Patent Description:
Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. In some articles of athletic footwear, for example, 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 lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. The outsole is secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material.

The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the cavity on the interior of the upper is generally provided by an ankle opening, a. throat opening, in a heel region of the footwear. A lacing or Velcro system is often incorporated into the exterior of the upper to adjust the geometry of the upper, thereby permitting entry and removal of the foot from the cavity within the upper. The lacing or Velcro system also permits the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear. A shoe tongue is a strip of leather or other material located under the laces or Velcro of a shoe. The tongue sits on the top center part of the shoe on top of the bridge of the foot. It is generally attached to the vamp and runs all the way to the throat of the shoe.

<CIT> and <CIT> disclose generic methods for knitting inner components of an upper.

The objective technical problem to be solved may be considered to consist in overcoming or at least reducing the disadvantages according to the prior art. The problem is solved by the subject matter of the independent claims.

The embodiments described herein may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale. Moreover, in the figures, like-referenced numerals designate corresponding parts throughout the different views.

It also should be understood that the drawings are not necessarily to scale, and in certain instances, details may have been omitted that are not necessary for an understanding of aspects disclosed herein, such as conventional fabrication and assembly.

Certain aspects of the present disclosure relate to uppers configured for use in an article of footwear and/or other articles, such as articles of apparel. When referring to articles of footwear, the disclosure may describe basketball shoes, running shoes, biking shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennis shoes, and/or walking shoes, as well as footwear styles generally considered non-athletic, including but not limited to dress shoes, loafers, and sandals.

Background knowledge useful for understanding the claimed invention relates to an upper for an article of footwear that includes a medial side, a lateral side, and a throat area between the medial side and the lateral side. An inner component forms an inner surface of the upper, where the inner component includes an inner throat region in the throat area, where a tensile strand of the inner component forms a loop in the inner throat region, and where the loop includes an opening for receiving a fastening element. An outer shroud forms the outer surface of the upper, where the outer shroud at least partially covers the inner throat region of the inner component such that the loop is located in a pocket formed between the inner component and the outer shroud. The upper may further include any other compatible feature, such as those described in this description.

Background knowledge useful for understanding the claimed invention relates to an upper for an article of footwear that includes an inner component forming an inner surface of the upper, where the inner component includes an inner throat region in a throat area of the upper. An outer shroud forming an outer surface of the upper may at least partially cover the inner throat region of the inner component such a pocket is formed between the inner component and the outer shroud. A fastening element may be included, where the fastening element extends through an opening of the inner component, and where the opening is located within the pocket. The upper may further include any other compatible feature, such as those described in this description.

The present disclosure provides a method according to the subject matter of claim <NUM>. The upper may further include any other compatible feature, such as those described in this description, and any suitable method step may be included for forming an upper with such features.

<FIG> and <FIG> are illustrations respectively depicting a lateral-side view and a top view of an example of an article of footwear <NUM>. As shown, the article of footwear <NUM> includes an upper <NUM> that is secured to a sole structure <NUM>. The area where the sole structure <NUM> joins the upper <NUM> may be referred to as a biteline <NUM>. The upper <NUM> may be joined to the sole structure <NUM> in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, etc. The upper <NUM> may extend partially or completely around a foot of a wearer (e.g., under the foot in some embodiments), and the sole structure <NUM> may cover at least the dorsal surface (e.g., bottom) of the wearer's foot. In some embodiments, the sole structure <NUM> may include a midsole and an outsole.

The upper <NUM> may include a lateral side <NUM>, a medial side <NUM>, a toe area <NUM>, and a heel area <NUM>. The upper <NUM> may additionally include a throat area <NUM> extending from an ankle opening <NUM> leading to a void <NUM>, and a collar <NUM> may at least partially surround the ankle opening <NUM>. The void <NUM> of the article of footwear <NUM> may be configured (e.g., sized and shaped) to receive and accommodate a foot of a person. The throat area <NUM> may be generally disposed in a midfoot area <NUM> of the upper <NUM>, which may be located between the heel area <NUM> and a toe area <NUM>.

The upper <NUM> includes an inner component <NUM> forming an inner surface <NUM> of the upper <NUM> and an outer shroud <NUM> forming an outer surface of the upper <NUM>. At least the inner component <NUM> and optionally the outer shroud <NUM> includes a knitted component <NUM> and/or <NUM>. For example, in the depicted embodiment, the inner component <NUM> is depicted as being formed substantially, or completely, of a knitted component <NUM>, but alternatively it may be at least partially formed of another non-knit material. For example, the inner component <NUM> may additionally formed with textile materials formed by a process other than knitting (e.g., weaving) and/or other materials, such as leather, plastic, rubber, etc. The outer shroud <NUM> is depicted as being formed of a non-knit material in the present figures, but in other embodiments the outer shroud <NUM> may be partially or fully formed of a knitted component.

Forming the inner component <NUM> and optionally the outer shroud <NUM> with a knitted component knitted materials may provide the upper <NUM> with advantageous characteristics including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. These characteristics may be accomplished by selecting a particular single layer or multi-layer knit structure (e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), and/or a combination thereof. Forming the upper <NUM> (e.g., the inner component <NUM> and/or the outer shroud <NUM>) at least partially with knitted material may also provide desirable aesthetic characteristics by incorporating yarns having different colors, textures or other visual properties arranged in a particular pattern.

The inner component <NUM> and/or the outer shroud <NUM> may be formed as an integral one-piece element during a single knitting process, such as a weft knitting process (e.g., with a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine may substantially form the knit structure of inner component <NUM> and/or the outer shroud <NUM> without the need for significant post-knitting processes or steps. Alternatively, two or more portions of the inner component <NUM> and/or the outer shroud <NUM> may be formed separately as distinct integral one-piece elements and then the respective elements attached. In some embodiments (not shown), it is contemplated that a single knitted component may be included (e.g., where inner component <NUM> and/or the outer shroud <NUM> are combined as an integral one-piece element), and that single knitted component may form the majority of or the entirety of the upper <NUM>. For example, if a multi-layer knitting technique is used, the inner component <NUM> may be defined by a first knit layer (e.g., formed on a first bed of a flat knitting machine), and the outer shroud <NUM> may be defined by a second knit layer (e.g., defined by a second layer formed on a second needle bed of a flat knitting machine). In other embodiments, it may be advantageous to form the inner component <NUM> and the outer shroud <NUM> separately such that, if formed on a knitting machine, the inner component <NUM> and/or the outer shroud <NUM> is formed alone using the full capacity of two needle beds of a knitting machine, thereby enhancing the ability for providing advanced knit structures (e.g. to provide certain mechanical and/or visual characteristics of the knitted material).

Further, the types of yarns used to form the inner component <NUM> (and/or the outer shroud <NUM> in other embodiments) may be varied at different locations such that the inner component <NUM> has areas with different properties (e.g., referring to <FIG> , a portion forming the throat area <NUM> of the inner component <NUM> may be relatively elastic while another portion may be relatively inelastic, as described in more detail below).

The inner component <NUM>, outer shroud <NUM>, whether formed of knitted textiles or not, or both may be formed from a variety of materials. Such materials may be included in yarns (e.g., when knitted components are used as described above). For example, the inner component <NUM>, outer shroud <NUM>, or both may be formed from elastomeric materials, such as polyurethane containing polymer, spandex, lycra, polyester or polyether polyols that allow the region to stretch and then recover to its original shape. Polyester may be used in locations where the inner component <NUM> and/or the outer shroud <NUM> will contact the foot of a wearer, such as the inner surface <NUM>, due to its comfort characteristics in combination with its suitable durability.

In some embodiments, the inner component <NUM>, outer shroud <NUM>, or both may be formed from thermoset polymeric materials and natural fibers, such as cotton, silk, wool, or polyester. When subjected to moderate levels of heat, thermoset polymeric materials tend to remain stable. Moreover, when subjected to elevated levels of heat, thermoset polymeric materials and natural fibers may burn or otherwise degrade or decompose. As such, thermoset polymeric materials generally always remain in a permanent solid state. In some aspects, the melting point or decomposition temperature of at least a portion of a yarn (or other element) used to form the inner component <NUM> and/or the outer shroud <NUM> is greater than about <NUM>, based on one atmosphere pressure, such as greater than about <NUM>, and such as greater than <NUM> or higher in certain embodiments.

Additionally or alternatively, in some embodiments, the inner component <NUM> may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). For example, the inner component <NUM> may include yarns formed of one or more thermoplastic polymer materials (including material composites) that transition from a solid state to a softened or liquid state when subjected to certain temperatures at or above the melting point and then transitions back to a solid state when cooled. The thermoplastic polymer material(s) may provide the ability to heat and then cool a portion of the knitted material to thereby form an area of bonded or continuous material (herein referred to as a "fused area") that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example. Non-limiting examples of thermoplastic polymer materials are polyurethanes, polyamides, polyolefins, and/or certain nylons.

<FIG> is an illustration showing the inner component <NUM> in isolation. The inner component <NUM> may form an inner surface <NUM> (see <FIG>) of the upper <NUM>, where the inner surface <NUM> defines the void of the article of footwear. As shown in <FIG>, the inner component <NUM> may have a second surface <NUM>, located opposite the inner surface <NUM>, having an inner medial region <NUM> and an inner lateral region <NUM>. An inner throat region <NUM> may occupy a proximal portion of the inner medial region <NUM>.

A tensile strand <NUM> extends through the inner lateral region <NUM> of the inner component <NUM> to the inner throat region <NUM>. The tensile strand <NUM> is included as a portion of the knitted component <NUM> (that is, formed on a knitting machine with the remainder of the inner component <NUM>), or not. The tensile strand <NUM> is inlaid within the knitted component by a flat knitting machine such that the inlaid strand <NUM> extends between certain intermeshed loops of the knitted component <NUM>. An inlaid strand and method of manufacturing is fully described in <CIT>. For example, some intermeshed loops of the knitted component <NUM> may be on one side of the inlaid strand <NUM> and other intermeshed loops of the knitted component <NUM> may be on the opposite side of the inlaid strand <NUM> such that the inlaid strand <NUM> extends between two opposite-facing surfaces formed by the knitted component <NUM>. In other embodiments that do not form part of the claimed invention, the tensile strand <NUM> may be assembled with the remainder of the inner component <NUM> after the knitting process. For example, the inner component <NUM> may include a set of channels <NUM> for receiving the tensile strand <NUM>, and the tensile strand <NUM> may be deployed through the channels <NUM> as a post-knitting manufacturing step.

In some embodiments, portions of the tensile strand <NUM> may be at least partially exposed from the remainder of the inner component <NUM> (i.e. , it may be exposed with respect to a surface of the inner component). For example, as shown in <FIG>, a set of loops <NUM>, which form openings <NUM> for receiving a shoe-fastening element, are exposed outside of the surface <NUM>, extend out of the knitted component <NUM> adjacent to the throat region to form lace-receiving openings (as described in more detail below).

The tensile strand <NUM> may be a yarn, a cable, a rope, or any other type of strand. The tensile strand <NUM> may have any suitable elasticity, and in some embodiments it may have a substantially fixed length measured from a first end to a second end. In other words, the tensile strand <NUM> may be substantially inelastic. In other embodiments, an elastic tensile strand may additionally or alternatively be included.

Any suitable material may be used to form the tensile strand <NUM>. For example, the tensile strand <NUM> may include a monofilament fiber and/or strands or fibers having a low modulus of elasticity as well as a high tensile strength including various filaments, fibers, and yarns, that are formed from rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramids (e.g., para-aramid fibers and meta-aramid fibers), ultra-high molecular weight polyethylene, and liquid crystal polymer. In some embodiments, a material forming most of the remainder of the upper <NUM> may elongate at least twice as much as the elongation of the tensile strand <NUM> when subjected to the same tensile force (e.g., such as a <NUM> pound force applied on a tensometer). Put another way, the Young's modulus of the tensile strand is at least twice as large as the Young's modulus of the material forming most of the remainder of the upper <NUM>, where the Young's modulus is measured using the ASTM E <NUM> standard test method for a material's Young's Modulus, measuring the rate of change of strain as a function of tensile stress.

<FIG> is an illustration showing an exploded view of the inner component <NUM> and the outer shroud <NUM> (when they are not formed integrally on a knitting machine). Referring to <FIG>, in the completed upper, the outer shroud <NUM> is positioned against the second surface <NUM> of the inner component <NUM> such that the outer shroud <NUM> forms an outer surface <NUM> of the upper <NUM>. The outer shroud <NUM> includes an outer medial region <NUM> and an outer lateral region <NUM>. Notably, the outer shroud <NUM> may optionally include some knit areas (e.g., outer lateral region) and other non-knit areas (e.g., the outer medial region <NUM>) to optimize surface characteristics on different areas of the article of footwear. An outer throat region <NUM> occupies a proximal portion of the outer medial region <NUM>. The outer shroud <NUM> may at least partially cover inner throat region <NUM> of the inner component <NUM>. In this way, the inner component <NUM> is positioned against the outer shroud <NUM> so that the loops <NUM> formed by the tensile strand <NUM> are located between the inner component <NUM> and the outer shroud <NUM>. For example, the loops <NUM> may be located in a pocket in the throat area, where the pocket is formed by coextensive layers (i.e. , the inner component <NUM> and the outer shroud <NUM>). The outer shroud <NUM> and the inner component <NUM> of the upper <NUM> may be attached to a sole to form an article of footwear <NUM>, as depicted in <FIG> and <FIG>.

Referring to <FIG>, the loops <NUM> formed by the tensile strands <NUM>, which may be situated between the inner and outer throat regions <NUM>, <NUM>, may be sized, shaped, positioned, and/or otherwise configured to receive a shoe-fastening element <NUM> (shown in <FIG>). The fastening element <NUM> may include, but is not limited to, a shoelace, a strap, an elastic band, or a drawstring, or any other suitable device that is configured to adjust the geometry of the upper upon application of a force or other input action. The fastening element <NUM> may be positioned between the outer shroud <NUM> and inner component <NUM> such that the fastening element <NUM> is at least partially obscured by the outer shroud <NUM> (from an external perspective, as depicted in <FIG>).

Referring to <FIG>, two loops <NUM> of the plurality of loops <NUM> overlap to form a single lacing loop eyelet <NUM>. This is advantageous because the fastening element <NUM> may be secured with two loops <NUM> at a fastening point <NUM>. By having at least two loops <NUM> at a fastening point <NUM>, there is built in redundancy in case one of the loops <NUM> breaks, allowing the remaining loop <NUM> to support the fastening element <NUM> without significantly changing the fit of the inner component <NUM>. This redundancy can be advantageous as the fastening element <NUM> is at least partially obscured by the outer shroud <NUM>, complicating any repair or replacement activities. Additionally, by using at least two separate loops <NUM> to form a single lacing loop eyelet <NUM>, the shoe-fastening element <NUM> may interact with multiple tensile strands <NUM> extending from the throat area <NUM> of the upper <NUM> to the medial and/or lateral biteline <NUM> (shown in <FIG>), thus providing an enhanced, snug fit around the foot.

One advantage of the systems described is the covering, or partial covering, of at least one of the loops <NUM> and/or the shoe-fastening element <NUM>. This feature may result in the upper <NUM> having a more uniform texture in certain regions of the outer surface <NUM>, such as in the medial region, the lateral region, and/or the throat area <NUM> where the shoe-fastening element <NUM> is typically exposed in other articles of footwear. This may affect air flow around the article of footwear <NUM>, decrease the movement of the shoe-fastening element <NUM> when the article of footwear <NUM> is in use, provide a more uniform surface in the medial region of the outer surface <NUM> if using the article of footwear <NUM> to interact with a ball or sport equipment (e.g., during a kick), provide additional area on the outer surface <NUM> for aesthetic applications or branding, among other advantages. Additionally, by covering, at least in part, the loop <NUM> or shoe-fastening element <NUM>, these aspects of the article of footwear <NUM> are partially protected from some environmental stresses including, but not limited to, UV light from sunlight, wind, particulate, water, soil, and debris. As a result of reducing the amount of contact these environmental irritants have with the loop <NUM> and shoe-fastening element <NUM>, the loop <NUM> and shoe-fastening elements <NUM> may experience a decreased rate of deterioration.

In some embodiments, and as shown in <FIG>, the inner component <NUM> and the outer shroud <NUM> may include respective eyelets <NUM> and <NUM>. When assembled, the eyelets <NUM>, <NUM> may be aligned when the upper <NUM> is assembled such that they are positioned for receiving a lace or other shoe-fastening element. The eyelets <NUM>, <NUM> may be included in addition to the loop <NUM> in a different location along the throat of the upper <NUM>, but they may be associated with the same shoe-fastening element. The eyelets <NUM>, <NUM> may be advantageous for communicating with the shoe-fastening element at a location that is accessible to a user, and also for providing a snug fit near the top of the foot without necessitating a high-degree of rigidity at that location (which may be uncomfortable) as provided by the tensile strands <NUM> in other locations lower on the foot. Optionally, at least one of the eyelets (in this case the depicted eyelets <NUM>) of the outer shroud <NUM> may be aligned with certain loops <NUM>, which may be advantageous for aesthetics, shoe-fastening element accessibility, and enhanced fit/comfort (particularly where the outer shroud <NUM> may move slightly with respect to the inner component <NUM> during wear.

The outer throat region <NUM> has an elasticity that is higher than an elasticity the lateral region of the shroud, and the inner throat region <NUM> may have an elasticity that is higher than the elasticity of the lateral region of the inner component <NUM>. This may be advantageous for providing rigidity, for structural integrity, of the medial and lateral sides (e.g., for providing desirable characteristics for use when a user makes lateral movements during athletic competition), while proving an elastic throat area to facilitate variable fit around the foot. The relatively high inner and outer throat region <NUM> elasticity may be provided using elastomeric materials, such as polyurethane containing polymer, spandex, lycra, polyester or polyether polyols that allow the region to stretch and then recover to its original shape, and/or by using certain knitting or other manufacturing techniques that impart a high elasticity into textiles (for example). In some embodiments, a material forming of the inner and outer throat regions of the outer shroud <NUM> may be may elongate at least twice as much as the elongation of the tensile strand <NUM> when subjected to the same tensile force (e.g., such as a <NUM> pound force applied on a tensometer). Put another way, the Young's modulus of the tensile strand is at least twice as large as the Young's modulus of the material forming most of the remainder of the upper <NUM>, where the Young's modulus is measured using the ASTM E111 standard test method for a material's Young's Modulus, measuring the rate of change of strain as a function of tensile stress. Alternatively, the relatively high elasticity of the inner and outer throat regions <NUM>, <NUM> may be the function using a knit, folded, or ridged structure that allows for additional regional elasticity or some combination using structure and elastomeric materials.

One advantage of the systems described is that the relatively high elasticity in the inner and outer throat regions <NUM>, <NUM> allows the upper <NUM> to stretch to accommodate a wearer's foot as it enters the void without the use of separate tongue pieces. By removing the need for a tongue piece, the upper <NUM> may have a more streamlined appearance and shape. Additionally, by removing the need for the tongue, only a single, uninterrupted inner surface <NUM> of the upper <NUM> comes in contact with the wearer's foot, increasing wearer comfort.

Claim 1:
A method, comprising:
knitting intermeshed loops of an inner component (<NUM>) of an upper (<NUM>), wherein the inner component (<NUM>) forms an inner surface (<NUM>) of the upper (<NUM>), and wherein the inner component (<NUM>) includes an inner throat region (<NUM>) in a throat area (<NUM>) of the upper (<NUM>);
inlaying a tensile strand (<NUM>) between loops of the inner component (<NUM>), wherein the tensile strand (<NUM>) of the inner component (<NUM>) forms a loop (<NUM>) in the inner throat region (<NUM>) that forms an opening (<NUM>) for receiving a fastening element (<NUM>); and
securing an outer shroud (<NUM>) to the inner component (<NUM>), wherein the outer shroud (<NUM>) forms an outer surface (<NUM>) of the upper (<NUM>), and wherein the outer shroud (<NUM>) at least partially covers the inner throat region (<NUM>) of the inner component (<NUM>) such that the opening (<NUM>) is located in a pocket formed between the inner component (<NUM>) and the outer shroud (<NUM>),
wherein the inner component (<NUM>) is a knitted component (<NUM>), wherein the at least one tensile strand (<NUM>) is inlaid within the knitted component (<NUM>) by a flat knitting machine such that the inlaid strand (<NUM>) extends between certain intermeshed loops of the knitted component (<NUM>),
wherein the inner component (<NUM>) comprises a set of loops (<NUM>) in the inner throat region (<NUM>),
and wherein the method is characterized in that an outer throat region (<NUM>) of the outer shroud (<NUM>) has an elasticity that is higher than an elasticity of an outer medial region (<NUM>) and an outer lateral region (<NUM>) of the outer shroud (<NUM>), and wherein at least two loops (<NUM>) of the plurality of loops (<NUM>) are configured to overlap to form a single lacing loop eyelet (<NUM>).