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

The upper of the article of footwear generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel area of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the void within the upper. 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.

According to <CIT>, an upper may comprise areas with tubular rib structures arranged in different orientations over the forefoot region, the midfoot region, and the heel region of the article of footwear. Some regions of the upper may have a greater number of tubular rib structures than other regions, and some tubular rib structures can include tensile elements. The tubular rib structures include a first layer and a second layer. The second layer of the tubular rib structures comprises an apex. The apex is offset with respect to a centerline of the scallop element. The apex extends to a location beyond a terminus of the first layer.

<CIT> discloses a respective method for producing a shoe upper, with which a shoe upper can be produced with high productivity.

In one aspect, the present claimed invention relates to an upper for an article of footwear at least partially formed by a knitted component. The knitted component includes a seamless portion extending from a toe area, through a midfoot area, and to a heel area of the upper on at least one of a lateral and a medial side of the upper. A first course at least partially forms the knitted component, and the first course extends from the heel area to the toe area of the upper. The knitted component includes a scallop element, the scallop element including a first layer and a second layer, wherein the second layer of the scallop element comprises an apex, wherein the apex is offset with respect to a centerline of the scallop element. The apex extends to a location beyond a terminus of the first layer, and the apex of the scallop element overlaps at least one other scallop element.

The first course may include a continuous strand of yarn extending from the heel area to the toe area of the upper.

The knitted component may include a first edge and a second edge, where the first edge and the second edge are attached at a seam. The seam may be located on the lateral side of the upper if the seamless portion is located on the medial side of the upper, or the seam may be located on the medial side of the upper if the seamless portion is located on the lateral side of the upper.

The first course may at least partially form one of a first layer and a second layer of a scallop element of the knitted component. The first layer of the scallop element may form an inner surface of the upper at least partially defining a void, and the second layer of the scallop element may form an external surface of the upper. The first layer of the scallop element may include more courses than the second layer of the scallop element.

The scallop element may include a length along the first direction and a width along the second direction, where the length is greater than the width. In some embodiments, the length may be at least twice the width.

In another aspect, the present claimed invention relates to a method for forming an upper for an article of footwear. The method includes knitting a knitted component on a knitting machine with a seamless portion extending from a toe area, through a midfoot area, and to a heel area of the knitted component. Knitting the knitted component includes moving a feeder through a single pass to form at least a portion of the heel area of the knitted component, at least a portion of the midfoot area of the knitted component, and at least a portion of the toe area of the knitted component. The pass at least partially forms one of a first layer and a second layer of a scallop element of the knitted component. Manipulating the second layer during manufacturing of the knitted component forms an apex of the scallop element that is positioned in a slanted position such that the apex is offset with respect to a centerline of the scallop element. The apex extends to a location beyond a terminus of the first layer, and the apex of the the scallop element overlaps at least one other scallop element.

The single pass may form a first course, and the first course may include a continuous strand of yarn extending from the heel area to the toe area of the upper.

The method may include attaching a first edge of the knitted component and a second edge of the knitted component at a seam after knitting the knitted component.

The first layer of the scallop element may form an inner surface of the upper at least partially defining a void, and the second layer of the scallop element may form an external surface of the upper. The first layer of the scallop element may include more courses than the second layer of the scallop element. The method may include pressing the first layer of the scallop element toward the second layer of the scallop element and providing heat to the first layer of the scallop element.

The accompany drawings, which are incorporated herein and constitute part of this specification, and, together with the general description given above and the detailed description given below, serve to explain features of the present claimed invention.

Certain aspects of the present disclosure may be applied to articles at least partially formed from textiles. One example of an article is an article of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear, or the like). The article in accordance with the claimed invention is an upper configured for use in an article of footwear. The upper may be used in connection with any type of footwear. Illustrative, non-limiting examples of articles of footwear include a basketball shoe, a biking shoe, a cross-training shoe, a global football (soccer) shoe, an American football shoe, a bowling shoe, a golf shoe, a hiking shoe, a ski or snowboarding boot, a tennis shoe, a running shoe, and a walking shoe. The upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal.

Referring to <FIG>, an article of footwear <NUM> may include an upper <NUM> secured to a sole structure <NUM>. The upper <NUM> may include a lateral side <NUM> and a medial side <NUM>. The area of the shoe where the sole structure <NUM> joins the upper <NUM> may be referred to as the biteline <NUM>. The upper <NUM> may be joined to the sole structure <NUM> in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, etc. It is contemplated that the upper <NUM> may extend partially or completely around the foot of a wearer and/or may be integral with the sole, and a sockliner may or may not be used. In some embodiments, the sole structure <NUM> may include a midsole (not shown) and an outsole.

The article of footwear <NUM> may additionally comprise a throat area <NUM> and an ankle opening <NUM>, which may be surrounded by a collar <NUM> and may lead to a void <NUM>. The void <NUM> of the article of footwear <NUM> may be configured to accommodate a foot of a person. The throat area <NUM> may be generally disposed in a midfoot area <NUM> of the upper <NUM>. The midfoot area <NUM> is generally an area of the upper <NUM> located between a heel area <NUM> and a toe area <NUM>. In some embodiments, a tongue may be disposed in the throat area <NUM>, but a tongue is an optional component. The tongue may be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included, the lateral and medial sides of the throat area <NUM> may be joined together. As shown, in some embodiments, the article of footwear <NUM> may include an optional fastening element, such as a lace (which may be associated with the lace apertures <NUM>). Any suitable type of fastening element may be used.

The article of footwear <NUM> includes scallop elements <NUM>. The scallop elements <NUM> may be arranged at any suitable location of the article of footwear, such as in the heel area <NUM> (as shown), the medial side <NUM>, the lateral side <NUM>, the toe area <NUM>, and/or another location. The scallop elements <NUM> may be formed by two layers with a pocket therebetween (as described in more detail below) and may extend outward with respect to an outer surface <NUM> of the upper <NUM>. The scallop elements <NUM> may be advantageous for providing the article of footwear <NUM> with suitable cushioning, rigidity (e.g., without sacrificing flexibility in certain directions), durability, desirable aesthetic properties, or other properties. Any suitable number of scallop elements <NUM> may be included. In some embodiments, up to about <NUM> scallop elements may be included, such as about <NUM> to about <NUM> scallop elements, and more particularly about <NUM> to about <NUM> scallop elements in certain embodiments.

Referring to <FIG>, at least a portion of the upper <NUM>, and in some embodiments substantially the entirety of the upper <NUM>, may be formed of a knitted component <NUM>. <FIG> shows the upper <NUM> formed by the knitted component <NUM> as it may appear after a knitting process (such as a weft-knitting process on a flat knitting machine, for example). The knitted component <NUM> may additionally form another element of the article of footwear, such as an underfoot portion, for example. The knitted component <NUM> may have a first side forming an inner surface of the upper <NUM> (e.g., facing the void of the article of footwear) and a second side forming an outer surface of the upper <NUM> (e.g. facing generally opposite the first side). The first side and the second side of the knitted component <NUM> may exhibit different characteristics (e.g., the first side may provide abrasion resistance and comfort while the second side may be relatively rigid and provide water resistance, among other advantageous characteristics mentioned herein). The knitted component <NUM> may be formed as an integral one-piece element during a knitting process, such as a weft knitting process (e.g., with a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine may substantially form the knit structure of the knitted component <NUM> without the need for significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component <NUM> may be formed separately as distinct integral one-piece elements and then the respective elements attached.

Forming the upper <NUM> with the knitted component <NUM> may provide the upper <NUM> with advantageous characteristics including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. These characteristics may be accomplished by selecting a particular single layer or multi-layer knit structure (e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), and/or a combination thereof. The knitted component <NUM> may also provide desirable aesthetic characteristics by incorporating yarns having different colors, textures or other visual properties arranged in a particular pattern. The yarns themselves and/or the knit structure formed by one or more of the yarns of the knitted component <NUM> may be varied at different locations such that the knitted component <NUM> has two or more portions with different properties (e.g., a portion forming the throat area <NUM> of the upper <NUM> may be relatively elastic while another portion may be relatively inelastic). In some embodiments, the knitted component <NUM> may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). For example, the knitted component <NUM> may include yarns formed of a thermoplastic polymer material (e.g., polyurethanes, polyamides, polyolefins, and nylons) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to the solid state when cooled. The thermoplastic polymer material may provide the ability to heat and then cool a portion of the knitted component <NUM> to thereby form an area of bonded or continuous material that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example.

Referring to <FIG>, the knitted component <NUM> may include a seamless portion <NUM> extending from the toe area <NUM>, through a midfoot area <NUM>, and to a heel area <NUM> on at least one of a lateral side and a medial side of the upper (such as the lateral side <NUM> as depicted). In some embodiments, the knitted component <NUM> may include a first edge <NUM> and a second edge <NUM>, which may be terminal ends of the knitted component <NUM> after the knitting process when the knitted component <NUM> is removed from the knitting machine. As illustrated in <FIG>, after the knitting process, the knitted component <NUM> may be folded or otherwise manipulated such that a first edge <NUM> and the second edge <NUM> are secured together at a seam <NUM> (shown in <FIG>) during formation of the upper <NUM>. The seam <NUM> (see <FIG>) may be located on the lateral side <NUM> of the upper <NUM>, on the medial side <NUM> of the upper <NUM>, and/or in another location (e.g., at the back of the heel area <NUM> of the upper). Forming the upper <NUM> such that it is in an appropriate shape for inclusion in an article of footwear may further include lasting the upper <NUM>. An example of a lasting process is described in <CIT>, and issued as <CIT>.

Referring to <FIG>, when forming the knitted component <NUM>, the knitted component <NUM> is oriented with respect to a needle bed <NUM> of a knitting machine <NUM> such that a feeder <NUM> of the knitting machine <NUM> is capable of moving in a single pass (i.e., without changing its feed direction direction) to knit a first course <NUM> from the toe area <NUM> of the knitted component <NUM>, through the midfoot area <NUM> of the knitted component <NUM>, and to the heel area <NUM> of the knitted component <NUM> (and/or vice versa). Thus, as shown in <FIG>, when the knitted component <NUM> is formed and removed from the knitting machine, the first course <NUM> (which may include one or more yarns dispensed from the feeder <NUM> during the single pass) may extend at least from the toe area <NUM> to the midfoot area <NUM> and/or at least from the midfoot area <NUM> to the heel area <NUM>, and potentially from the heel area <NUM> all the way to the toe area <NUM>.

In some embodiments, the first course <NUM> may include a continuous strand of yarn <NUM> that extends from the heel area <NUM> to the toe area <NUM> of the upper <NUM>. Additionally or alternatively, one or more strands of yarn forming at least a portion of the first course <NUM> may extend less than the full length of the first course <NUM>. For example, it is contemplated that a strand of yarn may extend from the heel area <NUM> to the midfoot area <NUM> but may terminate within the first course <NUM> prior to reaching the toe area <NUM>. Similarly, it is contemplated that a strand of yarn may extend within the first course <NUM> from the midfoot area <NUM> to the toe area <NUM>, but may terminate prior to reaching the heel area <NUM>. As shown in <FIG> (and <FIG>), the first course <NUM> may at least partially form the scallop elements <NUM> of the knitted component <NUM> and/or portions of the knitted component <NUM> without scallop elements.

<FIG> shows a close-up view of four scallop elements <NUM> of the knitted component <NUM>, and <FIG> shows the knitted component <NUM> with the scallop elements <NUM> of <FIG> depicted with hidden elements shown in broken lines. <FIG> shows a side sectional view of a scallop element <NUM> about line C-C of <FIG>. As shown best by <FIG>, each scallop element <NUM> has a first layer <NUM>, a second layer <NUM>, and a pocket <NUM> between the first layer <NUM> and the second layer <NUM>. The pocket <NUM> may be filled with another element (e.g., a filler material, such as foam, down, or another suitable material or object), but this is not required, and in exemplary embodiments, the pocket <NUM> may be empty and/or filled with just air. The first layer <NUM> and the second layer <NUM> may both be formed by knit structures of the knitted component <NUM> such that the scallop element <NUM> is primarily formed on a knitting machine with the rest of the knitted component <NUM>. In some embodiments, the above-described first course <NUM> (described above and shown in <FIG>) may form at least one of the first layer <NUM> and the second layer <NUM> of the scallop element <NUM>. The second layer <NUM> shown in <FIG> may have more courses, and thus more knitted material, than the first layer <NUM> at a particular cross section (e.g., the cross-section depicted in <FIG>). As a result, when the first layer <NUM> is taught (as shown), the second layer <NUM> may have some slack such that it sags or otherwise extends away from the first layer <NUM>.

The second layer <NUM> is configured such that an apex <NUM> (defined as an extreme or terminal peak) is configured to slant in a particular direction. For example, if the yarns forming the second layer <NUM> are relatively compliant, the second layer <NUM> may droop due to gravitational pull or otherwise slant such that the apex <NUM> is offset with respect to the centerline of the scallop element <NUM> depicted in <FIG>. In some embodiments (and referring to the y-axis of <FIG>), the apex <NUM> may extend to a location on the y-axis that is beyond the y-axis terminus of the first layer <NUM>. Further, it is contemplated that the second layer <NUM> may be manipulated during manufacturing of the knitted component <NUM> (e.g., during post-knitting process, such as a vacuum and/or heating process as described below) such that the apex <NUM> is positioned in, and remains in (or at least has a tendency to remain in), the slanted position.

As best shown in <FIG>, an apex <NUM> of one or more scallop elements <NUM> may overlap at least one other scallop element <NUM> such that a portion of the second layer <NUM> of the overlapped scallop element <NUM> is not visible (at least from a front perspective depicted in <FIG>). The scallop elements <NUM> may move during article use, which may cause the coverage of one scallop element <NUM> over another to change, thereby providing a dynamic visual effect. Also, advantageously, by providing dynamic/movable overlapping coverage, flexing and/or stretching of the knitted component <NUM> may occur without substantially changing the orientation or damaging the second layer <NUM> of the scallop elements <NUM>. It is contemplated, for example, that the taught first layer <NUM> may be configured (e.g., formed with a particular material) such that it provides suitable stretchability, strength, durability, and/or other characteristics, particularly in the direction of the depicted y-axis, without substantial help from the second layer <NUM>. The second layer <NUM> may also be rigid to form armor for protection of a foot within the article of footwear, for example. Further, in some embodiments it is contemplated that the first layer <NUM> may be capable of stretching in response to an input force to an extent that the second layer <NUM> becomes taught. In such embodiments, the second layer <NUM> may be formed of a relatively rigid material such that it provides lockdown (e.g., prevents further stretching) once the second layer <NUM> becomes taught, which may be advantageous when it is desirable for the knitted component to stretch/displace to a certain extend and then abruptly stop when it reaches a certain point. Thus, it is contemplated that the first layer <NUM> may have an elasticity that is greater than an elasticity of the second layer <NUM>, but this is not required in all embodiments.

When the knitted component <NUM> is included in an upper, the second layer <NUM> of the scallop elements <NUM> may form an external surface of an upper (depicted in <FIG>), and the first layer <NUM> of the scallop element <NUM> may form an inner surface of the upper. Advantageously, the scallop elements <NUM> may provide beneficial characteristics to the upper without sacrificing comfort-related surface characteristics within the upper's void. In other embodiments, the scallop elements <NUM> may be located inside the void, which may be advantageous when the scallop elements <NUM> are configured for comfort within the void (for example, when the scallop elements <NUM> are constructed to provide cushioning and/or include an additional cushioning element within their respective pockets).

As shown in <FIG>, the first course <NUM> (described in detail above with reference to <FIG>) may at least partially form a layer (i.e., the first layer <NUM> and/or the second layer <NUM>) of one or more of the scallop elements <NUM>. The first course <NUM> may extend along a direction that herein defines "a first direction" (which is illustrated as along the x-axis in <FIG>). The first direction may be approximately horizontal when the knitted component <NUM> is incorporated into an upper, for example, and/or when the knitted component <NUM> is being formed on a knitting machine (such that the "first direction" is parallel to the needle bed). The apex <NUM> of at least one scallop element <NUM> may slant in a second direction, which may be perpendicular to the first direction (e.g., such as towards the ground in the vertical direction along the y-axis). In other embodiments, certain scallop elements <NUM> may have one or more apices <NUM> that slant in respective different directions.

A scallop element <NUM> may include a length <NUM> along the first direction and a width <NUM> along the second direction. The length <NUM> may be larger than the width <NUM>, for example. The larger length <NUM> may provide the scallop element <NUM> with suitable dimensions such that the apex <NUM> is configured to slant in the second direction (perpendicular the length). For example, providing the scallop element <NUM> with a high length-to-width ratio may simplify the knitting process of the scallop element <NUM> when it is desired for the scallop element <NUM> to have an apex <NUM> slanting in the second direction. It is contemplated that, with a high length-to-width ratio, the scallop element <NUM> can be given appropriate characteristics for forming a suitable apex by knitting with an ottoman knit structure, where the second layer <NUM> includes more courses/passes than the first layer <NUM>. In some embodiments, the length <NUM> of the scallop element <NUM> may be at least <NUM>% larger than the width <NUM>, at least <NUM>% larger than the width <NUM>, at least twice the width <NUM>, at least five times the width <NUM>, or greater than five times the width <NUM>. In one non-limiting exemplary embodiment, the length <NUM> of the scallop element <NUM> may be about twice the width <NUM>. The length of scallop elements <NUM> on a single article can vary, or each scallop element <NUM> on a single article can have the same length. In some embodiments, the length <NUM> of a scallop element <NUM> may be about <NUM> to about <NUM>, such as about <NUM> to about <NUM>.

A variety of processes are contemplated for manipulating the scallop elements <NUM>, and these processes may occur during or after the knitting process for forming the knitted component <NUM>. For example, referring to <FIG>, the upper <NUM> with the knit scallop elements <NUM> may be placed in a vacuum press <NUM> after the knitting process. Before or during placement in the vacuum press <NUM>, the apices <NUM> of the scallop elements <NUM> may be situated in a desired orientation, such as offset with respect to the center of the scallop element <NUM>, by any suitable process (e.g., by hand, by blowing gas (air) or liquid, by vacuuming, or the like). Then, the vacuum press <NUM> may seal around the knitted component and provide force to press the layers of the scallop elements <NUM> towards each other. During or after the vacuuming process, heat may be applied to the scallop elements <NUM> by a steam-providing device, for example, which may activate thermoplastic polymer materials in the yarns forming the scallop elements <NUM>. Once this heat is removed and the article cools, the thermoplastic materials of the scallop elements <NUM> may at least partially fuse together when they transition to a solid state, which may cause the scallop elements <NUM> to remain fixed in (or at least have a tendency to remain fixed in) a desirable position and orientation.

While the embodiments of the scallop elements <NUM> and other features are described generally herein with reference to an upper for an article of footwear, those features could additionally or alternatively be incorporated into another type of article. For example, knitted scallop elements may be included in articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats).

In the present disclosure, the ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present embodiments are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges (including all fractional and whole values) subsumed therein.

Claim 1:
An upper (<NUM>) for an article of footwear (<NUM>), the upper (<NUM>) comprising:
a knitted component (<NUM>), the knitted component including a seamless portion (<NUM>) extending from a toe area (<NUM>), through a midfoot area (<NUM>), and to a heel area (<NUM>) of the upper (<NUM>) on at least one of a lateral and a medial side of the upper (<NUM>);
a first course (<NUM>) at least partially forming the knitted component (<NUM>), the first course (<NUM>) extending in a first direction from the heel area (<NUM>) to the toe area (<NUM>) of the upper (<NUM>),
wherein the knitted component (<NUM>) includes a scallop element (<NUM>), the scallop element (<NUM>) including a first layer (<NUM>) and a second layer (<NUM>), wherein the second layer (<NUM>) of the scallop element (<NUM>) comprises an apex (<NUM>), wherein the apex (<NUM>) is offset with respect to a centerline of the scallop element (<NUM>), wherein the apex (<NUM>) extends to a location beyond a terminus of the first layer (<NUM>), characterized in that the apex (<NUM>) of the scallop element (<NUM>) overlaps at least one other scallop element (<NUM>).