Patent Description:
The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under 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 void on the interior of the upper is generally provided by an ankle opening in a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing 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, and the upper may incorporate a heel counter to limit movement of the heel.

Articles of footwear often are constructed of many components. For example, an article of footwear may include many components, such as an upper, a sockliner, a strobel, a midsole, and an outsole. An outsole may have spikes, cleats, or other protrusions to provide additional traction under selected circumstances. Each of these components is attached to at least one, typically two, and maybe three or more of the other components. Some components thus are stitched to, adhered to, or otherwise attached to other components.

Construction of an article of footwear comprising many components may require that components having significantly different properties and characteristics must be attached to each other. For example, an upper may be formed from cloth, a midsole from soft foam, and an outsole from wear-resistant rubber. These components often can be adhered with adhesives. Adhesive may fail, causing delamination of the components. Further, wear may occur at joints between harder and softer materials, or between dissimilar materials. Therefore, such joints may cause premature failure of the article of footwear. Such joints also may provide uncomfortable sudden transitions between areas of softer or more compliant materials and areas of harder or more rigid materials.

Further, assembly of multiple components may be time-consuming and may lead to errors. For example, components from one style of an article of footwear may incorrectly be used on a different style of footwear. The number of potential errors and premature failures may be significant.

A variety of material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing an article of footwear. In athletic footwear, for example, the upper may have multiple layers that each include a variety of joined material elements. As examples, the material elements may be selected to impart stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, and moisture-wicking to different areas of the upper. Similarly, the sole structure may utilize a number of components to provide selected properties and characteristics. To impart the different properties to different areas of the article of footwear, material elements are often cut to desired shapes and then joined together, usually with stitching or adhesive bonding. Moreover, the material elements often are joined in a layered configuration to impart multiple properties to the same areas. As the number and type of material elements incorporated into the article of footwear increases, the time and expense associated with transporting, stocking, cutting, and joining the material elements also may increase. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and type of material elements incorporated into the article of footwear increases. Moreover, articles of footwear with a greater number of material elements may be more difficult to recycle than articles of footwear formed from fewer types and numbers of material elements. By decreasing the number of material elements utilized in the article of footwear, therefore, waste may be decreased while increasing the manufacturing efficiency and recyclability of the upper.

<CIT> discloses a material having non-slip characteristics which is formed by moulding an elastomeric material around at least one layer of metal fabric knitted from at least one strand of metal, such as steel wool. Such material is particularly suitable for shoe soles, which soles may contain a plurality of layers of knitted metal fabric, and optionally have studs containing rolls of knitted metal fabric.

<CIT> discloses a shoe comprising an upper and an outer sole and/or a midsole which is connected to the upper, the outer sole and/or the midsole comprising knitwear.

Reducing the number of material elements may require that one material element provide multiple and additional properties and characteristics sought by users. Thus, there exists a need in the art for articles of footwear comprising a minimum number of material elements while providing a number of properties and characteristics sought by users.

An article of footwear is provided according to the subject matter of claim <NUM>.

The cleat member may be configured to contact the ground.

The knitted component may form a knit outsole, the knit outsole comprising the cleat member.

The article of footwear may have an insert member disposed in an interior of the upper, the insert member having a protuberance extending into a cavity formed by the cleat member.

The knitted component may include a fusible yarn.

The sole system may have a cleat cover element covering at least a portion of the cleat member of the knitted component.

The lower portion of the knitted component comprises an inlaid tensile element.

The inlaid tensile element is located adjacent the cleat member.

A sole system is provided according to the subject matter of claim <NUM>.

The ground-facing surface is configured to contact the ground.

The sole system may have a top surface configured to be affixed to an upper formed separately from the sole system.

The sole system may include a fusible yarn.

Each cleat member of the plurality of cleat members may include a cavity filled with a reinforcing material.

The knitted component has at least one tensile element inlaid within the knitted component and which is positioned adjacent to at least one cleat member of the plurality of cleat members. According to the claimed invention, at least one tensile element may include a tensile element loop configured to permit the adjustment of the at least one tensile element within the knitted component.

A method of manufacturing a sole system is provided according to the subject matter of claim <NUM>.

The method may further include inserting an insert member within an upper of the article of footwear such that a protrusion extending from the insert member is received by a cavity of the cleat member.

A vacuum forming process may form the lower portion of the knitted component around an insert member having a protuberance to form the cleat member.

The method may include injecting a reinforcing material into a cavity of the cleat member.

The method may include inserting the knitted component into a mold prior to the step of injecting the reinforcing material into the cavity of the cleat member.

The claimed invention can be better understood with reference to the following drawings and description.

The following discussion and accompanying Figures disclose a variety of concepts relating to knitted components and the manufacture of knitted components. Although the knitted components may be utilized in a variety of products, an article of footwear that incorporates one of the knitted components is disclosed below as an example. The description will be directed in detail to an article of footwear. However, in addition to footwear, the knitted components may be utilized in other types of apparel (e.g., gloves or mittens) where the ability to securely grip an object may be enhanced by protuberances. Accordingly, the knitted components and other concepts disclosed herein may be incorporated into a variety of products for both personal and industrial purposes.

<FIG> illustrate exemplary embodiments of an article of footwear having an upper and a knit sole system incorporating a knitted component and the associated method of manufacturing. The upper and knit sole system incorporate a knitted component that is vacuum-formed to produce a knit outsole having cleat members. The individual features of any of the knitted components described herein may be used in combination or may be provided separately in different configurations for articles of footwear.

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term "longitudinal" as used throughout this detailed description and in the claims refers to a direction extending a length or major axis of an article. In some cases, the longitudinal direction may extend from a forefoot region to a heel region of the article. Also, the term "lateral" as used throughout this detailed description and in the claims refers to a direction extending a width or minor axis of an article. In other words, the lateral direction may extend between a medial side and a lateral side of an article. Furthermore, the term "vertical" as used throughout this detailed description and in the claims refers to a direction generally perpendicular to a lateral and longitudinal direction. For example, in cases where an article is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of an article, including an upper, a knitted component and portions thereof, and/or a sole system.

<FIG> illustrate an exemplary embodiment of an article of footwear <NUM>, also referred to simply as article <NUM>. In some embodiments, article of footwear <NUM> may include a sole system <NUM> and an upper <NUM>. Although article <NUM> is illustrated as having a general configuration suitable for enhanced traction, concepts associated with article <NUM> may also be applied to a variety of athletic footwear types, including soccer shoes, baseball shoes, basketball shoes, cycling shoes, football shoes, tennis shoes, training shoes, walking shoes, and hiking boots, for example. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed with respect to article <NUM> may be applied to a wide variety of footwear types.

For reference purposes, article <NUM> may be divided into three general regions: a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>. Forefoot region <NUM> generally includes portions of article <NUM> corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region <NUM> generally includes portions of article <NUM> corresponding with an arch area of the foot. Heel region <NUM> generally corresponds with rear portions of the foot, including the calcaneus bone. Article <NUM> also includes a lateral side <NUM> and a medial side <NUM>, which extend through each of forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and correspond with opposite sides of article <NUM>. More particularly, lateral side <NUM> corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot), and medial side <NUM> corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Forefoot region <NUM>, midfoot region <NUM>, heel region <NUM>, lateral side <NUM>, and medial side <NUM> are not intended to demarcate precise areas of article <NUM>. Rather, forefoot region <NUM>, midfoot region <NUM>, heel region <NUM>, lateral side <NUM>, and medial side <NUM> are intended to represent general areas of footwear <NUM> to aid in the following discussion. In addition to article <NUM>, forefoot region <NUM>, midfoot region <NUM>, heel region <NUM>, lateral side <NUM>, and medial side <NUM> may also be applied to sole system <NUM>, upper <NUM>, and individual elements thereof.

Embodiments of the disclosure provide a sole system for an article of footwear. The sole system includes a knitted component incorporating a one-piece knit outsole. The knit outsole has a ground-facing side and a top side. A protruding ground-engaging cleat member is formed on the ground-facing side of the knit outsole. The ground-engaging cleat member has a surface comprising a knitted textile that engages the ground.

In some embodiments, article <NUM> may include sole system <NUM> and upper <NUM> that are formed from portions of a knitted component incorporated into article <NUM>. The sole system <NUM> and upper <NUM> may be formed of unitary knit construction from a knitted component so as to form a one-piece element that includes sole system <NUM> and upper <NUM>. A portion of the knitted component may form a knit outsole of sole system <NUM> and another portion of the knitted component may form the majority of upper <NUM>.

Sole system <NUM> is secured to upper <NUM> and extends between the foot and the ground when article <NUM> is worn. In an exemplary embodiment, the primary element of sole system <NUM> is a knitted component lower portion <NUM> that forms a knit outsole <NUM> through a vacuum forming process, as further detailed below. Knit outsole <NUM> includes an outsole top surface or side <NUM> (see <FIG>), an outsole bottom surface or side <NUM>. In some embodiments, sole system <NUM> may include one or more protuberances or projections that may assist with providing traction to article <NUM>. Knit outsole <NUM> includes a plurality of ground-engaging cleat members <NUM> that extend outward from outsole bottom surface <NUM> in the vertical direction towards a ground surface.

Knitted component lower portion <NUM> forming knit outsole <NUM> is of unitary knit construction with the lower areas of upper <NUM>. In one embodiment, knit outsole <NUM> and upper <NUM> may be formed from different portions of a single one-piece knitted component. Outsole top surface or side <NUM> is located on the top surface of knit outsole <NUM>, and is positioned to extend under a lower surface of the foot. Outsole bottom surface or side <NUM> comprises the outer bottom ground-facing surface of sole system <NUM> and the bottom surface of article of footwear <NUM>. Referring now to <FIG>, outsole bottom surface or side <NUM> faces away from the foot, and is ground-engaging if ground-engaging cleat member <NUM> becomes embedded in the ground. Ground-engaging cleat members <NUM> protrude from outsole bottom surface <NUM> and include a cleat face <NUM> at a distal end that is oriented approximately parallel to outsole bottom surface <NUM>. In one embodiment cleat face <NUM> is a knit surface of a portion of knitted component lower portion <NUM> that has been vacuum formed to produce cleat members <NUM>.

With this configuration, cleat face <NUM> of ground-engaging cleat member <NUM> engages the ground first.

Additional embodiments provide a foot-enclosing sole system for an article of footwear. The sole system includes a one-piece foot-enclosing knit portion that encloses the foot and includes a knit outsole. The sole system thus includes both an outsole and an upper. The outsole and the upper may be knit together as a one piece element. The knit outsole has a ground-facing side and a top side. A ground-engaging cleat member protrudes from the ground-facing side of the outsole. The ground-engaging cleat member may include a knit surface that contacts the ground.

Upper <NUM> defines a void within article <NUM> for receiving and securing a foot relative to sole system <NUM>. The void is shaped to accommodate the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Access to the void is provided by an ankle opening <NUM> located in at least heel region <NUM>. In further configurations, upper <NUM> may include additional elements, such as (a) a heel counter in heel region <NUM> that enhances stability, (b) a toe guard in forefoot region <NUM> that is formed of a wear-resistant material, (c) a collar extending around ankle opening <NUM>, and (d) logos, trademarks, and placards with care instructions and material information.

Many conventional footwear uppers are formed from multiple material elements (e.g., textiles, polymer foam, polymer sheets, leather, and synthetic leather) that are joined through stitching or bonding, for example. In contrast, in embodiments of the disclosure, a majority of upper <NUM> may be formed from a knitted component upper portion <NUM>, which extends through each of forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> along both lateral side <NUM> (shown in <FIG>) and medial side <NUM> (shown in <FIG>), over forefoot region <NUM>, and around heel region <NUM>. In addition, knitted component upper portion <NUM> forms portions of both an exterior surface and an opposite interior surface of upper <NUM>. As such, knitted component upper portion <NUM> defines at least a portion of the void within upper <NUM>.

The disclosure provides a method of making a sole system for an article of footwear. In accordance with the method, a one-piece knitted component is knitted to include a knit outsole. A ground-engaging cleat member is formed in the ground-facing side of the knit outsole by knitting. A protruding ground-engaging cleat member may be formed by molding the knitted component. The cleat member has a ground-engaging surface comprising a knitted surface that engages the ground and may provide traction.

In some embodiments, article of footwear <NUM> may be formed from a one-piece knitted component that includes knitted component lower potion <NUM>, forming knit outsole <NUM> of sole system <NUM>, and knitted component upper portion <NUM>, forming the majority of upper <NUM>. Thus, the upper and the outsole may comprise a textile knitted together as a one-piece knit element. Forming an article of footwear as a one piece knit textile element through knitting provides significant advantages over typical articles of footwear. For example, there is no need to attach a separate outsole to an upper, thus significantly reducing the number of steps required for assembly and, therefore, the possibility of assembly errors. Also, there are no joints between the outsole and the upper at which disparate properties and characteristics of the joined materials may cause excessive wear and premature failure.

In some embodiments, upper <NUM> and sole system <NUM> are formed by a single knitted component, including knitted component lower portion <NUM> and knitted component upper portion <NUM>. <FIG> illustrate such an embodiment, wherein upper <NUM> and sole system <NUM> comprise a single knitted component. <FIG> illustrate such an embodiment, wherein knitted component <NUM> and sole system <NUM> comprise a single knitted component. In these embodiments, knitted component upper portion <NUM> and knitted component lower portion <NUM> of sole system <NUM> are formed of unitary knit construction so as to be a one-piece knit element. Boundary <NUM> (which may alternatively be referred to as join <NUM>) depicts an area of demarcation between upper <NUM> and sole system <NUM>. However, for embodiments of article <NUM> including upper <NUM> and sole system <NUM> formed from a single knitted component that encloses the foot and includes knit outsole <NUM>, boundary <NUM> may not be actually physically present or visible on article <NUM>. That is, boundary <NUM> may represent an imaginary dividing line between the portions of the single knitted component that form each of upper <NUM> and sole system <NUM> and no indicia corresponding to boundary <NUM> may be present. In other embodiments, boundary <NUM> may represent a transition between types of yarns used to form each of knitted component lower portion <NUM> and knitted component upper portion <NUM>.

In various embodiments, the single knitted component incorporating into article <NUM>, including each of knitted component lower portion <NUM> and knitted component upper portion <NUM>, may incorporate various types of yarn that impart different properties to separate areas of upper <NUM> and/or sole system <NUM>. For example, one area or portion of knitted component upper portion <NUM> may be formed from a first type of yarn that imparts a first set of properties, and another area or portion of first knitted component upper portion <NUM> may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout upper <NUM> by selecting specific yarns for different areas of knitted component <NUM>. Similarly, knitted component lower portion <NUM> of sole system <NUM> may be knitted from various yarns, including any of the yarns used to form knitted component upper portion <NUM>. With this configuration, different yarns may be used to impart different properties to each of knitted component lower portion <NUM> and knitted component upper portion <NUM>, as well as to different areas within each of knitted component lower portion <NUM> and knitted component upper portion <NUM>.

Yarns used in embodiments of the disclosure may be selected from monofilament yarns and multifilament yarns formed from natural or synthetic materials. Multifilament yarns may be twisted or untwisted. In some embodiments, yarn may be elastic or essentially inelastic. In some embodiments, yarn may be textured or have a natural finish. Natural materials may be selected from staple materials, such as silk, cotton, and wool. Synthetic materials may be selected from polymers that can be formed into filaments. Synthetic materials include but are not limited to polyesters; polyamides, such as any of the various types of homopolymeric and co-polymeric nylon; aramides, such as Kevlar® and Nomex®; and urethanes, such as thermoplastic polyurethane. Fusible yarns also may be suitable for some embodiments.

In embodiments of the disclosure, the yarn used to form the article of footwear may incorporate yarns with different deniers, materials (e.g., cotton, elastane, polyester, rayon, wool, and nylon), and degrees of twist, for example. The different types of yarns may affect the physical properties of a knitted component, including aesthetics, stretch, thickness, air permeability, and abrasion-resistance. In some configurations, multiple yarns with different colors may be utilized to form the knitted component. When yarns with different colors are twisted together and then knitted, the knitted component may have a heathered appearance with multiple colors randomly distributed throughout.

At least one tensile element is inlaid or placed along any suitable area of outsole bottom surface <NUM>. Moreover, tensile elements suitable for use with outsole bottom surface <NUM> may include the tensile strands or tensile elements and the method of manufacturing a knitted component incorporating tensile elements disclosed in one or more of the commonly-owned <CIT> and published as <CIT>; <CIT>; and <CIT>.

In some embodiments, sole system <NUM> may be provided with additional components configured to provide support and stability to knit outsole <NUM>. In an exemplary embodiment, sole system <NUM> may include an insert member <NUM> that is configured to be placed in relationship with knit outsole <NUM> from an interior of article <NUM>. Insert member <NUM> may fill and provide structural support and/or rigidity for cleat members <NUM>.

<FIG> illustrates an exemplary embodiment of insert member <NUM> shown in an exploded view positioned above article <NUM>. Insert member <NUM> may be placed in relationship with knit outsole <NUM> to form sole system <NUM>. Insert member <NUM> is disposed below a foot of wearer when placed within article <NUM> and includes a top side <NUM> that faces towards the foot and an opposite bottom side <NUM> that faces away from the foot. In some embodiments, knit outsole <NUM> includes a plurality of cavities <NUM> in outsole top surface <NUM> that correspond with and form cleat members <NUM>. In this embodiment, cavities <NUM> forming cleat members <NUM> in knit outsole <NUM> may be hollow.

In an exemplary embodiment, insert member <NUM> may further include a plurality of protuberances <NUM> that extend away from bottom side <NUM> in a vertical direction. Protuberances <NUM> may be configured and designed so as to correspond with and fit within cavities <NUM> of knit outsole <NUM> to reinforce and provide support and/or rigidity to cleat members <NUM>. In one embodiment, the location, size, and arrangement of protuberances <NUM> on insert member <NUM> may be substantially similar and correspond with the location, size, and arrangement of cavities <NUM> on outsole top surface <NUM> forming cleat members <NUM>. With this arrangement, protuberances <NUM> on bottom side <NUM> are aligned with cavities <NUM> on outsole top surface <NUM> so that when insert member <NUM> is placed in relationship with knit outsole <NUM> within the interior of article <NUM>, protuberances <NUM> substantially fill cavities <NUM> and provide reinforcement to cleat members <NUM>. Additionally, insert member <NUM> may have an outer peripheral edge defining a shape of insert member <NUM> that is configured and designed to fit within the interior of upper <NUM> of article <NUM>.

Referring now to <FIG>, insert member <NUM> having protuberances <NUM> extending from bottom side <NUM> is shown in relationship with knit outsole <NUM>. In this embodiment, knitted component upper portion <NUM> and knitted component lower portion <NUM> are shown in phantom view to illustrate the relationship of insert member <NUM> within knit outsole <NUM>. As seen in <FIG>, when insert member <NUM> is located within the interior of upper <NUM> of article <NUM> so that bottom side <NUM> is facing outsole top surface <NUM>, protuberances <NUM> are aligned with and fill cavities <NUM> of corresponding cleat members <NUM>.

In some embodiments, insert member <NUM> is placed or affixed to outsole top surface <NUM> of knit outsole <NUM>. A cross-sectional view shown in <FIG>, illustrates insert member <NUM> in place on outsole top surface <NUM> of knit outsole <NUM>. Protuberances <NUM> are located within and substantially fill cavities <NUM> to reinforce cleat members <NUM>. Top side <NUM> of insert member <NUM> may be the foot-contacting surface and bottom side <NUM> faces the opposite direction towards outsole top surface <NUM>. Outsole bottom surface <NUM> includes the ground-engaging cleat members <NUM> that are facing downward in a vertical direction away from outsole bottom surface <NUM>. Cleat face <NUM> of cleat members <NUM> is a knit surface that may be directly in contact with the ground when article <NUM> is worn. Other surfaces of knit outsole <NUM>, such as portions of outsole bottom surface <NUM>, also may be at least partially directly in contact with the ground when article <NUM> is worn.

With this configuration, insert member <NUM> fills and provides support to cleat members <NUM>. Insert member <NUM> is disposed below a foot of a wearer of article <NUM> and, in some embodiments, may be configured as a midsole element. That is in some embodiments, additional inserts may be provided within the interior of upper <NUM>, such as an insole element, to provide further cushioning to a foot of a wearer. In other embodiments, insert member <NUM> may be used within upper <NUM> without any additional inserts or elements. In this way, insert member <NUM> can serve as both a reinforcing member for knit outsole <NUM> and as a cushioning or padding material for a foot of a wearer.

In various embodiments, insert member <NUM> may be formed from a variety of different materials. Materials for forming insert member <NUM> may include any suitable reinforcing material. Reinforcing materials may include compositions that provide minimal support. Such compositions may be used to tune a cushioning response. More typically, however, a reinforcing material may be selected for its rigidity and strength. The material may be foamed material, such as foamed plastic materials. For example, foamed thermoplastic polyurethane may be suitable. The density of foamed materials may be controlled to tune cushioning response. Higher density may give a more supportive response and better reinforcement of ground-engaging cleat members.

In some embodiments, insert member <NUM> may be monolithic or may have zones that provide additional support or resistance to twisting, for example. For example, in some embodiments, a material having a greater rigidity may be used to form protuberances <NUM> of insert member <NUM> and a material having a lesser rigidity may be used to form remaining portions of insert member <NUM>. In some cases, portions or the entirety of insert member <NUM> may comprise foamed thermoplastic material. In other cases, one or more portions of insert member <NUM> may be formed from different materials. For example, in one embodiment, insert member <NUM> may comprise a zone of low-density foam, a zone of high-density foam, and a zone of unfoamed material.

In some embodiments, an insert member disposed within the interior of upper <NUM> may be used during the manufacturing of an article <NUM> to form the shape of a knit outsole, including one or more cleat members disposed on the knit outsole. <FIG> illustrate an exemplary process of vacuum forming a knitted component using an insert member to form a knit outsole. In an exemplary embodiment, insert member <NUM> may be used during the manufacturing of article <NUM> to form the shape of knit outsole <NUM>, including plurality of cleat members <NUM> corresponding to the shape of protuberances <NUM> of insert member <NUM>. In one embodiment, a vacuum forming process may be used to shape knitted component lower portion <NUM> around insert member <NUM> within upper <NUM> to form knit outsole <NUM>.

Thus, embodiments of the disclosure provide a method of manufacturing an article of footwear with a sole system having a knit outsole. In accordance with the method, a one-piece knitted component is knitted to include a portion that is vacuum formed around an insert member to produce the knit outsole. A ground-engaging cleat member is formed in the ground-facing side of the knit outsole by vacuum forming the portion of the knitted component around the insert member having a protuberance extending away from a bottom side of the insert member. The vacuum formed cleat member may have a ground-engaging face comprising a knitted surface that engages the ground and may provide traction.

Referring now to <FIG>, an exemplary process <NUM> for manufacturing an article of footwear including a knit sole system is illustrated. In one embodiment, process <NUM> may include one or more steps that may be repeated to form a completed article of footwear with a knit sole system. The order of the steps is exemplary, and in other embodiments, additional or different steps not shown in <FIG> may be included to produce an article of footwear having a knit sole system. In an initial step <NUM>, a knitted component configured to be incorporated into the upper of the article of footwear is knit. In an exemplary embodiment, the knitted component may be knit in the configuration of a bootie, including an upper portion for extending around and covering over the top of the foot of a wearer, as well as a lower portion for extending underneath the foot of the wearer. With this configuration, the knitted component may be knit as a bootie that is a one-piece element formed of unitary knit construction that encloses the foot of a wearer.

In one embodiment, step <NUM> may include knitting a knitted component, including portions of a knitted component substantially similar to knitted component lower portion <NUM> and knitted component upper portion <NUM>, to form a foot-enclosing knit bootie. Although knitting may be performed by hand, the commercial manufacture of knitted components is generally performed by knitting machines. An example of a knitting machine suitable for producing a knitted component includes a knitting machine having a configuration of a V-bed flat knitting machine for purposes of example, but any of the knitted components described herein may be produced on other knitting machines. The disclosure also is described in detail as it relates to knitted textiles formed by weft knitting, but textiles formed by any suitable knitting process, including but not limited to: weft knitting processes, for example, flat knitting operations or circular knitting operations; warp knitting process; or any other knitting process suitable for providing a knitted textile, may be used. In such embodiments, suitable knitting machines, for example, circular knitting machines or warp knitting machines may be used to form a foot-enclosing knit bootie of unitary knit construction at step <NUM>.

Knitted component <NUM>, knitted component <NUM>, and other embodiments of foot-enclosing booties can be formed of unitary knit construction. As used herein, the term "unitary knit construction" means that the respective component is formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures of unitary knit construction without the need for significant additional manufacturing steps or processes. A unitary knit construction may be used to form a knitted component having structures or elements that include, in the case of weft knitting, one or more courses of yarn or other knit material that are joined such that the structures or elements include at least one course in common (i.e., sharing a common yarn) and/or include courses that are substantially continuous between each of the structures or elements, or that include, in the case of warp knitting, one or more wales of yarn or other knit material that are joined such that the structures or elements include at least one wale in common (i.e., sharing a common yarn) and/or wales that are substantially continuous between each of the structures or elements. With this arrangement, a one-piece element of unitary knit construction is provided.

Examples of various configurations of knitted components and methods for forming knitted components with unitary knit construction are disclosed in <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>. Knitted component lower portion <NUM>, knitted component upper portion <NUM>, and other embodiments of foot-enclosing knit booties remain formed of unitary knit construction when other elements, such as logos, trademarks, placards with care instructions or other information, such as material information and size, tensile or structural elements, are added following the knitting procedure.

In some embodiments, a knitted component for forming a knit sole system may include areas knit using durable yarns and/or fusible yarns. Durable yarns and/or fusible yarns typically may provide the wear resistance users likely will prefer to have in ground-engaging areas and areas of the knit sole system that are likely to experience greater wear. For example, the outer surface of the knit sole system comprises a knitted textile, but is likely to experience greater wear because the surface faces the ground and is, at least in part, adjacent ground-engaging cleat members that are configured to be in contact with a ground surface. Further, fusible yarns may provide not only excellent wear resistance, but also support for the bottom of the foot when activated. Strands of fusible yarn may, when heated, fuse to form an impermeable mass and may also impart rigidity to the knitted component.

Cleat members <NUM> formed in knit outsole <NUM> may incorporate fusible yarns into knitted component lower portion <NUM> to impart rigidity to knit outsole <NUM>. Fusible yarns incorporated into a knitted component may further assist with allowing the knit outsole to retain the shape of inert member used during the vacuum forming process <NUM> to shape the knit outsole. Fusible yarns also may provide a highly water resistant surface that helps keep the interior of the article of footwear free of water that otherwise would enter the article of footwear from the outside.

Next, at step <NUM>, an insert member, including an insert member substantially similar to insert member <NUM>, described above, may be manufactured. In one embodiment of step <NUM>, the insert member may include a midsole, however, as noted above, in other embodiments, the insert member may be used with additional elements, for example, an insole element, or may be used alone and take the place of an insole element or other components. During step <NUM>, the insert member may be manufactured with a plurality of protuberances that will be used to form the various cleat members or traction elements of the knit outsole.

After a suitable midsole insert member has been made at step <NUM> with the desired location, size, and arrangement of protuberances for forming cleat members on the knit outsole, the midsole insert member may be placed inside the foot-enclosing knit bootie. At step <NUM>, the foot-enclosing knit bootie is vacuum formed around the foot-enclosing knit bootie to shape the knit outsole.

In some embodiments, an additional optional step <NUM> may be included in process <NUM> to provide protection to ground-engaging surfaces of the formed cleat members of the knit outsole. In this embodiment, step <NUM> includes a step of applying a cap element to the cleat member. As will be further described below, the cap element may provide protection to the knit surface of the cleat face, including cleat face <NUM>, that engages the ground surface. The cap element may also be configured to provide enhanced traction to the knit outsole.

Referring now to <FIG>, a representational view of step <NUM> of process <NUM> of vacuum forming a knit sole system for an article of footwear incorporating a knitted component is illustrated. As shown in this embodiment, knitted component lower portion <NUM> is vacuum formed around insert member <NUM> to form knit outsole <NUM>. In an exemplary embodiment, bottom side <NUM> of insert member <NUM> includes protuberances <NUM> that will be used to form cavities <NUM> of cleat members <NUM> on knit outsole <NUM>. In this embodiment, bottom side <NUM> of insert member <NUM> is brought in relation with outsole top surface <NUM> of knitted component lower portion <NUM>.

Once insert member <NUM> and knitted component lower portion <NUM> are brought in relation with each other, a vacuum forming process may be applied to shape knitted component lower portion <NUM> around bottom side <NUM> of insert member <NUM>, including the shape of protuberances <NUM>. Once vacuum formed, knitted component lower portion <NUM> forms knit outsole <NUM>, including cleat members <NUM> extending from outsole bottom surface <NUM>.

In some embodiments, fusible yarn may be knitted in this area, for example, at least on portions of knitted component <NUM> aligned with and corresponding to protuberances <NUM> for forming ground-engaging cleat members <NUM>. Fusible yarn may be optionally heated at step <NUM> to soften the outer surfaces of the yarn to assist with conforming to the shape of insert member <NUM> and protuberances <NUM>. Upon cooling, fusible yarn may also provide additional rigidity and assist with retaining the shape of cleat member <NUM>. Alternatively, a stiffening resin or plastic may be applied and activated and cured or heated at step <NUM> to assist with rigidity and/or shape retention.

<FIG> illustrate various steps of the process of vacuum forming described generally with reference to step <NUM> of process <NUM>. In this process, additional or different steps may be performed during the vacuum forming process without detracting from the principles of the exemplary process described herein.

Referring now to <FIG>, an exemplary embodiment of a vacuum press <NUM> suitable for performing the vacuum forming process is illustrated. In this embodiment, vacuum press <NUM> includes a moveable portion <NUM> and a base portion <NUM>. Moveable portion <NUM> is configured to move between an open and closed position in relation with base potion <NUM> and allows an article to be placed on base portion <NUM> for the vacuum forming process. In other embodiments, however, other configurations of a vacuum press with a different arrangement or different components may be used.

In an exemplary embodiment, moveable portion <NUM> of vacuum press <NUM> includes a support <NUM> surrounding and holding in place a flexible membrane <NUM>. In some cases, flexible membrane <NUM> may be any suitable flexible material, including, for example, silicone or rubber. In other cases, different flexible materials may be used. In addition, in some embodiments where heat is applied during the vacuum forming process, flexible membrane <NUM> may further include heating elements or other mechanisms for providing heat to flexible membrane <NUM>. In this embodiment, flexible membrane <NUM> includes an outside surface <NUM> and an opposite inside surface <NUM>. Inside surface <NUM> is configured to contact an article during the vacuum forming process and faces downward towards base portion <NUM> of vacuum press <NUM>.

In some embodiments, base portion <NUM> may include features configured to assist with holding an article in place in vacuum press <NUM> during the vacuum forming process. In an exemplary embodiment, where an article of footwear, for example, article <NUM>, is being vacuum formed, base portion <NUM> may include a last <NUM> that is configured to receive an upper or bootie of an article of footwear. In this embodiment, last <NUM> is arranged with a bottom surface <NUM> oriented in an upwards direction away from base portion <NUM> and facing towards inside surface <NUM> of flexible membrane <NUM>. With this arrangement, a bottom portion of an upper or bootie that is configured to extend under the foot of a wearer can be placed on bottom surface <NUM> of last <NUM> to assist with forming the knit outsole.

Referring now to <FIG>, insert member <NUM> is shown being placed onto bottom surface <NUM> of last <NUM> in preparation of vacuum forming the knit outsole using vacuum press <NUM>. As shown in this embodiment, top side <NUM> of insert member <NUM> is placed onto bottom surface <NUM> of last <NUM> such that bottom side <NUM> of insert member <NUM> that includes protuberances <NUM> is facing upwards away from base portion <NUM> of vacuum press <NUM>. With this arrangement, last <NUM> may be ready to receive an upper or bootie of an article of footwear for the vacuum forming process of a knit outsole.

Next, as shown in <FIG>, upper <NUM> that includes knitted component upper portion <NUM> and knitted component lower portion <NUM> formed of unitary knit construction so to form a one-piece foot-enclosing bootie is prepared for the vacuum forming process. In an exemplary embodiment, upper <NUM> is placed in an inverted position over last <NUM> having insert member <NUM> disposed on bottom surface <NUM>, as described above in reference to <FIG>. In one embodiment, ankle opening <NUM> may facilitate placement of upper <NUM> over last <NUM> such that insert member <NUM> may be located within the interior of upper <NUM>.

Referring now to <FIG>, upper <NUM> has been placed over last <NUM> having insert member <NUM> disposed on bottom surface <NUM>. In this configuration, bottom side <NUM> of insert member <NUM> that includes protuberances <NUM> is placed in loose relation with outsole top surface or side <NUM> within the interior of upper <NUM>. Outsole bottom surface or side <NUM> of knitted component lower portion <NUM> faces outwards away from base portion <NUM> of vacuum press <NUM>. As shown in <FIG>, protuberances <NUM> on insert member <NUM> may form loose mounds or lumps in outsole bottom surface <NUM> of knitted component lower portion <NUM> prior to the application of the vacuum forming step.

Next, <FIG> illustrates moveable portion <NUM> of vacuum press <NUM> being moved towards base portion <NUM> to place vacuum press <NUM> in a closed position before application of the vacuum forming step. As shown in this embodiment, inside surface <NUM> of flexible membrane <NUM> is being brought towards outsole bottom surface <NUM> arranged on last <NUM>. <FIG> illustrates vacuum press <NUM> in a closed position with moveable portion <NUM> brought into contact with base portion <NUM>. Together, moveable portion <NUM> and base portion <NUM> form a seal with flexible membrane <NUM> disposed around and covering last <NUM>. As shown in <FIG>, outside surface <NUM> of flexible membrane <NUM> extends upwards and away from base portion <NUM> where last <NUM> having upper <NUM> placed thereon is located. In this embodiment, vacuum press <NUM> is prepared for the application of the vacuum forming process.

<FIG> illustrates a representation of the vacuum forming process using vacuum press <NUM> on last <NUM> having upper <NUM> placed thereon. As shown in this embodiment, the application of a vacuum within the interior of vacuum press <NUM> between moveable portion <NUM> and base portion <NUM> draws flexible membrane <NUM> down towards base portion <NUM>. With this configuration, inside surface <NUM> of flexible membrane <NUM> exerts pressure onto upper <NUM> placed upon last <NUM>, including insert member <NUM> located on bottom surface <NUM> of last <NUM>. Accordingly, the pressure of the vacuum forming process causes knitted component lower portion <NUM> of upper <NUM> on last <NUM> to be drawn down onto bottom side <NUM> of insert member <NUM> that includes protuberances <NUM>. In some embodiments, heat also may be applied during the vacuum forming process along with the pressure from the vacuum.

Referring now to <FIG>, moveable portion <NUM> is moved to the open position away from base portion <NUM> after the application of the vacuum forming process. In this embodiment, knit outsole <NUM> including cleat members <NUM> is shown formed on outsole bottom surface <NUM> of knitted component lower portion <NUM> of upper <NUM> placed on last <NUM>. As described above, the location, size, and arrangement of cleat members <NUM> corresponds and aligns with the location, size, and arrangement of protuberances <NUM> on bottom side <NUM> of insert member <NUM> that has been placed on last <NUM>. With this arrangement, a one-piece foot-enclosing bootie may be formed with a knit outsole.

In addition, insert member <NUM> may be used not only for forming the knit outsole during the vacuum forming process, such as process <NUM> described above, but may also remain disposed with the interior of upper <NUM> and placed in relation with outsole top surface <NUM> such that protuberances <NUM> align with and fill cavities of cleat members <NUM>. With this arrangement, insert member <NUM> may both form knit outsole <NUM> and provide cushioning to a foot of a wearer and/or reinforcement to cleat members <NUM>.

In some embodiments, additional components or elements may be associated with a sole system, including sole system <NUM>, to provide for enhanced traction and/or wear resistance to portions of the article of footwear. In an exemplary embodiment, sole system <NUM> may include provisions that at least partially cover portions of cleat members <NUM> on outsole bottom surface <NUM>. In one embodiment, sole system <NUM> may include cap elements <NUM> that at least partially cover portions of cleat members <NUM> on outsole bottom surface <NUM> of knit outsole <NUM>. In this embodiment, cleat face <NUM> of cleat members <NUM> is formed from a knit surface of knitted component lower portion <NUM> and cap elements <NUM> may be attached or joined to cleat face <NUM> to at least partially cover this knit surface.

In an exemplary embodiment, cap elements <NUM> may include a top side <NUM> and an opposite bottom side <NUM>. As shown in <FIG>, top side <NUM> of cap element <NUM> is configured to face away from outsole bottom surface <NUM> and may directly engage with a ground surface when an article is worn. Bottom side <NUM> of cap element <NUM> is configured to be attached or joined with cleat face <NUM> on cleat member <NUM>. In various embodiments, cap elements <NUM> may be joined with or attached to cleat face <NUM> using any suitable mechanism. For example, in some cases, cap elements <NUM> may be bonded to cleat face <NUM> using a thermoplastic polymer material. In other cases, cap elements <NUM> may be attached to cleat face <NUM> by directly forming cap elements <NUM> onto the knit surface using a molding or printing process. In still other cases, cap elements <NUM> may be adhesively joined to cleat face <NUM>. Additionally, in some embodiments, portions of a knitted component forming a knit outsole, including knitted component lower portion <NUM>, may include yarns that facilitate or assist with attaching cap elements <NUM> to the knit outsole. For example, fusible yarns or yarns incorporating a thermoplastic polymer material may be used to facilitate or assist with attaching cap elements <NUM> to the knit outsole.

In some embodiments, cap elements <NUM> may be formed from any suitable material that may be used to form a traction element or an outsole. Examples of suitable materials include, but are not limited to: polymers, elastomers, siloxanes, natural rubber, other synthetic rubbers, aluminum, steel, natural leather, synthetic leather, plastics, or other materials suitable for providing traction or protection. With this configuration, cap elements <NUM> may cover portions of cleat face <NUM> of cleat members <NUM> so as to provide wear protection to the knit surface of knitted component lower portion <NUM> forming knit outsole <NUM>. In addition, cap elements <NUM> may also be configured to provide enhanced traction or a gripping surface to cleat members <NUM> and/or portions of the knit outsole <NUM>.

<FIG> and <FIG> illustrates an exemplary embodiment of cap element <NUM> that has a shape that approximately corresponds with and is similar to the shape of cleat face <NUM>. However, in other embodiments, a cap element may have different shapes and/or configurations. <FIG> various alternate embodiments of cap elements that may be used with knit outsole <NUM> to at least partially cover a portion of one or more cleat members <NUM>.

Referring now to <FIG>, an alternate embodiment of a cap element <NUM> is illustrated. In an exemplary embodiment, cap element <NUM> may entirely cover cleat face <NUM> of cleat member <NUM>, as well as extending up along one or both sides of cleat member <NUM>. In this embodiment, cap element <NUM> includes a lower portion <NUM> that covers cleat face <NUM> of cleat member <NUM> and two extending portions <NUM> disposed on either side of lower portion <NUM> that extend away from lower portion <NUM> along the sides of cleat member <NUM> towards outsole bottom surface <NUM>. In some cases, extending portions <NUM> may extend at least partially along the sides of cleat member <NUM>. In other cases, extending portions <NUM> may extend the entirety of the sides of cleat member <NUM> to an area adjacent to or abutting with outsole bottom surface <NUM>. With this configuration, an entirety of cleat member <NUM>, or at least a substantial majority of cleat member <NUM>, may be covered by cap element <NUM>. In some cases, cap element <NUM> may be used in embodiments where additional protection or rigidity for cleat member <NUM> of knit outsole <NUM> is desired, in addition to enhanced traction that may be generally provided by a cap element.

Referring now to <FIG>, another alternate embodiment of a cap element <NUM> is illustrated. In an exemplary embodiment, cap element <NUM> may extend less than the entirety of cleat face <NUM> of cleat member <NUM>. In this embodiment, cap element <NUM> includes a lower portion <NUM> that covers less than the entirety of cleat face <NUM> of cleat member <NUM>. In an exemplary embodiment, cap element <NUM> may be located approximately a first distance D1 from one side of cleat member <NUM> and a second distance D2 from the opposite side of cleat member <NUM>. In some cases, first distance D1 and second distance D2 may be approximately equal so as to center cap element <NUM> and lower portion <NUM> on cleat face <NUM> of cleat member <NUM>. In other cases, first distance D1 and second distance D2 may be different so as to offset cap element <NUM> towards one side or the other of cleat face <NUM>. With this configuration, a portion less than the entirety of cleat face <NUM> of cleat member <NUM> may be covered by cap element <NUM>. In some cases, cap element <NUM> may be used in embodiments where enhanced traction for specific portions of cleat member <NUM> of knit outsole <NUM> is desired.

Referring now to <FIG>, another alternate embodiment of a cap element <NUM> is illustrated. In an exemplary embodiment, cap element <NUM> may entirely cover cleat face <NUM> of cleat member <NUM>, as well as extending up along one or both sides of cleat member <NUM> and also covering a portion of outsole bottom surface <NUM>. In this embodiment, cap element <NUM> includes a lower portion <NUM> that covers cleat face <NUM> of cleat member <NUM> and further extends on either side of cleat member <NUM> and towards outsole bottom surface <NUM>, where cap element <NUM> also covers at least a portion of outsole bottom surface <NUM>. In some cases, cap element <NUM> may be configured in the shape of a semispherical or hemi-spherical dome that covers over cleat member <NUM>. In other cases, cap element <NUM> may have a different shape that covers cleat member <NUM> and a portion of outsole bottom surface <NUM>. With this configuration, an entirety of cleat member <NUM> and a portion of outsole bottom surface <NUM> may be covered by cap element <NUM>. In some cases, cap element <NUM> may be used in embodiments where a change in the shape of cleat member <NUM> of knit outsole <NUM> is desired, or where the material forming cap element <NUM> is used to reinforce sides of cleat member <NUM>, in addition to enhanced traction that may be generally provided by a cap element.

Referring now to <FIG>, another alternate embodiment of a cap element <NUM> is illustrated. In an exemplary embodiment, cap element <NUM> may have a tiered configuration that presents at least two different surfaces having different heights extending away from cleat face <NUM> of cleat member <NUM> in the vertical direction. In an exemplary embodiment, tiered cap element <NUM> may combine features of previous embodiments of cap elements, described above. For example, in this embodiment, tiered cap element <NUM> may generally include the features of cap element <NUM> with the features of cap element <NUM>. As shown in <FIG>, tiered cap element <NUM> includes a lower portion <NUM> that covers cleat face <NUM> of cleat member <NUM>, and presents a first surface located at a first height from cleat face <NUM>. In addition, tiered cap element <NUM> further includes an upper portion <NUM> that presents a second surface <NUM> located at a second height from cleat face <NUM> that is greater than and located on top of the first surface of lower portion <NUM>. With this configuration, benefits of multiple configurations of cap elements may be combined with cap element <NUM>. In other embodiments, other features of the various embodiments of cap elements described above may be similarly combined together into other embodiments of a cap element for use with knit outsole <NUM> and sole system <NUM>.

In some embodiments, rather than providing individual cap elements to cover each cleat member <NUM> of knit outsole <NUM>, an outsole cover assembly may be provided to cover all of knit outsole <NUM>, including cleat members <NUM> and outsole bottom surface <NUM>. <FIG> illustrate an exemplary embodiment of an outsole cover assembly <NUM> that may be configured to cover all of knit outsole <NUM>, including cleat members <NUM> and outsole bottom surface <NUM>.

Referring now to <FIG>, outsole cover assembly <NUM> is shown in exploded relation with article <NUM>. In an exemplary embodiment, outsole cover assembly <NUM> has a top surface <NUM> and an opposite bottom surface <NUM>. Top surface <NUM> is configured to be brought in relation with outsole bottom surface <NUM>. In some cases, top surface <NUM> of outsole cover assembly <NUM> may be joined with or attached to outsole bottom surface <NUM> of knit outsole <NUM> using any of the methods described above for attaching a cap element to cleat members <NUM> of knit outsole. Bottom surface <NUM> of outsole cover assembly <NUM> is configured to interact with a ground surface and may assist with providing durability, protection, and/or traction to sole system <NUM> of article <NUM>.

In some embodiments, outsole cover assembly <NUM> may be formed with one or more recesses <NUM> in top surface <NUM> of outsole cover assembly <NUM> that are configured to align with and correspond to cleat members <NUM> on outsole bottom surface <NUM> of knit outsole <NUM>. In an exemplary embodiment, the location, size, and arrangement of recesses <NUM> of outsole cover assembly <NUM> may be selected to be substantially similar to the location, size, and arrangement of cleat members <NUM> on outsole bottom surface <NUM> of knit outsole <NUM>. In one embodiment, recesses <NUM> form cleat cover elements <NUM> that extend outward from bottom surface <NUM> of outsole cover assembly <NUM>. With this configuration, an entirety of cleat member <NUM> and outsole bottom surface <NUM> of knit outsole <NUM> may be covered by cleat cover elements <NUM> and outsole cover assembly <NUM>. Accordingly, as shown in <FIG>, when knit outsole <NUM> of article <NUM> is brought in relation to and joined with outsole cover assembly <NUM>, cleat members <NUM> are received into recesses <NUM> of outsole cover assembly <NUM>.

In some embodiments, outsole cover assembly <NUM> may further include a lip <NUM> that extends around an outer periphery along a peripheral edge of outsole cover assembly <NUM>. Lip <NUM> may be configured to extend above top surface <NUM> of outsole cover assembly <NUM> along the outer periphery to form a wall or raised portion. Additionally, lip <NUM> may define a shape of the outer periphery of outsole cover assembly <NUM> that is substantially similar to and corresponds with the shape of knit outsole <NUM>, including outsole bottom surface <NUM>. In some embodiments, when article <NUM> is brought in relation with outsole cover assembly <NUM>, lip <NUM> may at least partially extend upwards along medial or lateral sides of knitted component lower portion <NUM>, as shown in <FIG>. With this configuration, lip <NUM> may assist with aligning article <NUM> within outsole cover assembly <NUM> and also assist with providing support and/or rigidity to portions of sole system <NUM> and article <NUM>.

In various embodiments, outsole cover assembly <NUM> may be made from any suitable material, including any of the materials described above for making a cap element, as well as any other suitable materials for making an outsole. In addition, while in the present embodiments outsole cover assembly <NUM> covers substantially all of knit outsole <NUM> and cleat members <NUM>, in other embodiments, an outsole cover assembly may cover only portions of knit outsole <NUM> and/or selected cleat members <NUM> located in specific portions or regions of sole system <NUM>. With this configuration, desired additional durability, wear resistance, rigidity, and/or traction may be provided by an outsole assembly in selected areas of sole system <NUM>.

In some embodiments, sole system <NUM> and knitted component <NUM> may be formed of unitary knit construction such that they may be knitted as a one-piece element to form a foot-enclosing knit portion <NUM>. <FIG> illustrates such an embodiment. <FIG> illustrates an essentially planar or flat foot-enclosing knit portion <NUM> comprising sole system <NUM> and knitted component <NUM>. Knitted component <NUM> is illustrated in two elements on opposite sides of sole system <NUM>. Sole system <NUM> includes knitted component <NUM> forming one-piece knit outsole <NUM> having bottom surface <NUM>, and ground-engaging cleat member <NUM> having bottom <NUM>. At least first tensile element <NUM>, and optionally second tensile element <NUM>, third tensile element <NUM>, and fourth tensile element <NUM> are inlaid within knitted component <NUM>. In some embodiments, one or more of tensile element <NUM>, tensile element <NUM>, tensile element <NUM>, or tensile element <NUM> may be exposed on bottom surface <NUM>. Line of demarcation <NUM> is illustrated for purposes of reference.

<FIG>, <FIG>, and <FIG> illustrate an exemplary process of forming article of footwear <NUM> from foot-enclosing knit portion <NUM>, which is flat or planar in <FIG>, and is configured into a completed article of footwear <NUM> in <FIG>. <FIG> illustrates an intermediate stage, wherein foot-enclosing knit portion <NUM> has been folded or bent upward from about line of demarcation <NUM>, clearly distinguishing sole system <NUM> from knitted component <NUM>. Knitted component <NUM>, one-piece knit outsole <NUM> having bottom surface <NUM>, ground-engaging cleat member <NUM> having bottom <NUM>, and first tensile element <NUM>, second tensile element <NUM>, third tensile element <NUM>, and fourth tensile element <NUM>, are clearly visible as part of sole system <NUM>. In <FIG>, the forefoot area is completely formed, but the heel edges of knitted component <NUM> have not been brought together.

In the embodiments illustrated in <FIG>, the tensile elements are located adjacent ground-engaging cleat members <NUM>. Location of the tensile elements in this way may control stretching of the sole during use. For example, location of the tensile elements longitudinally may control lengthwise stretch of outsole <NUM>. Further, locating a tensile element adjacent a ground-engaging cleat member controls stretch at the periphery of the base of the ground-engaging cleat member. Such stretch may be introduced by wear or as part of the manufacturing process, particularly the process by which the protuberance for the cleat member is formed in the knitted component. Extending the tensile element along a side of a plurality of cleat members also helps control stretching between cleats.

<FIG> illustrates a complete article of footwear <NUM> from foot-enclosing knit portion <NUM>. Article of footwear <NUM> comprises knitted component <NUM> and sole system <NUM>. Upper <NUM> is formed by stitching or otherwise attaching the ends of knitted component <NUM> at seam <NUM> in the forefoot region and the midfoot region and at seam <NUM> in the heel region to form a void for a wearer's foot.

In some embodiments, seam <NUM> and seam <NUM> resulting from the stitching or joining together of the sides of knitted component <NUM> may be located essentially on the longitudinal midline of article of footwear <NUM> if the size of knitted component <NUM> is essentially the same on each side of article of footwear <NUM>, as illustrated in the drawing Figures herein. In other embodiments of the disclosure, the seam may be located anywhere on the surface of upper <NUM>. Such an adjustment can be made by making one side of knitted component <NUM> wider than the other.

Line of demarcation <NUM> illustrates a dividing line between sole system <NUM> and other components of the article of footwear <NUM>. Ground-engaging cleat member <NUM> protrudes away from the bottom side or surface <NUM> of one-piece knit outsole <NUM>.

<FIG> illustrates an article of footwear in use by player P, with an exploded view of article of footwear <NUM> in contact with ground G. In this exploded view, upper <NUM> and ground-engaging cleat member <NUM> protruding from the bottom surface <NUM> of one-piece knit outsole <NUM> are clearly seen. Ground-engaging cleat member <NUM> makes contact with ground G at bottom surface <NUM> of ground-engaging cleat member <NUM>. In this embodiment, bottom surface <NUM> of ground-engaging cleat member <NUM> is a knit surface directly in contact with the ground. Portions of bottom surface <NUM> of one-piece knit outsole <NUM> also may contact the ground directly, such as on uneven ground surfaces or when ground-engaging cleat member <NUM> is embedded in the ground.

<FIG> is a block schematic diagram of a method <NUM> for manufacturing an article of footwear in accord with the disclosure. In accordance with the method of knitting a textile element (such as knitted component <NUM> and/or knitted component <NUM>) is begun in step <NUM>. As part of this knitting, a tensile element, such as tensile element <NUM>, is inlaid within the textile element in step <NUM>. Knitting continues (step <NUM>) until the textile element is complete. The tensile element may be adjusted in step <NUM>. Ground-engaging cleat members are formed in step <NUM>. The textile may be steamed to set the yarn, in accordance with known processes. Then, areas of the textile element may be stiffened at method step <NUM>. Typically, such stiffening would be useful in areas of the textile element subject to heavy abrasion. Fusible yarn may be used in this area, for example, on portions of knitted components corresponding to protuberances forming ground-engaging cleat members. Fusible yarn may be heated at step <NUM> to soften the outer surfaces of the yarn. Alternatively, a stiffening resin or plastic may be applied and activated and cured or heated at step <NUM>. Typically, stiffening resins or plastics are located so as not to interfere with adjustments by the tensile element. Then, the final folding, matching, sticking and adhering to form the article of footwear is carried out as step <NUM> to form an article of footwear.

A sole system for an article of footwear is provided. The sole system includes a knitted component incorporating a one-piece knit outsole. The knit outsole has a ground-facing side and a top side. At least two protruding ground-engaging cleat members are formed on the ground-facing side of the knit outsole. A tensile element may be inlaid within the ground-facing side of the one-piece knit outsole.

An article of footwear including the sole system is provided. The article of footwear includes an upper and the sole system connected thereto. The upper may be one-piece or may have a strobel sock or other closure at the bottom of the upper. The top side of the outsole and the bottom of the upper are affixed.

A method of making a sole system for an article of footwear is provided. In accordance with the method, a ground-engaging member is formed in a one-piece knit outsole having a ground-facing side and a top side. At least two protruding ground-engaging cleat members are formed by molding the knitted component.

Various methods, machines, and tools can be used for forming, treating, and otherwise adjusting knitted component <NUM> and for forming article of footwear <NUM> incorporating one-piece knit outsole <NUM>. It will be appreciated that the order of steps within the method may vary from the order described herein. Certain steps or aspects of some steps may be skipped or eliminated as well. Moreover, two or more steps within the method may be carried out sequentially or simultaneously. Furthermore, the steps within the method may be carried out manually or automatically, using any suitable tool, machine, or implement.

<FIG> and <FIG> illustrate an exemplary process of knitting a knitted component, including a knitted component substantially similar to knitted component <NUM>, knitted component <NUM>, and foot-enclosing knit portion <NUM> described above. Although knitting may be performed by hand, the commercial manufacture of knitted components is generally performed by knitting machines. An example of a knitting machine <NUM> that is suitable for producing any of the knitted components described herein is depicted in <FIG>. Knitting machine <NUM> has a configuration of a V-bed flat knitting machine for purposes of example, but any of the knitted components described herein may be produced on other knitting machines.

Knitting machine <NUM> includes first needle bed <NUM> and second needle bed <NUM> having needles <NUM> that are angled with respect to each other, thereby forming a V-bed. That is, needles <NUM> from first needle bed <NUM> lay on a first plane, and needles <NUM> from the second needle bed <NUM> lay on a second plane. The first plane and the second plane are angled relative to each other and meet to form an intersection that extends along a majority of a width of knitting machine <NUM>. As described in greater detail below, needles <NUM> each have a first position where they are retracted and a second position where they are extended. In the first position, needles <NUM> are spaced from the intersection where the first plane and the second plane meet. In the second position, however, needles <NUM> pass through the intersection where the first plane and the second plane meet.

Rail <NUM> and rail <NUM> extend above and parallel to the intersection of needles <NUM> and provide attachment points for standard feeder <NUM>. Rail <NUM> and rail <NUM> each have two sides, each of which may accommodate one standard feeder. Therefore, knitting machine <NUM> may include a total of four feeders. Three such feeders are illustrated in <FIG>. Standard feeder <NUM> is on the front of rail <NUM>, feeder <NUM> is on the front of rail <NUM>, and feeder <NUM> is on the back of rail <NUM>. Although two rails are depicted, additional rails could be present. Such additional rails would accommodate additional feeders. Such feeders may be useful to manufacture embodiments including two or more types of yarn. These additional feeders are supplied with yarn and are operated in the same way as the feeders described in detail.

Feeder <NUM> moves along rail <NUM> and needle beds <NUM> and <NUM>, thereby supplying yarn to needles <NUM>. Yarn <NUM> is provided to feeder <NUM> by a spool <NUM>. More particularly, yarn <NUM> extends from spool <NUM> to various yarn guides <NUM>, yarn take-back spring <NUM>, and yarn tensioner <NUM> before entering feeder <NUM>. Although not depicted, additional spools <NUM> may be utilized to provide yarns to other feeders.

Standard feeders are conventionally utilized for a V-bed flat knitting machine <NUM>. Each feeder has the ability to supply yarn that needles <NUM> manipulate to knit, tuck, and float. In some embodiments, only one feeder may be needed. In other embodiments, such as when the ground-engaging cleat members are knitted into the one-piece outsole, more than one feeder may be utilized. For such embodiments, a knitting machine <NUM> in <FIG> may include first standard feeder <NUM>, second standard feeder <NUM>, and third standard feeder <NUM> that are substantially similar to each other. The combination feeder has these abilities, and also has the ability to inlay a yarn. First standard feeder <NUM> may be secured to a front side of rail <NUM>, second standard feeder <NUM> may be secured to a front side of rail <NUM>, and third standard feeder <NUM> may be secured to a rear side of rail <NUM>. In other embodiments of the disclosure, additional feeders may be used and may be located on the front or rear side of rail <NUM>.

In this embodiment, first yarn <NUM> from spool <NUM> passes through first standard feeder <NUM> and an end of yarn <NUM> extends outwardly from first dispensing tip <NUM> at the end of first feeder arm <NUM>. Although yarn <NUM> is depicted, any other strand (e.g., a filament, thread, rope, webbing, cable, chain, or yarn) may pass through first standard feeder <NUM>. A second yarn (not shown) similarly passes through second standard feeder <NUM> and extends outwardly from second dispensing tip <NUM> on second feeder arm <NUM>. A third yarn (not shown) may pass in a similar manner through third standard feeder <NUM> to third dispensing tip <NUM> on third feeder arm <NUM>.

Needles <NUM> are manipulated to form loops <NUM>, with a plurality of loops forming knitted component <NUM>. The knitting process discussed herein relates to the formation of a knitted component <NUM>, which may be any knitted component, including knitted components that are similar to knitted component <NUM>, knitted component <NUM>, and foot-enclosing knit portion <NUM>. For purposes of the discussion, only a relatively small section of knitted component <NUM> is shown in the Figures in order to permit the knit structure to be illustrated. Moreover, the scale or proportions of the various elements of knitting machine <NUM> and knitted component <NUM> may be enhanced to better illustrate the knitting process.

First standard feeder <NUM> includes first feeder arm <NUM> with first dispensing tip <NUM>. First feeder arm <NUM> is angled to position first dispensing tip <NUM> in a location that is (a) centered between needles <NUM> and (b) above an intersection of needle beds <NUM>. Note that needles <NUM> lay on different planes, which planes are angled relative to each other. That is, needles <NUM> lay on the different planes of first needle bed <NUM> and second needle bed <NUM>. Needles <NUM> each have a first position in which needles <NUM> are retracted, and a second position, in which needles <NUM> are extended. In the first position, needles <NUM> are spaced from the intersection where the planes upon which needle beds <NUM> meet. In the second position, however, needles <NUM> are extended and pass through the intersection where the planes upon which needle beds <NUM> meet. That is, needles <NUM> cross each other when extended to the second position. It should be noted that first dispensing tip <NUM>, second dispensing tip <NUM>, and third dispensing tip <NUM>, are located above the intersection of the planes. In this position, first dispensing tip <NUM>, second dispensing tip <NUM>, and third dispensing tip <NUM> supply yarn to needles <NUM> for purposes of knitting, tucking, and floating.

Referring again to <FIG>, first standard feeder <NUM> moves along rail <NUM> and a new course is formed in knitted component <NUM> from yarn <NUM>. More particularly, needles <NUM> pull sections of yarn <NUM> through the loops of the prior course, thereby forming the new course. Accordingly, courses may be added to knitted component <NUM> by moving standard feeder <NUM> along needles <NUM>, thereby permitting needles <NUM> to manipulate yarn <NUM> and form additional loops from yarn <NUM>.

Knitted components described herein can be formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a knitted component having a variety of courses and wales. Thus, adjacent areas of a knitted component can share at least one common course or at least one common wale. That is, knitted components can have the structure of a knitted textile. It will be appreciated that the knitted components can be formed via weft knitting operations, including flat knitting operations and circular knitting operations, warp knitting operations, or other suitable methods.

The knitted components may incorporate various types and combinations of stitches and yarns. With regard to stitches, the yarn forming the knitted components may have one type of stitch in one area of a knitted component and another type of stitch in another area of the knitted component. Depending upon the types and combinations of stitches utilized, areas of knitted components may have a plain knit structure, a mesh knit structure, or a rib knit structure, for example. The different types of stitches may affect the physical properties of a knitted component, including aesthetics, stretch, thickness, air permeability, and abrasion-resistance. That is, the different types of stitches may impart different properties to different areas of the knitted component. With regard to yarns, the knitted component may have one type of yarn in one area of a knitted component <NUM> and another yarn in a different area of the knitted component.

Although embodiments of the disclosure have been described in detail as providing an upper comprising a single layer, the disclosure also contemplates uppers having plural layers. The plural layers may be fused, double-knit, or otherwise associated with each other.

<FIG> illustrates a portion of a knitted component <NUM>, which may represent any of knitted component <NUM>, knitted component <NUM>, or foot-enclosing knit portion <NUM>. In particular, the portion is that portion in which ground-engaging cleat member <NUM> are formed, so it includes portions that will become one-piece knit outsole <NUM>, and at least two ground-engaging cleat members <NUM>. The portion also includes first tensile element <NUM>, second tensile element <NUM>, third tensile element <NUM>, and tensile element <NUM>. The portion also includes tensile element loops <NUM>, which represent the travel of the tensile element at the end of the knitted component from one location to another, and tensile element leads <NUM>, which represent the travel of the tensile element at the beginning and end of the tensile element. Tensile element loops <NUM> and tensile element leads <NUM> may permit the inlaid tensile elements to be adjusted with the knitted component. In some embodiments, tensile element loops <NUM> and tensile element leads <NUM> may be removed from the edges of the textile element when the textile element is formed into a portion of an article of footwear. In some embodiments, tensile element loops <NUM> and tensile element leads <NUM> may be secured or attached to the bottom of the upper of the article of footwear.

Although the disclosure is described in detail as it relates to a knitted component for a sole system for an article of footwear, the principles described herein may be applied to any textile element to provide a knit surface on a protruding portion of an object to engage another object. For example, the principles may be applied to studs that protrude from the front or back of a glove or mitten to provide a secure grip on an object grasped with the glove or mitten. In such a case, the knitted component on the surface of the protruding object would not be ground-engaging, but rather would be object-engaging, and the tensile elements may be located analogously. The tensile element also may be located along or adjacent to the knuckles, across the palm, at the cuff, or any location amenable of adjustment, as described herein.

At least two ground-engaging members are formed on the knitted component in the sole system. The ground-engaging members protrude from the ground-facing surface of the outsole. At least the bottom surface of the ground-engaging member engages the ground, and the sides of the ground-engaging member also may engage the ground.

In some embodiments, a ground-engaging member may be formed by stretching the knitted component in the area of the outsole where the ground-engaging member is to be located to form a protuberance. Typically, protuberances are found in the forefoot and in the heel, although protuberances may be placed anywhere on the outsole surface. Plural ground-engaging members may be formed by stretching the knitted component individually, essentially simultaneously, in groups, or simultaneously to form the protuberances.

In some embodiments, a mold may be formed by any suitable method. The mold may have a single protuberance, or may have a protuberance for each ground-engaging member to be formed by the stretching operation. In other embodiments, two molds may be necessary. One mold may be used to form protuberances extending from the forefoot area, and the second mold may be used to form protuberances extending from the heel area.

In some embodiments, all protuberances are formed essentially simultaneously. A mold may have a male part and a mated female part into which the male part is pressed. The knitted component is placed in an open mold, typically on the female part of the open mold. The knitted component is located so that the portion of the knitted component that forms the bottom of the sole is appropriately registered with the portions of the female mold that form the protuberances. The mold ensures that the knitted component is retained at the edges so that the protuberances are formed by stretching, rather than by forcing extra textile into the cavity and wrinkling the remainder of the knitted component. Then, the male part of the mold is pressed into the knitted component and into the female part of the mold to form the protuberances in the sole. The mold parts then are separated, and the knitted component with protuberances is advanced for further processing.

<FIG> illustrate the method steps by which ground-engaging cleat members may be formed. Mold <NUM> is open, and knitted component <NUM> is placed between mold male part <NUM> and mold female part <NUM>, as shown by the direction of the arrow. The mold is closed and the mold secures the edges of knitted component <NUM> to ensure that knitted component <NUM> is stretched to form ground-engaging cleat members <NUM> when the mold is closed.

<FIG> illustrates that male mold part <NUM> and female mold part <NUM> are moved together to press knitted component <NUM> therebetween. <FIG> illustrates that the mold parts have been separated, and one-piece outsole <NUM> has formed. In particular, the top surface of the outsole <NUM> and ground-engaging cleat member <NUM> are visible as the knitted textile is removed in the direction of the arrow from the separated mold.

In other embodiments, all protuberances may be formed essentially simultaneously by injection molding. Injection molding uses a fluid under pressure to form protuberances in a surface, here the knitted component. Injection molding may be used to inject materials such as elastomers and thermoplastic and thermosetting polymers. The knitted component is held in place and the knitted component is stretched to form the protuberances. Typically, thermoplastic polymers are used because such materials are well-suited for injection molding. Thermoset materials may react too quickly or not quickly enough while being injected. Further, thermoplastic polymers may be reused and recycled, thus making such material an environmentally sensitive choice.

A knitted component is correctly oriented on the female mold part. Then, the mold is closed. The other part of the mold contains runners and other tubes for delivering the injected material through nozzles to the mold cavity. Heated material is forced into the mold cavity to stretch the knitted component and form the protuberances. The material cools and hardens to the configuration of the protuberances. The molds then are separated and the molded knitted component is removed.

In some embodiments, the injected material may remain in the protuberances to provide rigidity. In some such embodiments, an additional feature such as a shank may be formed between the forefoot portion and the heel portion. The shank may provide additional rigidity to the outsole and thus to an article of footwear made with the sole system. In other embodiments, the injected material may be removed from the protuberances. In some such embodiments, the protuberances may be filled with another rigid material, or may be filled with soft material to provide a perception of cushioning.

<FIG> discloses another embodiment for forming ground-engaging cleat member <NUM>. Mold <NUM> includes female part <NUM> and injectors <NUM> including nozzles <NUM>. Each nozzle <NUM> corresponds with a cavity <NUM> shaped to form a ground-engaging cleat member <NUM>. Knitted component <NUM>, including first tensile element <NUM>, second tensile element <NUM>, third tensile element <NUM>, fourth tensile element <NUM>, tensile element loops <NUM>, and tensile element leads <NUM>, is placed between the injection nozzles, as shown by the arrow. Then, the mold parts are brought together and a material is injected from nozzles <NUM> into cavities <NUM> to form ground-engaging cleat members <NUM>.

The material injected may be left in a ground-engaging cleat member <NUM> to provide additional support. Also, the individual pieces of injected material may be connected by a sprue or another manner. A mass of injected material also may be used to form a structure that will attenuate forces from the ground-engaging cleat member <NUM> reinforcement into the wearer's foot. A skilled practitioner will be able, with the guidance provided herein, to select suitable materials for this purpose.

Moving ahead to <FIG> illustrates a representation of a tensile element inlaid within the sole of a knitted component used to reduce differences in stress in an outsole. The top panel illustrates how formation of cleat <NUM> in outsole portion <NUM> introduces stress into the knitted structure. Unstressed outsole portion <NUM> on the left then is moved into a press, as indicated by the movement arrows. When cleat <NUM> is formed by pressing, the area surrounding the cleat is subjected to essentially equal stress in all directions, thus causing approximately equal stretching of the knitted component in the area of the cleat. This approximately equivalent stretch is illustrated by expanded view <NUM> and arrows <NUM>, which, by their relative size, illustrate approximately equal stress in all directions.

The center panel on <FIG> illustrates knitted component <NUM> having tensile element <NUM> and tensile element <NUM> inlaid therein. Cleat <NUM> is formed by pressing down, displacing tensile element <NUM> and tensile element <NUM> and introducing stress, as indicated by different arrows <NUM> and <NUM>. The magnitude of this stress introduced into knitted component <NUM> is greater in the lateral direction (arrows <NUM>) than in the longitudinal direction (arrows <NUM>). Knitted component <NUM> is stretched close to cleat <NUM>, as illustrated in magnified view <NUM>. The amount of stress in this location can be compared to the lack of stress in magnified view <NUM>.

The bottom panel of <FIG> illustrates how the tensile elements may be used to restore a knitted component to typical stress or tension levels. Knitted component <NUM> having tensile element <NUM> and tensile element <NUM> inlaid therein is pressed (movement arrows) to form cleat <NUM>. To reduce the stress introduced by the pressing, loop <NUM> in tensile element <NUM> is pulled to reduce the lateral stress. Loop <NUM> is pulled along the surface of knitted component <NUM> and then secured under tensile element <NUM>, such as at <NUM>, to retain the tension. Re-establishment of more typical stress distribution is illustrated by equal-sized force arrows <NUM> and by enlarged view of the knitted surface at <NUM> and <NUM>. Enlarged view <NUM> illustrates a typical knit pattern away from cleat <NUM>, as was found in enlarged view <NUM>. Further, enlarged view <NUM> illustrates stress on knitted component <NUM> in the vicinity of cleat <NUM>. The stress pattern at enlarged view essentially matches that at magnification <NUM> away from cleat <NUM>. This is because tensile element <NUM> has been adjusted to relieve this stress.

The tensile elements may be manipulated to adjust the tension in a portion of a knitted component. The wearer may adjust the tension to provide a secure fit by adjusting longitudinal (along the length of an article of footwear) tension, lateral (across the width of the article of footwear) tension, or both. Such adjustments also may be made to compensate for any slackness that develops during wear and use of the article of footwear. The tensile elements also may be used to adjust tension in the shoe outsole in the area of cleat members or other protuberances.

<FIG> illustrate exemplary embodiments of adjusting tensile elements to increase longitudinal (<FIG>) tension or both longitudinal and lateral (<FIG>) tension. These are merely several exemplary embodiments of how the tensile elements can be used in an article of footwear.

<FIG> illustrates equal adjustment of adjacent tensile elements. Knitted component <NUM> includes tensile element <NUM> and tensile element <NUM>. Portions of the tensile elements are shown. <FIG> illustrates equal tension being introduced into adjacent tensile element <NUM> and tensile element <NUM> by pulling on them equally, thus forming loop <NUM> in tensile element <NUM> and loop <NUM> in tensile element <NUM>. Increasing the size of the loop increases the tension in the tensile element, and thus in the affected region of knitted component <NUM>.

In some embodiments, the loops can be made by pulling the tensile element with the fingers or a suitable tool. The loop may be pulled away from the ground-engaging surface, may be pulled parallel to the surface of the sole, or may be pulled at any angle.

<FIG> illustrates an exemplary process of introducing additional tension into a single tensile element. As can be seen, loop <NUM> is larger than loop <NUM>. Therefore, more tension is introduced into tensile element <NUM> by loop <NUM> than is introduced into tensile element <NUM> by loop <NUM>, as loop <NUM> is much larger than loop <NUM>. In various embodiments, the loops may extend in any direction.

<FIG> illustrate two steps of a process to introduce tension both longitudinally and laterally. As shown in <FIG>, a small loop <NUM> is introduced into tensile element <NUM>. A larger loop <NUM> is introduced in tensile element <NUM>. Loop <NUM> in tensile element <NUM> is pulled in the direction of the other tensile element, tensile element <NUM>, and is pulled across the surface of the outsole.

In a second step illustrated in <FIG>, loop <NUM> is pulled sufficiently to entrap the top <NUM> of loop <NUM> under tensile element <NUM> at loop <NUM>. Loop <NUM> then is eliminated to hold the top <NUM> of loop <NUM>. This arrangement introduces both longitudinal and lateral tension into this area of outsole <NUM>.

Moving back to <FIG>, <FIG> illustrate assembly of an article of footwear <NUM>. Article of footwear <NUM> comprises both an upper and a sole system in a unitary knit construction, whereas article of footwear <NUM> comprises an upper separate from the sole system. <FIG> illustrates sole system <NUM>, including knitted component <NUM> forming a one-piece knit outsole <NUM> having top surface <NUM> and ground-engaging cleat members <NUM>. The bottom surface or side <NUM> of the outsole and the ground-engaging portion <NUM> of selected ground-engaging cleat members <NUM> also are indicated.

<FIG> illustrates assembly of article of footwear <NUM> using sole system <NUM>. Upper <NUM> is brought into contact with sole system <NUM> and affixed to the top surface <NUM> thereof. Upper <NUM> may be made from any material, such as leather, plastic, woven materials, and the like. <FIG> illustrates an assembled article of footwear <NUM>. This article of footwear <NUM> includes a one-piece knit outsole <NUM>.

Still other embodiments provide a method of making a sole system for an article of footwear. In accordance with the method, a one-piece knitted component is knitted to include a knit outsole. At least two ground-engaging cleat members are formed in the ground-facing side of the knit outsole by knitting. A surface of the ground-engaging cleat member may include a knitted surface that contacts the ground.

<FIG> illustrates knitted component <NUM>, another embodiment of a knitted component. In this embodiment, ground-engaging cleat members <NUM> are knit into the one-piece knit outsole. Therefore, there is less stress in the textile in the vicinity of the ground-engaging cleat members, and in the ground-engaging cleat members. In this embodiment, ground-engaging cleat members <NUM> are knitted into one-piece knit outsole <NUM> as pockets or cavities extending from bottom surface <NUM> of the outsole. Each of ground-engaging cleat members <NUM> may be knitted from the same yarn as the remainder of the knit outsole <NUM>; other embodiments may form pockets using a different yarn.

<FIG> illustrates the difference in stress in the ground-engaging cleat members between stretching or molding to form ground-engaging cleat member <NUM> and knitting to form ground-engaging cleat member <NUM>. Knitted component <NUM> and knitted component <NUM> are molded in molds <NUM> to form knitted component <NUM>. Knitted component <NUM> is molded to stretch the textile of knitted component <NUM> to form ground-engaging cleat members <NUM> in knitted component <NUM>. However, when knitted component <NUM> is molded to form knitted component <NUM>, there is essentially no stretching of the knit ground-engaging cleat member <NUM> or of the remainder of the knit structure forming knitted component <NUM>. The exploded views of stretched ground-engaging cleat member <NUM> and of unstretched ground-engaging cleat member <NUM> clearly illustrate this difference.

In some embodiments, the ground-engaging cleat members <NUM> may be reinforced from the inside. In some embodiments, a cap-type protector may be used to cover the bottom and at least a portion of the sides of the ground-engaging cleat members. In some embodiments, the ground-engaging cleat member is filled with a reinforcing material. In some embodiments, the filling may be done by using injection molding to stretch-form ground-engaging cleat members <NUM>. In other embodiments, a midsole insert form to fill the ground-engaging cleat members is used.

<FIG> illustrate a method for reinforcing ground-engaging cleat members by filling them with reinforcing material. <FIG> illustrates knitted component <NUM> with stretch-formed ground-engaging cleat members <NUM>, but knitted ground-engaging cleat members <NUM> also may be reinforced by filling them. Container <NUM> is in position to dispense filler <NUM> through filler nozzle <NUM>, as illustrated in <FIG>.

<FIG> further illustrates that some ground-engaging cleat members <NUM> have not yet been filled with reinforcing material <NUM>. Some ground-engaging cleat members <NUM> may be left empty to provide a selected cushioning response. However, as illustrated in <FIG>, each ground-engaging cleat member <NUM> may be filled with filler or reinforcement material <NUM>.

<FIG> is a cross sectional view take at line <NUM> of <FIG>. One-piece knit outsole <NUM>, including outsole top side <NUM>, outsole bottom side <NUM>, bottom surfaces <NUM> of ground-engaging cleat members <NUM>, and ground-engaging cleat member <NUM> filled with reinforcement material <NUM> are illustrated in <FIG>. As illustrated, reinforcement material <NUM> may extend above outsole top surface <NUM>. The individual masses filling the ground-engaging cleat members <NUM> also may be connected, as described above. Bottom surface <NUM> of ground-engaging cleat member <NUM> is a knit surface that may be directly in contact with the ground. Other surfaces of one-piece knit outsole <NUM>, such as outsole bottom side <NUM>, also may be in direct ground contact.

Filler material <NUM> may be any suitable reinforcing material. Reinforcing materials may include compositions that provide minimal support. Such compositions may be used to tune a cushioning response. More typically, however, a reinforcing material <NUM> may be selected for its rigidity and strength. The material may be foamed material, such as foamed plastic materials. For example, foamed thermoplastic polyurethane may be suitable. The density of foamed materials may be controlled to tune cushioning response. Higher density may give a more supportive response and better reinforcement of ground-engaging cleat members.

In some embodiments, thermoplastic material may be used because such materials may be tough and strong, and can be foamed to tune cushioning response. Thermoset materials also may be used, but may present additional complications in manufacture because the thermoset reaction should not be completed before the material is in place. Further, as set forth above, thermoplastic materials may be more easily recycled, and thus present less waste.

Reinforcing materials may be liquid or may be in powder or particulate form, particularly in a form that can be compressed into the ground-engaging cleat members to provide reinforcement. Therefore, a retaining seal may be used to retain these reinforcing materials in the ground-engaging cleat members.

In other embodiments, a properly-designed midsole insert may be used to both reinforce the ground-engaging cleat members and to provide support for the foot. Reinforcement of the ground-engaging cleat members in this way is subject to the same considerations regarding selection of reinforcing material as are set forth above, but also may be formed to provide additional comfort or support for the wearer. An additional benefit also may be obtained by designing the insert to improve the strength of the shoe by, for example, providing arch support.

Thus, in some embodiments, the midsole may be monolithic or may have zones that provide additional support or resistance to twisting, for example. Midsoles are illustrated in <FIG>. Reinforcement zones may be more rigid than the midsole surface <NUM> that is in contact with the foot. Reinforcement zones may be found in the ground-engaging cleat members and in other areas of midsole <NUM>. For example, midsole <NUM> may have a strengthened zone in the midfoot region for arch protection and comfort.

In some embodiments, some regions of midsole <NUM> may comprise foamed thermoplastic material while other regions may be formed of the same or different materials. In some embodiments, midsole <NUM> may comprise a zone of low-density foam, a zone of high-density foam, and a zone of unfoamed material.

Midsole <NUM> having reinforcing members <NUM> protruding from the bottom thereof is shown in relationship to one-piece knit outsole <NUM> in <FIG>. Reinforcement members <NUM> are aligned with corresponding ground-engaging cleat members <NUM>.

<FIG> illustrates midsole <NUM> affixed to the top surface <NUM> of one-piece knitted component outsole <NUM>. A cross-sectional view at line <NUM>, shown in <FIG>, illustrates midsole <NUM> in place on the top surface <NUM> of one-piece knit outsole <NUM>. Reinforcement members <NUM> are in place in ground-engaging cleat members <NUM>. Foot-contacting surface <NUM> of midsole <NUM> is the upper surface of the assembly, and the bottom surface <NUM> of the ground-engaging cleat members <NUM> are facing downward. Bottom surface <NUM> of ground-engaging cleat member <NUM> is a knit surface that may be directly in contact with the ground. Other surfaces of one-piece knit outsole <NUM>, such as outsole bottom side <NUM>, also may be in direct ground contact.

Embodiments including a foot-enclosing sole system may comprise areas in which different yarns are used. Different types of yarns may impart different properties to different areas of the knitted component. By combining various types and combinations of stitches and yarns, each area of knitted component may have specific properties that enhance the comfort, durability, and performance of the article of footwear.

In such embodiments, tensile elements also extends into portions of the knitted component forming the upper and may be inlaid within the knitted component portions forming the upper. Although the tensile elements illustrated in these figures run longitudinally, it may be possible to inlay a tensile element laterally within the knitted component. In such embodiments, the tensile element may be routed through the insole to pass from one side of the outsole to another. This arrangement would allow a single tensile element to be inlaid from one side (lateral or medial, for example) of the upper through the outsole. The tensile element is inlaid around the cleat members and extends, whether by inlay or onlay, to the upper. Such an arrangement would aid in alignment of parts and secure attachment of parts for form an article of footwear.

Suitable materials also may be added anywhere on the outer surface where water resistance or another property or characteristic, such as rigidity, is sought. Such materials, typically in the form of a film, may be applied to the surface of the knitted component before the sole system is formed. Application of a film to a knitted component also may be accomplished after formation of components of the sole system.

For example, resistance of an article of footwear to incursion of water, particularly through the sole system, may be increased by affixing a thin film or water-resistant material on the outside surface of the outsole. The entirety of the outer sole surface may be covered with thin film, or only a portion or portions of the lower surface may be covered with film for wear resistance and water repellence.

Suitable thin film materials include polymers such as polyethylene and polypropylene, which may retain flexibility when bonded to the outer surface of a knitted component. Such films may suitably be used on surfaces of a knitted component that preferably retain their flexibility, such as an upper of an article of footwear. The skilled practitioner will be able to identify appropriate films.

In other embodiments, a thin film may be rigid or resistant to bending before or upon application, typically with heat and pressing. Application with heat and pressing causes the film to adhere or being adhered to the knitted component. Such rigid film may be formed of plural thin layers or one or two thicker layers. Plural materials may be stacked to form a more rigid film. A thicker, single layer also may be used.

Embodiments of a foot-enclosing sole system may include areas of softer yarns, compliant yarns, durable yarns, and fusible yarns, for example. Softer and compliant yarns typically may be used where comfort is an important feature, with durable yarns used in areas susceptible to wear. In particular, embodiments may have fusible yarns on the outsole, the protruding ground-engaging projection, and on the ground-engaging surface. Fusible yarns may be particularly durable and may serve the same purposes ascribed to them above. Similarly, a thin film may be used to the same advantage as set forth above.

Another suitable yarn may be a core and sheath-type bi-component construction. Core and sheath construction is obtained having a sheath of material having one set of properties essentially concentric with and surrounding a core of yarn material having another set of properties and characteristics. In embodiments, the sheath material is one type of yarn having a first set of properties and characteristics. Other bi-component yarns, such as "islands in the sea" type, also may be suitable. Such yarns typically may have fusible material on the outside, just as a core and sheath fiber has fusible material as a sheath material. Still another technique may be to spray a solvent-based fusible composition onto yarn. In such embodiments, the solvent may be water, thus making the composition environmentally sensitive.

In still further embodiments, a plurality of yarns may be used to provide transition zones for areas of the knitted component. For example, whereas durable, rigid yarns may be preferred for surfaces of the knitted component that are ground-facing, such yarns may not be preferred for an upper of an article of footwear. Rather, softer, more compliant yarns may be preferred on the upper, but such yarns may wear out prematurely in areas of high abrasion or stress, such as in the area of the heel, for example. For such high abrasion areas, if may be preferable to have a durable yarn.

In some embodiments, a rigid layer may be applied to both the top side of the outsole and the ground-facing side of the outsole. Such embodiments provide a rigid outsole, yet retain the look, properties, and characteristics of a knitted textile formed from a knitted component. Further, the rigid layer of material attached to the top side of the outsole may be useful in forming a protruding ground-engaging member.

Other embodiments may include a rubberized portion on the ground-facing surface of the outsole. A rubberized portion may be formed on the surface of the outsole by painting on a rubberized material, by adhering a rubberized material to the portion of the knitted component that forms the ground-facing surface of the outsole, or in any suitable method.

In embodiments having a layer of material on the ground-facing surface of the outsole, the shape of the layer may be formed to reduce adhesion of mud and dirt to the bottom of the sole, and thus to the bottom of an article of footwear incorporating the sole system. Various geometric shapes may be formed in the covering layer, or added to the ground-facing surface of the outsole, to minimize adhesion of mud and dirt.

The disclosure provides a sole system for an article of footwear. The sole system includes a knitted component incorporating a one-piece knit outsole. The knit outsole has a ground-facing side and a top side. At least two protruding ground-engaging cleat members are formed on the ground-facing side of the knit outsole.

Claim 1:
An article of footwear (<NUM>) having an upper (<NUM>) and a sole system (<NUM>), the article of footwear comprising:
a knitted component with a lower portion (<NUM>) included in the sole system, wherein the lower portion of the knitted component has a first surface (<NUM>) configured to face the ground and a second surface (<NUM>) facing opposite the first surface,
the knitted component including a plurality of cleat members (<NUM>) protruding from the first surface,
wherein the knitted component is continuous between each of the plurality of cleat members,
wherein the knitted component forms at least a portion of the upper,
wherein the lower portion (<NUM>) of the knitted component comprises an inlaid tensile element (<NUM>), wherein the tensile element (<NUM>) is positioned adjacent to at least one cleat member (<NUM>) of the plurality of cleat members (<NUM>) along a longitudinal or lateral direction of the sole system (<NUM>).