Shoe having knit wingtip upper

A shoe includes a knit upper and a sole secured to the upper. The knit upper has a wingtip pattern knit into the knit upper.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

Not Applicable.

APPENDIX

Not Applicable.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention pertains to shoes having knit uppers.

SUMMARY

One aspect of the invention is a shoe comprising a knit upper and a sole secured to the upper. The knit upper has a knitted element. The knitted element is formed of a unitary one-piece construction during a knitting process on a knitting machine. The knitted element comprises a knitted upper heel region, a knitted upper lateral midfoot region, a knitted upper medial midfoot region, a knitted upper metatarsal region, a knitted upper lateral ball region, a knitted upper medial ball region, and a knitted upper toe region. The upper metatarsal region includes a knitted upper lateral metatarsal region and a knitted upper medial metatarsal region. The upper has a knitted upper lateral side region and a knitted upper medial side region. The upper lateral side region includes the upper lateral midfoot region, the upper lateral metatarsal region and the upper lateral ball region. The upper medial side region includes the upper medial midfoot region, the upper medial metatarsal region and the upper medial ball region. The upper toe region is seamlessly knitted with the upper medial and lateral ball regions during the knitting process. The upper medial and lateral ball regions are seamlessly knitted with the upper metatarsal region during the knitting process. The upper metatarsal region is seamlessly knitted with the upper lateral and medial midfoot regions during the knitting process. The knitted element includes a wingtip pattern. The wingtip pattern comprises portions of at least the upper toe region, the upper lateral and medial ball regions, and the upper lateral and medial metatarsal regions. The upper toe region, the upper lateral and medial ball regions, and the upper lateral and medial metatarsal regions collectively are knitted with the wingtip pattern during the knitting process.

Another aspect of the invention is a shoe comprising a knit upper and a sole secured to the upper. The knit upper has a knitted element formed of a unitary one-piece construction during a knitting process on a knitting machine. The knitted element comprises a knitted upper heel region, a knitted upper lateral midfoot region, a knitted upper medial midfoot region, a knitted upper metatarsal region, a knitted upper lateral ball region, a knitted upper medial ball region, and a knitted upper toe region. The upper metatarsal region includes a knitted upper lateral metatarsal region and a knitted upper medial metatarsal region. The upper has a knitted upper lateral side region and a knitted upper medial side region. The upper lateral side region includes the upper lateral midfoot region, the upper lateral metatarsal region and the upper lateral ball region. The upper medial side region includes the upper medial midfoot region, the upper medial metatarsal region and the upper medial ball region. The upper toe region is seamlessly knitted with the upper medial and lateral ball regions during the knitting process. The upper medial and lateral ball regions are seamlessly knitted with the upper metatarsal region during the knitting process. The upper metatarsal region is seamlessly knitted with the upper lateral and medial midfoot regions during the knitting process. The knitted element includes a line of broguing. The upper toe region is knitted with the line of broguing during the knitting process. The line of broguing comprises a line of holes. The knitted element comprises a first area of a first type of knit structure and a second area of a second type of knit structure. The second type of knit structure is different from the first type of knit structure. The first area is at least in the upper toe region. The second area is at least in the upper lateral and medial metatarsal regions. The line of broguing being adjacent a rear boundary of the first area. The line of broguing being adjacent a forward boundary of the second area.

Another aspect of the invention is a method of manufacturing an upper for an article of footwear. The method comprises knitting with a knitting machine to form a knitted element of the upper such that the knitted element is of a unitary one-piece construction comprising a knitted upper heel region, a knitted upper lateral midfoot region, a knitted upper medial midfoot region, a knitted upper metatarsal region, a knitted upper lateral ball region, a knitted upper medial ball region, and a knitted upper toe region. The upper metatarsal region includes an upper lateral metatarsal region and an upper medial metatarsal region. The knitted element has an upper lateral side region and an upper medial side region. The upper lateral side region includes the upper lateral midfoot region, the upper lateral metatarsal region and the upper lateral ball region. The upper medial side region includes the upper medial midfoot region, the upper medial metatarsal region and the upper medial ball region. The knitted element includes a line of broguing. The line of broguing comprises a line of holes. The knitted element comprises a first area of a first type of knit structure and a second area of a second type of knit structure. The second type of knit structure is different from the first type of knit structure. The first area is at least in the upper toe region. The second area is at least in the upper lateral and medial metatarsal regions. The line of broguing being adjacent a rear boundary of the first area. The line of broguing being adjacent a forward boundary of the second area. The upper toe region is seamlessly knitted with the upper medial and lateral ball regions during the knitting step. The upper medial and lateral ball regions are seamlessly knitted with the upper metatarsal region during the knitting step. The upper metatarsal region is seamlessly knitted with the upper lateral and medial midfoot regions during the knitting step. The upper toe region is knitted with the line of broguing during the knitting step. The first and second areas are knitted during the knitting step.

Another aspect of the invention is a method of manufacturing an article of footwear having a knitted upper and a sole. The method comprises knitting with a knitting machine to form a knitted element of the upper such that the knitted element is of a unitary one-piece construction comprising a knitted upper heel region, a knitted upper lateral midfoot region, a knitted upper medial midfoot region, a knitted upper metatarsal region, a knitted upper lateral ball region, a knitted upper medial ball region, and a knitted upper toe region. The upper metatarsal region includes an upper lateral metatarsal region and an upper medial metatarsal region. The knitted element has an upper lateral side region and an upper medial side region. The upper lateral side region includes the upper lateral midfoot region, the upper lateral metatarsal region and the upper lateral ball region. The upper medial side region includes the upper medial midfoot region, the upper medial metatarsal region and the upper medial ball region. The knitted element comprises a first area of a jersey stitch knit and a second area of a pointelle stitch knit. The first area is at least in the upper toe region. The second area is at least in the upper lateral and medial metatarsal regions. The method further comprises attaching the sole to the upper. The upper toe region is seamlessly knitted with the upper medial and lateral ball regions during the knitting step. The upper medial and lateral ball regions are seamlessly knitted with the upper metatarsal region during the knitting step. The upper metatarsal region is seamlessly knitted with the upper lateral and medial midfoot regions during the knitting step. The first and second areas are knitted during the knitting step.

Further features and advantages, as well as the operation, are described in detail below with reference to the accompanying drawings.

Reference numerals in the written specification and in the figures indicate corresponding items.

DETAILED DESCRIPTION

An embodiment of a shoe in accordance with the present invention is indicated by reference numeral10inFIGS. 1-4. The shoe10comprises a sole, generally indicated at12, a knit upper, generally indicated at14, and a welt, generally indicated at16. The sole12and welt16are secured to the upper14. The shoe10extends forward from a heel end18to a toe end19. The knit upper14has a knitted element20and a tongue22secured to the knitted element. The knitted element20is shown alone inFIG. 5and shown as part of the assembled shoe inFIGS. 1-5.

The knitted element20is formed of a unitary one-piece construction during a knitting process on a knitting machine (not shown). The knitted element20comprises a knitted upper heel region24, a knitted upper lateral midfoot region26a, a knitted upper medial midfoot region26b, a knitted upper metatarsal region28, a knitted upper lateral ball region30a, a knitted upper medial ball region30b, and a knitted upper toe region32. The upper heel region24includes a knitted upper lateral heel region24aand a knitted upper medial heel region24b. The upper metatarsal region28includes a knitted upper lateral metatarsal region28aand a knitted upper medial metatarsal region28b. The knitted upper toe region32includes a knitted upper lateral toe region32aand a knitted upper medial toe region32b. The upper14has a knitted upper lateral side region14aand a knitted upper medial side region14b. The upper lateral side region14aincludes the upper lateral heel region24a, the upper lateral midfoot region26a, the upper lateral metatarsal region28a, the upper lateral ball region30a, and the upper lateral toe region32a. The upper medial side region14bincludes the upper medial heel region24b, the upper medial midfoot region26b, the upper medial metatarsal region28b, the upper medial ball region30b, and the upper medial toe region32b. The upper toe region32is seamlessly knitted with the upper lateral and medial ball regions30a,30bduring the knitting process. The upper lateral and medial ball regions30a,30bare seamlessly knitted with the upper lateral and medial metatarsal regions28a,28bduring the knitting process. The upper lateral and medial metatarsal regions28a,28bare seamlessly knitted with the upper lateral and medial midfoot regions26a,26bduring the knitting process.

The knitted element includes a first wingtip pattern, generally indicated at36, and a second wingtip pattern, generally indicated at38. Each of the first and second wingtip patterns36,38comprises portions of at least the upper toe region32, the upper lateral and medial ball regions30a,30b, and the upper lateral and medial metatarsal regions28a,28b. The upper toe region32, the upper lateral and medial ball regions30a,30b, and the upper lateral and medial metatarsal regions28a,28bcollectively are knitted with the first and second wingtip patterns36,38during the knitting process.

The first wingtip pattern36comprises a line of broguing40comprising a lateral line of broguing40aand a medial line of broguing40b. The upper toe region32, the upper lateral and medial ball regions30a,30b, and the upper lateral and medial metatarsal regions28a,28bcollectively are knitted with the lateral and medial lines of broguing40a,40b. The lateral line of broguing40acomprises a wing-shaped curved line of holes42a. The lateral line of broguing40acomprises a lateral side broguing portion44aextending forward from at least the upper lateral metatarsal region28ato the upper toe region32, and a central broguing portion46aextending rearward from the upper toe region32. The lateral side broguing portion44aand the central broguing portion46aare each comprised of some of the holes42aof the lateral line of broguing40a. The medial line of broguing40bcomprises a wing-shaped curved line of holes42b. The medial line of broguing40bcomprises a medial side broguing portion44bextending forward from at least the upper medial metatarsal region28bto the upper toe region32, and a central broguing portion46bextending rearward from the upper toe region32. The medial side broguing portion44band the central broguing portion46bare each comprised of some of the holes42bof the medial line of broguing40b. The central broguing portions46a,46bconverge rearwardly toward each other, and meet to constitute a rearwardly pointing apex48. The upper14further comprises a throat50. The apex48points rearwardly toward the throat50of the upper14. Preferably, the holes42a,42bof the lateral and medial lines of broguing40a,40bare in the knitting element via the knitting process as opposed to being formed by removal of material such as by cutting or punching.

The knitted element20comprises a first area, generally indicated at52, of a first type of knit structure and a second area, generally indicated at54, of a second type of knit structure. The second type of knit structure is different from the first type of knit structure. The first area52is generally forward of the second area54. The first area52has a rear boundary56and the second area54has a forward boundary58. The rear boundary56of the first area52and the forward boundary58of the second area54is coincident and coextensive with each other and define a boundary line60between the first and second areas52,54. The second wingtip pattern38comprises the boundary line60. The first wingtip pattern36is forward of and adjacent the second wingtip pattern38. Also, the lateral and medial lines of broguing40a,40bare adjacent the boundary line60. As such the lateral and medial lines of broguing40a,40bare adjacent the rear boundary56of the first area52, and adjacent the forward boundary58of the second area54. The boundary line60has a lateral boundary line60aand a medial boundary line60b. The lateral boundary line60acomprises a wing-shaped curved line having a lateral side portion62aextending forward from at least the upper lateral metatarsal region28ato the upper toe region32, and a central portion64aextending rearward from the upper toe region32. The medial boundary line60bcomprises a wing-shaped curved line having a medial side portion62bextending forward from at least the upper medial metatarsal region28bto the upper toe region32, and a central portion64bextending rearward from the upper toe region32. The central portions64a,64bof the lateral and medial boundary lines60a,60bconverge rearwardly toward each other, and meet to constitute a rearwardly pointing apex66. The apex66points rearwardly toward the throat50of the upper14.

The first type of knit structure (that is, the knit structure of the first area52) may be more tightly knit than the second type of knit structure (that is, the knit structure of the second area54). In this embodiment, the first type of knit structure is a jersey stitch knit and the second type of knit structure is a pointelle stitch knit. The knitted element20may be knitted with one or more yarns, such as polyester yarns, nylon yarns, cotton yarns, and spandex yarns. In one embodiment, the knitted element20is knitted of polyester covered spandex yarn and hot melt yarn, such that of the finished knitted element, the polyester covered spandex yarn constitutes at least 50% by mass (and more preferably at least 60% by mass), and the hot melt yarn constitutes at least 15% by mass (and more preferably at least 20% by mass but not more than 30% by mass). The hot melt yarn is knitted with the polyester covered spandex yarn during the knitting process. Preferably, the polyester covered spandex yarn has a linear density of between about 120 denier and about 180 denier, and the hot melt yarn has a linear density of between about 80 denier and about 120 denier. In addition to the polyester covered spandex yarn and the hot melt yarn, the knitted element20may be knitted with stretch yarn, with the stretch yarn preferably constituting at least 5% by mass of the knitted upper. If stretch yarn is included, it is preferably limited (but need not be limited) to the topline area of the knitted element20to provide a stretch function primarily in the ankle region of the upper14of the shoe10. Preferably, the polyester covered spandex yarn includes a double layer of polyester. Also preferably, the stretch yarn is spandex yarn. In another embodiment, the knitted element20is formed by knitting hot melt yarn with polyester yarn during the knitting process such that polyester yarn constitutes at least 50% by mass of the knitted element and the hot melt yarn constitutes at least 15% by mass of the knitted element.

FIG. 6is a flow diagram of a method of making the shoe20ofFIGS. 1-5. In step100, the knitted element20is formed via a knitting machine, such as a CNC knitting machine, as a unitary one-piece construction. During the knitting step100, the upper lateral and medial heel regions24a,24bare knitted, the upper lateral and medial midfoot regions26a,26bare knitted, the upper lateral and medial metatarsal regions28a,28bare knitted, the upper lateral and medial ball regions30a,30bare knitted, and the upper lateral and medial toe regions32a,32bare knitted. By being knitted as a as a unitary one-piece construction, it is to be understood these various regions of the knitted element are formed together via the knitting process, as opposed to the regions being formed separately and then sewn or bonded together. As such, the upper toe region32is seamlessly knitted with the upper medial and lateral ball regions30a,30bduring the knitting step, the upper medial and lateral ball regions are seamlessly knitted with the upper metatarsal region28during the knitting step, the upper metatarsal region is seamlessly knitted with the upper lateral and medial midfoot regions26a,26bduring the knitting step, and the upper lateral and medial midfoot regions are seamlessly knitted with the upper lateral and medial heel regions24a,24bduring the knitting step.

The knitted element20is also knitted with a multiple of different types of knit structures during the knitting step. As described above, the first area52is of the first type of knit structure (e.g., jersey stitch knit) and the second area54is of the second type of knit structure (e.g., pointelle stitch knit). Also, the holes42a,42bof the lateral and medial lines of broguing40a,40bare formed via the knitting step, as opposed to being formed via removal of material (e.g., punching, cutting, etc.) after the knitting step. As shown inFIG. 5, the knitted element20also includes lateral and medial heel areas70a,70bof the second type of knit structure (e.g., pointelle stitch knit), lateral and medial midfoot areas72a,72bof the second type of knit structure (e.g., pointelle stitch knit), and lateral and medial eyestay areas74a,74bof the second type of knit structure (e.g., pointelle stitch knit). Broguing holes forming lines of broguing (the same or similar in form and construction to the lateral and medial lines of broguing40a,40b) are between the lateral heel area70aand the lateral midfoot area72a, between the lateral midfoot area and the lateral eyestay area74a, between the lateral midfoot region and the second area52, between the lateral eyestay area and the second area, between the medial heel area70band the medial midfoot area72b, between the medial midfoot area and the medial eyestay area74b, between the medial midfoot region and the second area, and between the medial eyestay area and the second area.

After the knitted element20is knitted via the knitting step100, the knitted element is pressed with a hot press during a pressing step, indicated at reference number102inFIG. 6.

During step104, the upper14is formed by attaching a strobel board80(seeFIG. 2)) to the knitted element20, attaching the tongue22to the knitted element, and attaching the upper lateral heel region24ato the upper medial heel region24b. A heel counter82(seeFIG. 1) may also be attached to the inner surface of the upper lateral and medial heel regions24a,24b. The upper14is then placed around a last at step106. Adhesive is applied to the underside of the strobel board80, and the upper14is passed via a conveyer through an oven (or heat tunnel). The oven heats the adhesive and also heats the hot melt yarn of the knitted element20. The heating and subsequent cooling of the hot melt yarn causes the hot melt yarn to affix to the other yarns (e.g., to the polyester yarn or polyester covered spandex yarn) so that the upper14conforms to the shape of the last. The sole12and welt16are bonded via the adhesive to the strobel board80and bottom periphery of the knitted element at step108.

An inner surface of the knitted element20(i.e., the surface facing the inside of the shoe10) may be lined or unlined. In an unlined configuration, the inner surface of the knitted element20is devoid of a lining (other than the heel counter82or eyelet reinforcement adjacent the throat) and such inner surface of the knitted element defines at least a majority of a foot receiving cavity of the shoe. In a completely lined configuration, a lining is between the inner surface of the knitted element and the foot receiving cavity of the shoe such that the foot receiving cavity of the shoe is in part defined by the lining (instead of by the inner surface of the knitted element).

In view of the foregoing, it should be appreciated that the invention has several advantages over the prior art.

As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, the wedge shoe may be any type of wedge shoe, such as a wedge sandal, a wedge pump, an open-toe wedge, a platform wedge, etc. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents

It should also be understood that when introducing elements of the present invention in the claims or in the above description of exemplary embodiments of the invention, the terms “comprising,” “including,” and “having” are intended to be open-ended and mean that there may be additional elements other than the listed elements. Additionally, the term “portion” should be construed as meaning some or all of the item or element that it qualifies. Moreover, use of identifiers such as first, second, and third should not be construed in a manner imposing any relative position or time sequence between limitations.