Patent Description:
A variety of articles are formed from textiles. As examples, 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) are often at least partially formed from textiles. These textiles are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines.

In some applications, the textile may be embroidered with at least one embroidery element, such as a strand, thread, yarn, or the like (herein referred to as a "strand" when referring to an embroidered element). The embroidery process may be accomplished on a mechanical device called an embroidery machine. Typically, an embroidery machine includes a needle for mechanically manipulating the strand through the base layer of the textile. Usually, the embroidery process occurs after the base layer of the textile is formed, and the embroidery machine is typically separate from the machine used to form the base textile layer (e.g., a knitting machine or a weaving loom). Thus, the embroidery, when incorporated into a knitted component, includes strands that are separate from those used in the knitting process.

<CIT> discloses a textile component according to the preamble of claim <NUM>. <CIT> and <CIT> disclose generic knitted structures.

The present disclosure can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the present disclosure. Moreover, in the figures, like-referenced numerals designate corresponding parts throughout the different views.

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

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

Background knowledge useful for understanding the invention relates to a textile component, including: a knitted component having a first knit layer, a second knit layer, and a pocket, where the pocket is located between the first knit layer and the second knit layer; a spacing element located within the pocket; and an embroidered element on an exterior surface of the first knit layer that extends through the first knit layer but does not extend through the second knit layer.

A textile component is provided according to the subject matter of claim <NUM>. The textile component includes among other features: a knitted component having a first area with a first knit layer and a second knit layer, and a single-layer boundary area including a fused structure, where the boundary area at least partially surrounds the first area; and an embroidered element that extends through the first knit layer in the first area.

Background knowledge useful for understanding the invention relates to a method, including: knitting a knitted component having a first knit layer and a second knit layer to form a pocket; embroidering an emblem through an external surface of the first knit layer; and including a spacing element within the pocket.

Referring to <FIG>, a textile component <NUM> suitable for a number of applications, e.g., footwear, apparel, and industrial textiles, is shown. The textile component <NUM> includes a knitted component <NUM>, a spacing element <NUM> (which in some embodiments may be a portion of the knitted component <NUM> as described below), and an embroidered element <NUM>.

The knitted component <NUM> may be formed as an integral one-piece element from a single knitting process, such as a weft knitting process (e.g., with a flat knitting machine with one, two, or more needle beds, or with a circular knitting machine), a warp knitting process, or any other suitable knitting process. As used in this application, a yarn may include a strand, and is not intended to limit the present disclosure to multifilament materials. The process that forms the knitted component <NUM> 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 may be attached.

The knitted component <NUM> may incorporate various types of yarn that impart different properties to separate areas of the knitted component <NUM>. That is, one area of the knitted component <NUM> may be formed from a first type of yarn that imparts a first set of properties, and another area of the knitted component <NUM> may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout the knitted component <NUM> by selecting specific yarns for different areas of the knitted component <NUM>. The properties that a particular type of yarn will impart to an area of the knitted component <NUM> partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the yarns selected for the knitted component <NUM> may affect the properties of the knitted component <NUM>. For example, a yarn forming the knitted component <NUM> may be a monofilament yarn or a multifilament yarn. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different linear densities, may also affect the properties of the knitted component <NUM>. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of the knitted component <NUM>.

The knitted component <NUM> includes at least a first knit layer <NUM> and a second knit layer <NUM>. The first knit layer <NUM> and the second knit layer <NUM> may be formed on one or more needle beds of a knitting machine, e.g., a first needle bed and/or a second needle bed. At least a portion of the first knit layer <NUM> may be freely separable from the second knit layer <NUM> such that a space or pocket <NUM> is formed therebetween. In other words, the first knit layer <NUM> and the second knit layer <NUM> may each have two opposite facing surfaces, and the first knit layer <NUM> may be freely separable and/or movable relative to the second knit layer <NUM>.

Further, an external surface of the first knit layer <NUM> generally faces a first direction, and an external surface of the second knit layer <NUM> generally faces the opposite direction, and internal surfaces of the first knit layer <NUM> and the second knit layer <NUM> generally face each other. Although the first knit layer <NUM> may be freely separable from the second knit layer <NUM> in certain areas, it does not need to be freely separable everywhere. For example, the knitted component <NUM> may include one or more interlayer knit stitches (e.g., stitches formed during the same knitting process and extending between a first needle bed and a second needle bed). Such interlayer knit stitches may be formed by the same yarn(s) that forms the first and/or second knit layers <NUM> and <NUM>, or a different yarn. The portions of the first knit layer <NUM> and the second knit layers <NUM> that are freely separable from each other may form an unsecured area <NUM> where a space or pocket <NUM> is located between the first knit layer <NUM> and the second knit layer <NUM>. Portions of the knitted component <NUM> that do not include separable layers (e.g., where only one layer is included, and/or where multiple layers are included but secured together without a pocket therebetween) may form a secured area <NUM> (which may herein be referred to as a "base portion" of the knitted component <NUM>). In various non-limiting applications, the first knit layer <NUM> or the second knit layer <NUM> may correspond with at least part of an outer or inner layer of an article of apparel or industrial textile, an exterior or interior layer of an upper for an article of footwear, or a layer of another application.

The first knit layer <NUM> and/or the second knit layer <NUM> may include one or more materials selected to impart advantageous properties to the knitted component <NUM>. For example, the first knit layer <NUM> may eventually correspond with an exterior layer of an article of footwear, such as when the article has been assembled and is configured to accommodate the foot of a wearer, and therefore may include courses of a relatively inelastic first yarn providing abrasion resistance, water resistance and/or durability. Suitable materials for the first knit layer <NUM> may include polyester yarns, e.g., polyester yarns having a maximum tensile strength of at least approximately <NUM>-f (e.g., ranging from approximately <NUM>-f to approximately <NUM>-f) and a linear density of at least approximately <NUM>,<NUM> tex (<NUM> denier) (e.g., ranging from approximately <NUM>,<NUM> tex (<NUM> denier) to approximately <NUM>,<NUM> tex (<NUM>,<NUM> denier)). The first knit layer <NUM> may also be weatherized, e.g., it may be formed from yarns having water repellant and or resistant properties or it may have a durable water repellent finish.

The second knit layer <NUM> may eventually correspond with an interior layer of an article of footwear, such as when the article has been assembled and is configured to accommodate the foot of a wearer, and therefore, the second knit layer <NUM> may include one or more courses of yarn having comfort-related characteristics (e.g., softness), for example a yarn having a napped finish or otherwise provide breathability and comfort to the wearer. Additionally or alternatively, the second knit layer <NUM> may include one or more elasticized yarns to give resiliency to the knitted component <NUM>. The examples are non-limiting and are intended to illustrate the versatility of the first and second knit layers <NUM> and <NUM> which may be formed from the same yarn(s) or different yarns or a combination thereof to provide advantageous properties to the respective layers, and/or different portions, areas or regions of the respective layers, as necessary or desired.

The space <NUM> between the first knit layer <NUM> and the second knit layer <NUM> may receive a spacing element <NUM>, e.g., to enhance strength, provide cushioning protection, generate desired structures for different areas of the knitted component <NUM>, or for other advantages. The spacing element <NUM> may include cushioning components, and by incorporating the cushioning components within the space <NUM>, the unsecured area <NUM> of the knitted component <NUM> is turned into a cushioning area <NUM> and the secured area <NUM> surrounding the cushioning area <NUM> is turned into a fused and/or depressed boundary area <NUM> (as described in more detail below). In some embodiments, the spacing element <NUM> may include conventional cushioning components that are inserted into the space <NUM> within the previously formed knitted component <NUM>. Particular, non-limiting examples of cushioning components may include insert elements composed of foam materials, fluid-filled bladders, or other cushioning elements used singularly or in combination with other elements. By varying the materials and configurations of the cushioning components inserted into the space <NUM>, the dimension, shape, and degree of cushioning of the cushioning area <NUM> may be varied accordingly.

In other embodiments, the spacing element <NUM> may include one or more cushioning yarns (e.g., yarns formed of compactible or other materials that provide cushioning and/or protection) that are inlaid within one or more courses of the knitted component <NUM>. Thus, the spacing element <NUM> may be incorporated into the knitted component <NUM> while the first knit layer <NUM> and the second knit layer <NUM> are formed (e.g., without the need for inserting a separate cushioning component into the knitted component <NUM> after knitting processes). The inlaid cushioning yarn(s) located between the first and second knit layers <NUM> and <NUM> in the cushioning area <NUM> may also pass through courses of the knitted component <NUM> in the secured area <NUM>. In the unsecured area <NUM>, the cushioning yarn(s) may be substantially free to expand to, or remain in, a lofted or expanded state such that a maximum diameter may be reached. For example, as shown in <FIG>, in the tubular structure of the unsecured area <NUM>, inlaid segments of the cushioning yarn(s) have the freedom to extend radially outward to reach their respective maximum diameters. This may push the first and second knit layers <NUM> and <NUM> radially outward to form a "pillow-like" cushion, and the interior space or pocket <NUM> between the first and second knit layers <NUM> and <NUM> may be filled with the material of the cushioning yarn(s). In contrast, the portions of the cushioning yarn(s) that are located in the secured area <NUM> may remain in a relatively restricted or compressed state such that the maximum diameter of the cushioning yarn(s) is not reached, and thus the cushioning yarn(s) may not be noticeable. The degree of restriction/compression may be varied by varying the stitch density of the knitted component <NUM>, by varying the elasticity of the yarns forming the knitted component <NUM>, etc. In some embodiments, the portions of the cushioning yarn(s) located within the unsecured area <NUM> are free to expand into a first diameter within the interior volume or space <NUM> formed between the first and second knit layers <NUM> and <NUM>, while the portions of the cushioning yarn(s) located within the secured area <NUM> are restricted by the knitted component <NUM> to a smaller second diameter. In this manner, the unsecured area <NUM> may protrude from the secured area <NUM> that are adjacent to or at least partially surrounding the unsecured area <NUM> in a visible manner. Similar (or identical) cushioning yarn(s) that form cushioning areas are depicted and described in <CIT>.

The embroidered element <NUM> is stitched on the first knit layer <NUM> of the knitted component <NUM> such that it is visible on an exterior surface of the first knit layer <NUM>, thereby forming one or more embroidery patterns <NUM> (which may be an emblem) in selected locations of the knitted component <NUM>. The embroidered element <NUM> includes a strand, thread, yarn, or the like. Materials of the embroidered element <NUM> may include cotton, man-made, polyester, cotton-wrapped polyester, linen, filament polyester, silk, and the like. The embroidery process may be accomplished on a mechanical device called an embroidery machine (or sewing machine), or it may be accomplished by hand. Typically, an embroidery machine includes a needle for mechanically manipulating the embroidered element <NUM> through a layer, such as the first knit layer <NUM>, of the knitted component <NUM>. Usually, the embroidery process occurs after the knitted component <NUM> is formed, and the embroidery machine is typically separate from the machine used to form the knitted component <NUM> (e.g., a knitting machine). The one or more embroidery patterns <NUM> may include an emblem, which may include a logo, text, another graphic or image, or the like.

The embroidery patterns <NUM> may have a plurality of appearances made from a plurality of different embroidered elements <NUM>. For example, in the depicted embodiment as shown in <FIG>, the embroidery pattern <NUM> is a football, but any other image may be formed (e.g., lettering in a company or product name, etc.). It will be appreciated that the appearance of the embroidery pattern <NUM> may be varied by varying the size of the embroidered elements <NUM> used, the type of the embroidered elements <NUM> used (including the material and color used), the number of the embroidered elements <NUM> used, the density of the embroidered elements <NUM> used (e.g., the number of strands per unit length in a direction perpendicular to the longitudinal axis of the strands), the state of the materials of the embroidered elements <NUM> used (for example, when the same embroidered strands are heat-processed differently), the visual or mechanical properties of the embroidered elements <NUM> used, or the like.

The textile component <NUM>, which includes the knitted component <NUM> and the non-knit embroidery pattern <NUM>, provides a variety of advantages. For example, forming embroidering patterns on the knitted component <NUM> after the knitted component <NUM> is formed is not limited by the manufacturing process, and thus may enhance the appearance (e.g., including various colors) of patterns relative to other methods of forming an image, and may provide the ability to use enhanced materials (e.g., for better durability). For example, embroidery patterns <NUM> may additionally or alternatively be configured to exhibit other selected properties, such as a desirable degree of stretchability, flexibility, durability, breathability, weight (as compared to a knit layer), permeability, water-resistance, water repellence, or any other property. Additionally or alternatively, by embroidering patterns on the knitted component, waste may be decreased, recyclability may be simplified, manufacturing efficiency may be increased, and manufacturing costs may be reduced.

The embroidered element <NUM> is stitched on the first knit layer <NUM> within the cushioning area <NUM> of the knitted component <NUM> such that the embroidery pattern <NUM> is spaced from the second knit layer <NUM> by the spacing element <NUM>. In some embodiments, the configuration (e.g., the shape) of the cushioning area <NUM> may be substantially the same as the configuration of the embroidery pattern <NUM> formed thereon, and/or may outline the major features of the embroidery pattern <NUM>. In some embodiments, the cushioning area <NUM> and the embroidery pattern <NUM> share respective edges. In other embodiments, the cushioning area <NUM> and the embroidery pattern <NUM> may have substantially the same shape while the cushioning area <NUM> has larger overall dimensions than the embroidery pattern <NUM> (or vice versa if it is desired for the embroidery pattern <NUM> to extend beyond the cushioning area <NUM>). The boundary area <NUM> surrounding the cushioning area <NUM> also surrounds the embroidery pattern <NUM> in the cushioning area <NUM>.

The cushioning area <NUM> protrudes from the boundary area <NUM>, which is a single-layer fused area relative to the unsecured area <NUM>. This is advantageous for imparting a three-dimensional visual effect to the embroidery pattern <NUM> and its background cushioning area <NUM>, thus enhancing the visual prominence of the embroidery pattern <NUM>. The three-dimensional visual effect of the embroidery pattern <NUM> may be varied by varying the degree of cushioning in the cushioning area <NUM>, which corresponds to the degree of elevation of the cushioning area <NUM> (and embroidery pattern <NUM>) relative to its surroundings.

When incorporated into an article of footwear, separating the embroidery pattern <NUM> from the void (and thus the wearer's foot) by the spacing element <NUM> may enhance the comfort of the article of footwear since the embroidery pattern <NUM> (which may be rigid and/or abrasive in some embodiments) will be separated from the void. In addition, when incorporated into an article of footwear, this configuration also allows the embroidery pattern <NUM> to be located in various portions of the article of footwear. Conventionally, it may be desirable to position the embroidery pattern <NUM> away from high stress points of the article of footwear to avoid stressing the embroidered elements <NUM> due to the repeated bending of the wearer's foot. By stitching the embroidery pattern <NUM> on the first knit layer <NUM> within the cushioning area <NUM>, the compressibility provided by the spacing element <NUM> located between the embroidery pattern <NUM> and the second knit layer <NUM> improves the strength of the embroidery pattern <NUM> (and/or reduce its degree of wear over time), and imparts a desirable degree of stretch-resistance and/or cushioning protection to the embroidery pattern <NUM>, thereby allowing the embroidery pattern <NUM> to be incorporated into high stress regions of the article of footwear. For example, as shown in <FIG>, the embroidery pattern <NUM> may be located in a heel region of the footwear. It will be appreciated that <FIG> is representative, and the embroidery pattern <NUM> may be located in other locations throughout the article of footwear. Similarly, when a similar embroidery pattern <NUM> and cushioning area <NUM> are used in an article of apparel or other article, the above-descried configuration may increase the comfort and enhance the mechanical properties of the article of apparel or other article.

At least a portion of the knitted component <NUM> is formed from a thermoplastic polymer material with a relatively high melting point, such as a polyester. In some aspects, the melting point or decomposition temperature of at least a portion of a yarn (or other element) used to form the knitted component <NUM> is greater than about <NUM>, based on one atmosphere pressure, such as greater than about <NUM>, and such as greater than <NUM> or higher in certain embodiments.

The knitted component <NUM> includes one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). The knitted component <NUM> includes yarns formed of one or more thermoplastic polymer materials (including material composites) that transition from a solid state to a softened or liquid state when subjected to certain temperatures at or above the melting point and then transitions back to a solid state when cooled. The thermoplastic polymer material(s) provide the ability to heat and then cool a portion of the knitted material to thereby form an area of bonded or continuous material (herein referred to as a "fused area") that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example. Non-limiting examples of thermoplastic polymer materials are polyurethanes, polyamides, polyolefins, and/or certain nylons. For example, a melting point of a thermoplastic polymer material included in the knitted component <NUM> may be less than about <NUM>, such as less than about <NUM> (e.g., <NUM>, which may be optimal (or particularly suitable) for post-knit heat processing). In some embodiments, the embroidered strands of the embroidery pattern <NUM> may include a thermoplastic polymer material that may be fused after the embroidery process, as described in <CIT>.

The boundary area <NUM> that surrounds the cushioning area <NUM> is at least partially fused such that the spacing element <NUM> located within the cushioning area <NUM> and the embroidery pattern <NUM> are secured in a desired place. The fused boundary area <NUM> is formed by heat-processing thermoplastic polymer materials (which may be included via knitted yarns) around the perimeter of the cushioning area <NUM>. For example, a heat press or plate that has the shape of the boundary area <NUM> may be used, which may be particularly advantageous because it may depress the boundary area <NUM> relative to other portions of the knitted component <NUM>. The geometry of the outline of the fused boundary area <NUM> may be the same as, similar to, or different than the geometry of the outline of the embroidery pattern <NUM>. In some embodiments, the geometry of the outline of the fused boundary area <NUM> may be substantially the same as the geometry of the outline of the embroidery pattern <NUM> while the outline of the fused boundary area <NUM> may have larger overall dimensions than the embroidery pattern <NUM>. In some embodiments, the fused boundary area <NUM> may have a smoother outline than the embroidery pattern <NUM>.

In general, comparing to unfused areas, fused areas (e.g., the boundary area <NUM>) may have greater stretch-resistance, stability, support, abrasion-resistance, durability, and stiffness, for example. Advantageously, when the textile is incorporated into an article of footwear, these benefits may be achieved without significantly inhibiting the air-permeability of the textile or increasing the weight of the footwear. In some embodiments, the fused boundary area <NUM> may increase the stiffness of the edges of the cushioning area <NUM> and the embroidery pattern <NUM>, thereby ensuring that the edges of the cushioning area <NUM> and the embroidery pattern <NUM> are uniformly drawn toward each other. The fused boundary area <NUM> may also help define the embroidery pattern <NUM>, create an attractive appearance of the embroidery pattern <NUM>, and prevent unraveling of the embroidered element <NUM> that forms the embroidery pattern <NUM>. The stretch-resistance, stiffness, stability, support, abrasion-resistance, and durability provided by the fused boundary area <NUM> to the edges of the embroidery pattern <NUM> may be imparted through an alternate procedure, such as by incorporating additional elements surrounding the embroidery pattern <NUM>. Although the additional elements may impart the required properties to the embroidery pattern <NUM>, the additional elements would also increase the expense of manufacturing the textile component <NUM> and add weight to the textile component <NUM>. In contrast, the fused boundary area <NUM> beneficially utilize the preexisting textile component <NUM> to impart the desired properties without utilizing additional elements or increasing the weight. Furthermore, the additional elements are generally formed of materials that are not air-permeable, thereby limiting the overall air-permeability of the textile component <NUM>. The fused boundary area <NUM> may retain a substantial portion of the air-permeability of the remainder of the textile component <NUM>.

While various embodiments of the present disclosure have been described, the present disclosure is not to be restricted except in light of the attached claims.

Claim 1:
A textile component (<NUM>), comprising:
a knitted component (<NUM>), the knitted component (<NUM>) comprising:
a first area with a first knit layer (<NUM>) and a second knit layer (<NUM>); and
a single-layer boundary area (<NUM>) comprising a fused structure, wherein the boundary area (<NUM>) at least partially surrounds the first area; and
an embroidered element (<NUM>) that extends through the first knit layer (<NUM>) in the first area, wherein the embroidered element (<NUM>) is stitched on the first knit layer (<NUM>) of the knitted component (<NUM>),
wherein the knitted component (<NUM>) includes yarns formed of at least one thermoplastic polymer material, wherein the fused structure is formed by heat-processed thermoplastic polymer material,
the textile component (<NUM>) being characterized in that the knitted component (<NUM>) comprises an elevated cushioning area (<NUM>) surrounded by the boundary area (<NUM>), and wherein the embroidered element (<NUM>) is located within the cushioning area (<NUM>).