material. In some configurations, any single filament may be formed of a thermoplastic polymer material and a thermosetting polymer material using any of the sheath-core or bicomponent arrangements.

Finally, while the above-described embodiments have generally referenced structures and products in the form of shoes, the present embodiments contemplate the manufacture of articles other than shoes, such as accessories or other apparel.

Although various embodiments of the present invention have been described, the present invention is not limited except in accordance with the appended claims and their equivalents. In addition, the advantages described herein are not necessarily the only advantages of the present invention, and it is not necessarily expected that every embodiment of the present invention will achieve all of the advantages described.

Claims (18)

1. A knitted component forming an upper foot portion and a lower foot portion of a footwear article, said knitted component comprising: The first layer defines the cavity; The second layer, wherein the second layer at least partially surrounds the first layer, wherein the second layer forms an outer surface on the upper and lower portions of the foot, and wherein a portion of the first layer is continuous with a portion of the second layer in the ankle region of the knitted component; A gap space is formed between the first layer and the second layer; A component disposed between the first layer and the second layer, the component being a waterproof membrane shaped like an upper, wherein the component extends from the outer side of the upper of the footwear article to the inner side of the upper; and A holding system, formed in the second layer and comprising a plurality of first yarns, wherein the holding system is movable from a first state to a second state, wherein in the first state, a plurality of float portions of the first yarns have slack such that the float length of the first yarns is greater than the size of the holding system; and At least the second layer comprises at least one yarn having a thermoplastic material. 2. The knitted component of claim 1, wherein the first layer and the second layer are formed on a circular knitting machine, and wherein the second layer is flipped relative to the first layer. 3. The knitted component according to claim 1, wherein the seam is formed in at least the second layer in the toe region of the knitted component. 4. The knitted component of claim 3, wherein the seam is formed in the first layer and the second layer such that the seam connects the first layer to the second layer. 5. The knitted component of claim 1, wherein the second layer holds the component in the foot region of the gap space via tension. 6. The knitted component of claim 1, wherein the component is held in the foot region of the gap space, and wherein the gap space is free of adhesive. 7. The knitted component according to claim 1, wherein the component is a shoe sole interlayer. 8. The knitted component of claim 1, wherein the retaining system further comprises a plurality of second yarns, wherein the first yarns and the second yarns at least partially form the second layer of the knitted component. The second yarn biases the holding system toward the first state, and The holding system applies tension in the second state. 9. The knitted component of claim 1, wherein the thermoplastic material is configured to bond the second layer to the second component. 10. The knitted component of claim 9, wherein the second component is a shoe outsole. 11. An upper for footwear articles, comprising: First layer; The second layer, wherein the second layer at least partially surrounds the first layer, wherein a portion of the first layer is continuous with a portion of the second layer, and wherein the first layer is continuous with the second layer in at least a portion of the ankle region of the shoe upper; A component disposed between the first layer and the second layer, wherein the component comprises a material having properties different from the first layer and the second layer, and wherein the component is a waterproof membrane in the shape of an upper, the component extending from the outer side of the upper to the inner side of the upper; and A holding system, formed in the second layer and comprising a plurality of first yarns, wherein the holding system is movable from a first state to a second state, wherein in the first state, a plurality of float portions of the first yarns have slack such that the float length of the first yarns is greater than the size of the holding system; and At least the second layer is formed of at least one yarn having a thermoplastic material. 12. The upper of claim 11, wherein the component extends together with at least a forefoot region and a midfoot region of the upper. 13. The upper of claim 11, wherein the component extends together with a portion of the heel area of the upper. 14. The upper of claim 11, wherein the first layer and the second layer are formed from a single integral knitted component, the single integral knitted component being folded such that the first layer and the second layer are connected at the collar region of the upper. 15. The upper of claim 11, wherein a second pocket is disposed between the first layer and the second layer, wherein the second pocket receives the component. 16. The upper of claim 11, further comprising a seam formed in the first layer and the second layer such that the seam connects the first layer to the second layer in the toe region of the upper. 17. The upper of claim 11, wherein the thermoplastic material is configured to bond the second layer to the second component. 18. The upper of claim 17, wherein the second component is an outsole.