Patent Description:
Conventional footwear articles have a sole and an upper attached to the sole. Footwear manufacturing has historically been a cut-sew-assembly operation that is labor intensive. Panels of upper materials are cut to size and sewn together to create the upper. The sole is attached to the upper using a number of different techniques to create the finished footwear article. Recent developments in footwear design employ knitting technology to form portions of footwear and the upper in particular. In some instances, flat bed knitting is used to form a planar knitted fabric blank. The planar knitted fabric blank is formed into a specific shape so that it can be folded or wrapped into a near completed shoe upper. Once the upper is formed, the sole component or other durable structures are attached to the knitted shoe upper consistent with conventional footwear manufacturing techniques. While some sewing is required to create the shoe upper using flat-bed knitting, fewer sewing steps are required compared to conventional shoe manufacturing. Although flat knitting may result in increased material utilization, because fabric cutting in minimized, there are design limits and production inefficiencies inherent in flat knitting. Examples are shown by <CIT> and <CIT>.

Embodiments of the present disclosure include a footwear article that includes a circular knitted fabric formed into a double-layer knitted upper of a footwear article <NUM>. The footwear article <NUM> is disclosed as having a configuration suitable for walking or running. Concepts associated with the footwear may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, sprinting 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. The concepts disclosed in this application apply to a wide variety of footwear types.

Referring to <FIG>, a footwear article <NUM> includes a sole component <NUM> and an upper knitted component <NUM>. For reference purposes, footwear article <NUM> may be divided into three general regions: a forefoot region <NUM>, a midfoot region <NUM> rearward of the forefoot region, and a heel region <NUM>. The forefoot region <NUM> generally includes portions of footwear article <NUM> corresponding with the toes and the joints connecting the metatarsals with the phalanges. The midfoot region <NUM> generally includes portions of footwear article <NUM> corresponding with an arch area of the foot. The heel region <NUM> generally corresponds with rear portions of the foot. The footwear article <NUM> also includes a medial side <NUM> and a lateral side <NUM>, which extend through each of the regions <NUM>-<NUM> and correspond with opposite sides of footwear article <NUM>. The lateral side <NUM> corresponds with an outside area of the foot, i.e. the surface that faces away from the other foot, and the medial side <NUM> corresponds with an inside area of the foot, i.e., the surface that faces toward the other foot. Regions <NUM>-<NUM> and sides <NUM>-<NUM> are intended to represent general areas of footwear article <NUM>. In addition to footwear article <NUM>, regions <NUM>-<NUM> and sides <NUM>-<NUM> may also be applied to sole component <NUM> and/or the upper knitted component <NUM>.

Continuing with <FIG>, the sole component <NUM> is secured to the upper knitted component <NUM> and extends between the foot and the ground when footwear article <NUM> is worn. The sole component <NUM> may include a midsole, an outsole, and a liner (not shown). The midsole is secured to the upper knitted component <NUM>, as further explained below. The mid-sole may be formed from a compressible polymer foam element, e.g., a polyurethane or ethylvinylacetate foam, that attenuates ground reaction forces and provides cushioning when compressed between the foot and the ground during walking, running, or other ambulatory activities. The outsole is secured to a lower surface of midsole and may be formed from a wear-resistant rubber material that is textured to impart traction. The structure and features of sole component <NUM> or any sole component utilized with upper knitted component <NUM> may vary considerably.

The footwear article <NUM> includes a plurality of tabs 22a-22d that extend upwardly from the sole component <NUM> along a medial side <NUM> and a lateral side <NUM> of the footwear article <NUM>. The plurality of tabs 22a-22d include securing members 24a-24d in the form of openings, slots, and/or hooks that receive a cord <NUM>.

Continuing with <FIG>, the upper knitted component <NUM> forms an internal void <NUM> within footwear article <NUM> for receiving and securing a foot relative to sole component <NUM>. The void <NUM><NUM> is shaped to accommodate the foot and extends along the lateral side of the foot, along the 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>. A cord <NUM> extends through portions of upper knitted component <NUM>, as described above, and permits the wearer to modify dimensions of the upper knitted component <NUM> to accommodate the proportions of the foot. The cord <NUM> permits the wearer to tighten the upper knitted component <NUM> around the foot, and cord <NUM> permits the wearer to loosen the upper knitted component <NUM> to facilitate entry and removal of the foot from the void <NUM> through ankle opening <NUM>.

Continuing with <FIG>, the upper knitted component <NUM> is a double layer knitted upper having a substantially monolithic, circular knit, fabric construction. The double layer knitted upper has a foot bed <NUM>, a toe portion <NUM>, a mid-foot portion <NUM> (sometimes called an upper portion <NUM>) continuous with the toe portion <NUM>, a heel portion <NUM> adjacent and continuous with the mid-foot portion <NUM> and an ankle portion <NUM> that defines the ankle opening <NUM>. The foot bed <NUM> extends from the toe portion <NUM> along the mid-foot portion <NUM> to the heel portion <NUM>. The sole component <NUM> is attached to the foot bed <NUM>. In an alternative embodiment, a liner (not shown) is positioned within the double layer knitted upper along the foot bed <NUM>. The toe portion <NUM>, mid-foot portion <NUM>, heel portion <NUM>, and ankle portion <NUM>, and foot bed <NUM> refer to generally areas of the upper knitted component <NUM>.

Referring to <FIG> and <FIG>, the double layer knitted upper has an outer knit layer <NUM> and an inner knit layer <NUM>. The outer knit layer <NUM> and the inner knit layer <NUM> together form the toe portion <NUM>, the mid-foot portion <NUM>, the heel portion <NUM>, and the ankle portion <NUM> of the double layer knitted upper. The outer knit layer <NUM>, however, defines an exterior surface <NUM> of the double layer knitted upper and the inner knit layer defines an inner surface <NUM> of the double-layer knitted upper. Thus, it can be said that the outer knit layer <NUM> forms the exterior facing surfaces (not numbered) of the toe portion <NUM>, the mid-foot portion <NUM>, the heel portion <NUM>, and the ankle portion <NUM>. Conversely, the inner knit layer <NUM> defines the inward facing surfaces (not numbered) of the toe portion <NUM>, the mid-foot portion <NUM>, the heel portion <NUM>, and the ankle portion <NUM>. Furthermore, both the outer knit layer <NUM> and the inner knit layer <NUM> substantially define the foot bed <NUM> of the double-layer knitted upper. The outer knit layer <NUM> and the inner knit layer <NUM> may define an edge <NUM> along the ankle opening <NUM>. An optional binding <NUM> may be disposed along the edge <NUM> of the ankle opening <NUM>.

The double layer knitter upper include at least one attachment member that consolidates the outer knit layer <NUM> to the inner knit layer <NUM>, thereby forming the double layer knitted upper. The attachment member may be any material that fuses the outer knit layer <NUM> and the inner knit layer <NUM> together. Because the outer and inner knit layers are circular knit structure, each layer has float yarns on side due to the different knit constructions formed in the knitted regions described below. When the double layer knitter upper is formed the floats from the outer knit layer <NUM> face the floats from the inner knit layer <NUM>. The floats can create snags and deform the knit construction when the floats are pulled or the layers or otherwise deformed. The attachment members address this problem by consolidating the outer knit layer and the inner knit layer together. In particular, the attachment member bonds the yarns from the outer knit layer <NUM> to the yarns from the inner knit layer <NUM>. This bonding minimizes distortion in the knit structure created in use. The attachment members also bind the outer and inner knit layers together so that the two layers do not slide relative to one another. The attachment member provides stability to the double layer knitted upper. In one example, the attachment member may comprise binding yarns. The binding yarns may comprise part of the knit stitches, may be laid-in, or plated in during knitting. When the binding yarns exposed to a desired temperature (at above glass transition temperature), the binding yarns melt, thereby consolidating the outer and inner knit layers <NUM>, <NUM> together. The binding yarns may be thermoplastic polyurethane yarns. In another example, the binding yarns are low-melt thermoplastic yarns that have a lower melt temperature than the yarns used to form the outer and inner knit layers <NUM>, <NUM>. In an alternative embodiment, the attachment member may be a low-melt adhesive film, a low melt adhesive nonwoven web, or an adhesive coating. In still another alternative embodiment, the attachment member could be binding yarns that tack the outer layer and inner layer together.

The outer knit layer <NUM> has plurality of outer knit regions 62a-62f and the inner knit layer <NUM> has a plurality of inner knit regions 82a-<NUM>. The outer and inner knit regions comprise selected textile structural elements. The selected textile structural elements may include specific knit stiches and/or presence of certain yarns. Furthermore, the selected textile structural elements may include the absence of certain knit stiches and/or yarns. One or more of the plurality of outer knit regions 62a-62f of the outer knit layer <NUM> may spatially correspond to one or more of the plurality of inner knit regions 82a-<NUM>. In embodiments where the inner knit regions spatially correspond to the outer knit regions, the inner knit regions completely or partially underlie the outer knit regions. For example, each one of the inner knit regions 82a-82e underlie the respective outer knit regions 62a-62d. However, the outer knit layer <NUM> and the inner knit layer <NUM> may comprise different knit regions in different locations from the other.

<FIG> illustrates the plurality of outer knit regions 62a-62f. As illustrated, the plurality of outer knit regions comprise a first outer knit region 62a along the toe portion <NUM> and a portion of the foot bed <NUM>. The first outer knit region 62a may be called a forward toe knit region. A second outer knit region 62b extends across the top of the toe portion <NUM>. The second outer knit region 62b may be called an upper toe knit region. A third outer knit region 62c extends across the top part of the mid-foot portion <NUM> and rearward of the toe portion <NUM>. The third outer knit region 62c may be called an upper mid-sole knit region. A fourth outer knit region 62d extends across heel portion <NUM>. The fourth region 62d is referred to as an outer heel region. A fifth outer knit region 62e forms the remaining areas of the outer knit layer. A sixth outer knit region 62f is located along the ankle portion <NUM> above the outer heel portion <NUM>. Each outer knit region 62a through 62f may have different textile structural elements, in terms of knit structure and/or yarns. Alternatively, each outer knit regions 62a-62f may have similar knit constructions, in terms of knit structure and/or yarns. In one example, the upper mid-sole knit region 62c may comprise binding yarns. Binding yarns may be, for example, thermoplastic polyurethane yarns. The binding yarns may facilitate consolidating the outer and inner knit layers <NUM>, <NUM> together.

As best shown in <FIG> and <FIG>, the inner knit layer <NUM> includes a plurality of inner knit regions 82a-<NUM> that comprise selected textile structural elements. Regions 82a-<NUM> are not shown in <FIG> but are illustrated in <FIG> as part of the knitted blank <NUM>. As illustrated, the plurality of inner knit regions include a first inner knit region 82a along the toe portion and a portion of the foot bed. The first inner knit region 82a may be called a forward toe knit region. A second inner knit region 82b extends across the top of the toe portion. The second inner knit region 82b may be called an upper toe knit region. A third inner knit region 82c extends across the top part of the mid-sole portion and rearward of the toe portion. The third inner knit region 82c may be called an upper mid-sole knit region. A fourth inner knit region 82d extends across the heel portion. The fourth region 82d is referred to as an inner heel region. A fifth inner knit region 82e forms the remaining areas of the inner knit layer <NUM>. A sixth inner knit region <NUM> extends across the bottom part of the mid-sole portion and rearward of the toe portion. The sixth inner knit region <NUM> may be called a lower mid-sole knit region <NUM>. A seventh inner knit region 82f is located along the ankle portion. Each inner knit region 82a through <NUM> may have different textile structural elements, in terms of knit structure and/or yarns. Alternatively, each inner knit regions 82a-<NUM> may have similar knit constructions, in terms of knit structure and/or yarns. In one example, the upper mid-sole knit region 82c and/or the lower mid-sole knit region <NUM> may comprise binding yarns. Binding yarns may be thermoplastic polyurethane yarns, as described above. Binding yarns may facilitate consolidating the outer and inner knit layers <NUM>, <NUM> together.

The double layer knitted upper can have a variety of circular knit constructions. For instance, the double layer knitted upper may have include a single jersey knit construction, a double knit construction, rib knit construction, a terry knit construction, or other types of weft knit constructions. Furthermore, the different regions of the double layer knitted upper may comprise different knit stitches, such as float stiches, held stiches, missed stiches, and other knit stiches known to a person of skill in the art. In one example, the outer knit toe regions 62a, 82a of the outer and/or inner layer may comprise a cushioned knit construction. Likewise, the heel regions 62d, 82d of the outer and/or inner layer can have cushioned knit construction. A cushioned knit construction includes knitted terry loops.

The double layer knitted upper can be formed from any number of yarn types, such as spun yarns or continuous filament yarns. Spun yarns may include natural fibers, synthetic fibers, or blends of natural and synthetic fibers. Natural fibers include cotton, wool, bamboo, flax, hemp, or others. Synthetic fibers may include polyethylene terephthalate (PET), polyolefin, polyamide <NUM>, polyamide <NUM>,<NUM>, polylactic acid (PLA) fibers, viscose rayon, acrylic, or other fiber types. Suitable thermoplastic synthetic staple fibers may be mono-component or bi-component type fibers. A variety of yarn spinning types can be used, such as ring spun, open end, air-jet, compact spinning, and the like. Continuous filament yarns may include either or both mono-component or bicomponent filaments types. Continuous filament yarns can be polyethylene terephthalate, polyolefin, and/or polyamide <NUM>, polyamide <NUM>,<NUM>, polylactic acid filaments. Yarns used in the knit fabric can have a range of yarn counts. For instance, in one example, the knit yarn can have a count in a range between about <NUM> denier to about <NUM> denier (or higher). The yarns are not limited to the stated range of deniers. Binding yarns are used in selected regions of the outer knitted layer <NUM> and the inner knitted layer <NUM> to help consolidate the outer layer and the inner layers together. Binding yarns may be low melt thermoplastic yarns, or yarns such as thermoplastic polyurethane yarns.

Another embodiment of the present disclosure is a method for forming a footwear article <NUM>. The method may include a knitting phase form forming a circular knitted blank <NUM>. Following the knitting phase, the method may include an assembling phase where the circular knitted blank <NUM> is formed into an upper knitted component <NUM> and the sole component <NUM> is attached to foot bed <NUM> of the upper knitted component <NUM>. Referring to <FIG>, the circular knitted blank <NUM> has a first knit section <NUM> defining the outer knit layer <NUM> and the second knit section <NUM> defining the inner knit layer <NUM>. The circular knitted blank <NUM> is folded into to itself to define the double layer knitted upper so that the inner knit layer <NUM> forms the inner void <NUM> of the footwear article <NUM>.

The knitting phase utilizes a circular knitting machine (not shown) familiar to a person of skill in the art. The circular knitting machine may be a double needle machine that includes two cylinders. Alternatively, a circular knitting machine with a cylinder and a dial may be used. The knitting process is described below using a knitting machine with two cylinders for purposes of illustration and clarity. It should be appreciated that other types of knitting machines could be used. Each cylinder has a plurality of needles disposed around the circumference of the cylinder with each needle housed in moveable tracks. A cam assembly engages the needles along each cylinder. Rotational movement of the cam assembly (or relative movement of the cylinders) causes the needles to move up and down the tracks through what is known in the art as the knitting cycle to create courses of interconnected knitted loops of yarns. The courses of knitted loops define the circular knitted fabric blank <NUM>. By altering the knitting cycles and/or holding certain needles in place during knitting, specific knit stitches and/or patterns can be formed into the circular knitted blank <NUM>. The circular knitting machines and the basic circular knitting process is familiar to a person of skill in the art. Various circular knit processes may be used, such as tube circular knitting, narrow tube circular knit jacquard, single knit circular knit jacquard, double knit circular knit jacquard knitting.

Referring to <FIG>, the circular knitted blank <NUM> has a first terminal end <NUM> and a second terminal end <NUM>. The circular knitted blank <NUM> is formed to have a first knit section <NUM> that defines the first terminal end <NUM> and a second knit section180 that defines the second terminal end <NUM>. The circular knitted blank <NUM> is comprised of interconnected rows of knitted loops, called courses, as described above. The first "course" of the knitted blank <NUM> is located at the first terminal end <NUM>. The circular knitted blank <NUM> is formed course-by-course, in the direction K shown in <FIG> until the circular knitted blank <NUM> is complete, as shown in <FIG>. Accordingly, during the knitting phase, the first knit section <NUM> is knitted first, then the second knit section <NUM> is formed in a single monolithic fabric with the first knit section <NUM>.

Circular knitting of the knitted blank <NUM> initiates with the cylinder needles knitting the first toe portion <NUM> of the first knit section <NUM>. Next, the circular knitting machine knits the mid-sole portion, which includes a first upper portion 144a and the first lower portion 144b. Then, the first heel portion <NUM> the first knit section <NUM> is knit adjacent to the first lower portion 144b. During the knitting the first heel portion <NUM>, the knitting machine can selectively drop needles to alter the direction of knitting to form the desired curve of the first heel portion <NUM>. After the first heel portion <NUM> is formed, the circular knitting machine knits the first ankle portion <NUM> of the first knit section adjacent <NUM> to the first heel portion <NUM> and the first upper portion 144a. At this point, the first knit section <NUM> is substantially complete. The first knit section <NUM> comprises the outer knit layer <NUM> of the double layer knitted upper, as explained below. Accordingly, as the knitting machine forms the first knit section <NUM>, the different knit regions 62a-62f are created in the circular knitted blank <NUM>, as shown.

The knitting process continues to form the second knit section <NUM>. During this phase of knitting, the second ankle portion <NUM> of the second knit section <NUM> is formed adjacent to the first heel portion <NUM>. The circular knitting machines knits a second heal portion <NUM> adjacent to and continuous with the second ankle portion <NUM>. The circular knitting machine knits a second upper portion 244a and a second lower portion 244b of the second knit section <NUM>. The knitting process continues and forms the second toe portion <NUM> of the second knit section <NUM> adjacent to the second upper portion 244a and the second lower portion 244b. The second toe portion <NUM> is formed to the terminal end <NUM> to complete the circular knitted blank <NUM>. As the knitting machines forms the second knit section <NUM>, the different knit regions 82a-<NUM> are created in respective areas of the circular knitted blank <NUM>. As illustrated, the formed circular knitted blank <NUM> is substantially a tubular structure having the shape of two crew-cut socks connected as the ankle portion.

Additional courses of yarns may be added to facilitate transition to the next knitted blank formed by the circular knitting machine. Optional cutting devices are used to cut the completed circular knitted blank <NUM> from the knitting machine. The circular knitted blank <NUM> is the ejected out of the knitting machines for later processing.

The completed circular knitted blank <NUM> may have toe openings <NUM> and <NUM> at toe portion <NUM> and toe portion <NUM>, respectively. The toe openings <NUM> and <NUM> can be closed with seams <NUM> and <NUM> as illustrated in <FIG>. In an alternative embodiment, the circular knitted blank <NUM> can be formed to automatically close the toe openings <NUM> and <NUM> using bridge stiches or inlayed yarns and the like.

The circular knitted blank <NUM> may be cut to form the ankle opening <NUM> by removing a panel <NUM> from the circular knitted blank <NUM>. In an alternative embodiment, the circular knitted blank <NUM> can be formed to define the ankle opening <NUM> during knitting. In such an embodiment, the circular knitted blank <NUM> may form a welted edges along the border of the ankle opening <NUM> to prevent fraying and provide a place to attach a binding <NUM> (<FIG> and <FIG>).

When the circular knitted blank <NUM> is completed, the second knit section <NUM> is folded into the first knit section <NUM> to form a double layer knitted upper of the footwear article. At this stage, the double layer knitted upper comprises the outer knit layer <NUM> defined by the first knit section <NUM> and the inner knit layer <NUM> defined by the second knit section <NUM>. In this state, at least two of the plurality of the outer knit regions 62a-62d of the outer knit layer <NUM> spatially correspond to at least two of the plurality of inner knit regions. In accordance with the illustrated embodiment, the inner knit regions 82a-82e underlie the outer knit regions 62a-62e.

The method may comprise, before folding, positioning a liner component along a lower portion of the first knit section. The liner component is therefore disposed between the outer knit layer and the inner knit layer.

The method may include attaching a sole directly to the outer knit layer of the double layer knitted upper. Attaching the sole to the outer knit layer comprises positioning the double layer knitted upper over a positioning member of an injection-molding device (not shown). Then, the sole component is injection molded onto the outer knit layer of the double layer knitted upper. In addition, the method may include injection molding a plurality of tabs 22a-22d along medial and lateral sides of the double layered knitted upper. The injection molding process may melt the TPU yarns in the specific knitted regions thereby bonding the outer knit layer to the inner knit layer to form a monolithic, double layer knitted upper.

Double layer knitted uppers that are circular knit as described herein have several advantages. A wide range of knit constructions across different regions of the upper is possible while using a single fabric construction. Specific knit structures can be designed into different regions of the footwear article as needed. In addition, complex three-dimensional shapes that better conform to the anatomy of the foot of the wearer may be formed during the knitting process. Because circular knitted uppers are made to conform to the foot of the wearer, fewer assembly steps are required prior to attaching the upper to the sole to create the finished footwear article. Fewer total components in the finished footwear article decreases supply chain complexity and increases production efficiency and output. Furthermore, circular knitted double layer uppers can be manufactured at relatively fast production rates further increasing production efficiency.

A footwear article <NUM> may comprise a plurality of layers or may be continuous so as to form a unitary body. The footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise soft materials such as fabric. The first layer <NUM> and the second layer <NUM> may be generally tubular or may comprise other shapes. The second layer <NUM> may comprise rigid material such as leather or plastic. The first layer <NUM> and the second layer <NUM> may be circular-knit, flat-knit or formed by other manufacturing methods or from other materials. The second layer <NUM> may be folded or inverted to be disposed adjacent at least a portion of the first layer <NUM>. The second layer <NUM> may comprise at least a portion of the interior or the exterior of the footwear article <NUM>. The footwear article <NUM> may comprise additional layers which may provide additional functionalities.

As shown in <FIG>, the footwear article <NUM> may comprise the first layer <NUM> and the second layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise generally tubular shapes. The first layer <NUM> may comprise waterproof breathable material suitable for forming at least a portion of the exterior of the footwear article <NUM>. The first layer <NUM> may be coated with a spray application to provide waterproofing and may also be breathable. The second layer <NUM> may comprise soft material suitable for conforming to a wearer's foot and providing comfort. The second layer <NUM> may be or comprise a comfort liner. When the second layer <NUM> is folded into the first layer <NUM>, the second layer <NUM> defines the interior of the footwear article <NUM> and the first layer <NUM> defines the exterior of the footwear article <NUM>. Although reference is made to the first and second layers <NUM>, <NUM> other arrangements may be used. For example, the features of each layer may be switched or combined between the layers.

One problem in conventional circular knit applications is the difficulty in sewing or bonding other materials to a circular knit upper because it has a finished 3D shape.

As an example, most heat presses and sewing machines are optimized to work with roll goods in the flat. When a circular knit upper has a 3D shape, the typical flat operations may not be suitable.

As a further example, 3D direct injection may be used to apply additive structures, cushioning, lace details, etc. to a circular knit upper. The process may be implemented on a lasted upper, which may be finished in a 3D shape.

As illustrated in <FIG>, a footwear article <NUM> may comprise a plurality of layers or may be continuous so as to form a unitary body. The footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise soft materials such as fabric. The first layer <NUM> and the second layer <NUM> may be generally tubular or may comprise other shapes. The second layer <NUM> may comprise a rigid material such as leather or plastic. The first layer <NUM> and the second layer <NUM> may be circular-knit, flat-knit or formed by other manufacturing methods or from other materials. The second layer <NUM> may be folded or inverted to be disposed adjacent at least a portion of the first layer <NUM>. The second layer <NUM> may comprise at least a portion of the interior or the exterior of the footwear article <NUM>. The footwear article <NUM> may comprise additional layers which may provide additional functionalities.

As shown in <FIG>, the footwear article <NUM> may comprise a first layer <NUM>, a second layer <NUM> and a lacing system <NUM>. The lacing system <NUM> may comprise laces, eyelets, straps, hook and loop or other types of fasteners. The lacing system <NUM> may be disposed adjacent a portion of the first layer <NUM>, a portion of the second layer <NUM> or a portion of both layers <NUM>, <NUM>. The first layer <NUM> and the second layer <NUM> may comprise generally tubular shapes which may be circular-knit. The second layer <NUM> may be folded into the first layer <NUM>. The second layer <NUM> may define the interior portion of the footwear article <NUM> and the first layer may define the exterior portion of the footwear article <NUM>. As shown, the lacing system <NUM> may be circumferentially disposed around the second layer <NUM>. When the second layer <NUM> is folded into the first layer <NUM>, the lacing system <NUM> may be disposed in-between the first and second circular-knit layers <NUM>, <NUM> of the footwear article <NUM>.

As illustrated in <FIG>, a footwear article <NUM> may comprise a plurality of layers or may be continuous so as a form a unitary body. The footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise soft materials such as fabric. The first layer <NUM> and the second layer <NUM> may be generally tubular or may comprise other shapes. The second layer <NUM> may comprise a rigid material such as leather or plastic. The first layer <NUM> and the second layer <NUM> may be circular-knit, flat-knit or formed by other manufacturing methods or from other materials. The second layer <NUM> may be folded or inverted to be disposed adjacent at least a portion of the first layer <NUM>. The second layer <NUM> may comprise at least a portion of the interior or the exterior of the footwear article <NUM>. The footwear article <NUM> may comprise additional layers which may provide additional functionalities.

As shown in <FIG>, the footwear article <NUM> may comprise a first layer <NUM>, a second layer <NUM> and a collar portion <NUM>. As shown, the first layer <NUM> may comprise a generally tubular shape. The first layer <NUM> may be circular-knit. The second layer <NUM> may comprise a planar rectangular shape. The second layer <NUM> may be flat knit. The second layer <NUM> may comprise one or more welded reinforcements <NUM> for securing the second layer <NUM> to the first layer <NUM>. The second layer <NUM> may be configured for flat sewing operations <NUM> such as flat sewing, molding or screen printing. The second layer <NUM> may be configured to be folded into or around the first layer <NUM> to define the collar portion <NUM>. The second layer <NUM> may be configured to be disposed partially circumferentially around an exterior portion of the first layer <NUM> to define the collar portion <NUM>. The second layer <NUM> may also be disposed adjacent a midfoot, an ankle or another portion of the first layer <NUM> to define other features.

<FIG> illustrates a footwear article <NUM> may comprise a plurality of layers or may be continuous so as to form a unitary body. The footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise soft materials such as fabric. The first layer <NUM> and the second layer <NUM> may be generally tubular or may comprise other shapes. The second layer <NUM> may comprise a rigid material such as leather or plastic. The first layer <NUM> and the second layer <NUM> may be circular-knit, flat-knit or formed by other manufacturing methods or from other materials. The second layer <NUM> may be folded or inverted to be disposed adjacent at least a portion of the first layer <NUM>. The second layer <NUM> may comprise at least a portion of the interior or the exterior of the footwear article <NUM>. The footwear article <NUM> may comprise additional layers or features which may provide additional functionalities.

As shown in <FIG>, the footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> may be generally tubular. The first layer <NUM> may be circular-knit. The second layer <NUM> may comprise hard or rigid material such as leather, rubber or plastic which are suitable for defining at least a portion of the exterior of the footwear article <NUM>. The second layer <NUM> may be flat-knit. The second layer <NUM> may be configured to be disposed adjacent at least an exterior portion of the first layer <NUM>. The second layer <NUM> may comprise reinforcement regions <NUM>. For example, as shown, the reinforcement regions <NUM> may define a heel cup 610a and a toe cup 610b. The second layer <NUM> may comprise apertures <NUM> that define a lacing system <NUM> or other functions. The apertures <NUM> may comprise lace holes or eyelets configured to receive shoe laces or straps.

The footwear article <NUM> may further comprise one or more venting regions <NUM> which provide ventilation. The venting regions <NUM> may be generally triangular or planar or may have other shapes. As shown, the first layer <NUM> and the second layer <NUM> may comprise a plurality of venting regions <NUM>. The venting regions <NUM> of the first layer <NUM> may correspond with and be configured to be disposed adjacent the venting regions <NUM> of the second layer <NUM> when inverted to form the footwear article <NUM>.

A footwear article <NUM> may comprise a plurality of layers or may be continuous so as to form a unitary body. The footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise soft materials such as fabric. The first layer <NUM> and the second layer <NUM> may be generally tubular or may comprise other shapes. The second layer <NUM> may comprise a rigid material such as leather or plastic. The first layer <NUM> and the second layer <NUM> may be circular-knit, flat-knit or formed by other manufacturing methods or from other materials. The second layer <NUM> may be folded or inverted to be disposed adjacent at least a portion of the first layer <NUM>. The second layer <NUM> may comprise at least a portion of the interior or the exterior of the footwear article <NUM>. The footwear article <NUM> may comprise additional layers which may provide additional functionalities.

As illustrated in <FIG>, the footwear article <NUM> may comprise a first layer <NUM> and second layer <NUM>. The first layer <NUM> and the second layer <NUM> may be continuous so as to define a unitary body. The second layer <NUM> may be configured to be inverted adjacent an exterior surface of the first layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise one or more features. As shown, the second layer <NUM> may comprise a plurality of strips 709a, 709b, 709c. The strips 709a, 709b, 709c may comprise knit material, rigid material or a combination of knit and rigid materials to define different features. As shown, the first strip 709a may comprise a reinforcement region <NUM> which may define a heel cup 710a. The second strip 709b may comprise apertures <NUM> that may define a lacing system <NUM>.

As illustrated in <FIG>, the footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> may be generally tubular. The first layer <NUM> may be circular knit. The second layer <NUM> may comprise an irregular planar shape. The second layer <NUM> may be flat-knit. The footwear article <NUM> may further comprise a lacing system <NUM>. As shown, the second layer <NUM> may comprise members <NUM> configured to extend through at least a portion of the first layer <NUM>. The members <NUM> may be configured to be removably received in apertures <NUM> within the first layer <NUM>. The members <NUM> may comprise loops and hooks to define a footwear article <NUM> with a pull through feature.

A footwear article <NUM> may comprise a plurality of layers or may be continuous so as to a form a unitary body. The footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> and the second layer <NUM> may comprise soft materials such as fabric. The first layer <NUM> and the second layer <NUM> may be generally tubular or may comprise other shapes. The second layer <NUM> may comprise a rigid material such as leather or plastic. The first layer <NUM> and the second layer <NUM> may be circular-knit, flat-knit or formed by other manufacturing methods or from other materials. The second layer <NUM> may be folded or inverted to be disposed adjacent at least a portion of the first layer <NUM>. The second layer <NUM> may comprise at least a portion of the interior or the exterior of the footwear article <NUM>. The footwear article <NUM> may comprise additional layers which may provide additional functionalities.

As illustrated in <FIG>, the footwear article <NUM> may comprise a first layer <NUM> and a second layer <NUM>. The first layer <NUM> may comprise a generally tubular shape. The first layer <NUM> may be circular-knit. The second layer <NUM> may comprise a planar irregular shape. The second layer <NUM> may be flat knit. The second layer <NUM> may be inverted adjacent an exterior surface of the first layer <NUM>. The second layer <NUM> may comprise a lacing system <NUM>. As shown, the second layer <NUM> may comprise apertures <NUM> (e.g. lace holes) which define the lacing system <NUM>. The second layer <NUM> may comprise reinforcement regions <NUM> which may define a heel cup 910a and a toe cup 910b that provide structure and integrity to the exterior of the footwear article <NUM>.

illustrates footwear articles <NUM> - <NUM> which comprise functional layers <NUM> - <NUM>. Functional layers <NUM> - <NUM> comprise footbeds and midsoles, the functional layers <NUM>-<NUM> may further comprise insulation, socks, collars and other functional features within the footwear articles <NUM> - <NUM>. The functional layers are interposed between two knit layers such as using a fold over technique or other technique. The functional layer may comprise a waterproof material or membrane or a breathable waterproof membrane. The functional layer may be a pre-formed laminate or composite. The functional layer may be a spray application. The function layer may be a 3D direct injection. The functional layer may be applied in other configurations or on other surfaces. As a non-limiting example, one problem that is being addressed by the present disclosure is that circular knit, while fast, it may be hard to sew or bond things to a circular knit upper because it is a finished 3D shape. Most heat presses and sewing machines in the state of the art are optimized to work with roll goods in the flat. As an illustrative example, 3D direct injection is one method of applying additive structures, cushioning, lace details, etc. that is optimized to work in 3D shaping. This process may be implemented on a lasted upper, as fully finished and 3D shape.

Claim 1:
A footwear article (<NUM>-<NUM>), comprising:
a first circular-knit layer;
a second circular-knit layer coupled to the first circular-knit layer, the second circular-knit layer configured to be disposed adjacent at least a portion of the first circular-knit layer when folded into or around the first circular-knit layer; and
a functional layer (<NUM>-<NUM>) interposed between the first circular-knit layer and the second circular-knit layer using a fold-over technique, such that, when the second circular-knit layer is folded into or around the first circular-knit layer, the functional layer is trapped between the first circular-knit layer and the second circular-knit layer and comprises a trapped midsole and a knit footbed within the footwear article, wherein the trapped midsole comprises outsole lugs that extend through the first and the second layers, and wherein the first layer or the second layer comprises apertures to allow the outsole lugs of trapped midsole to extend therethrough.