Patent ID: 12195889

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIGS.1-3, a knit component10suitable for a number of applications, e.g., footwear and apparel, 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. Knit component10may have integral knit construction in that it may be formed by a knitting process without the need for significant post-knitting processes or steps. Alternatively, two or more portions of knit component10may be formed separately as distinct integral one-piece elements, and then the respective elements may be attached. In all of the aforementioned cases, the resulting knit component may be formed via integral knit construction.

Knit component10may include at least a first layer12and a second layer14. The first layer12and second layer14may be formed on one or more needle beds of a knitting machine, e.g., a first needle bed and/or a second needle bed. When the first layer12is formed on a different needle bed than the second layer14, or when either of the first or second layers12,14are formed on more than one needle bed, the resulting knit component10has multi-bed knit construction. As used in this application, the first layer12may form a first surface16comprising a first plurality of knit loops, and the second layer14may form a second surface18comprising a second plurality of knit loops. The first layer12may overlap at least a portion of the second layer14, and the first and second layers12,14may be coterminous in one or more dimensions but need not be coterminous. In some areas, the first layer12may be freely separable from the second layer14. In other words, the first layer12and second layer14may have opposite facing internal surfaces. Although the first layer12may be freely separable from the second layer14in certain areas, it need not be freely separable. For example, knit component10may include one or more interlayer knit stitches that join the first and second layers12,14(e.g., stitches formed between a first needle bed and a second needle bed on a weft knitting machine). Such interlayer knit stitches may be formed by the same yarn(s) that forms the first and/or second layers12,14, or a different yarn (such as a tensile material, discussed below). A single course of material may form both the first layer12and second layer14, e.g., a knit structure formed on both a first and second needle bed that includes a first plurality of knit loops on a surface of the first layer12and a second plurality of loops on a surface of the second layer14. Alternatively, different courses of material may form the first and second layers12,14, e.g., a first course forming a single jersey layer on a first needle bed and a second course forming another single jersey layer on a second needle bed.

Knit component10may include additional layers, e.g., to add cushioning, protection, or for other advantage. In various applications, the first layer12or second layer14may correspond with an outer or inner layer of an article of apparel, and exterior or interior layer of an upper for an article of footwear, or other application.

First and second layers12,14may be knitted from the same or different materials, and may each be knitted from one or more materials, depending upon the application. For example, the first layer12may be knitted partially or completely from a material selected for durability, e.g., a material with relatively high abrasion resistance and tenacity. As another example, the second layer14may be knitted from a material selected for soft hand.

Still referring toFIGS.1-3, the knit component10may include one or more knit-in tensile areas20, which may be located where it is desirable to limit stretch, to improve ventilation, to permit visibility through knit component10, and/or to provide additional technical properties. For example, knit component10may be incorporated into an article of footwear, and knit-in tensile area20may be positioned in a location where it is desirable to limit the movement of a wearer's foot in a medial and/or lateral direction. As another example, knit component10may be incorporated into a shirt, a pair of pants, or other garment, and knit-in tensile area20may be positioned where it is desirable to improve ventilation. As yet another example, knit component10may be incorporated into an industrial textile, and knit-in tensile area20may be positioned where it is desirable to have relatively high strength, minimal stretch, and relatively high permeability.

The knit-in tensile area20may include portions of the first layer12and the second layer14, and also includes one or more courses of tensile material22that are integrally knitted into the first and/or second layers12,14. Suitable tensile materials include yarns formed with low-stretch/low-elasticity materials with relatively high tensile strength (e.g., at least approximately 25 kg-f) and high tenacity, e.g., cables, strands, and cords with a diameter of at least 0.5 mm (e.g., 0.8 mm or 0.5 mm-2.0 mm). Other suitable tensile materials may include strands or fibers having a low modulus of elasticity as well as a high tensile strength, such as strands of monofilament material, or fibers such as SPECTRA™ fibers, manufactured by Honeywell International Inc. (Morris Township, N.J.). Other suitable tensile materials may include various filaments, fibers, and yarns, formed from rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramids (e.g., para-aramid fibers and meta-aramid fibers), ultra-high molecular weight polyethylene, and liquid crystal polymer. As one non-limiting example, the tensile material may be a 1.0 mm diameter sheathed polyester cable having a minimum tensile strength of 30 kg-f and a maximum elongation of less than approximately 50%. The selection of the tensile material may be further influenced by knitting machine considerations. For example, the tensile material may have a sufficiently small diameter to permit periodic interlooping with the first and/or second layers12,14without damaging the knitting machine, e.g., interlooping every third, fourth, fifth, sixth, seventh, eighth, or greater needle on a needle bed. Generally, the tensile material may have the same or different visual properties as other material that form the knit component. By utilizing a tensile material with at least one different visual property (e.g., a contrasting color or texture), the knit component may provide an attractive appearance.

Each course of tensile material22may include a single yarn or strand, or may include a plurality of yarns or strands of tensile material. For example, course of tensile material22may include a single 1.0 mm diameter sheathed polyester cable, or alternatively may include a plurality of smaller diameter strands of tensile material, e.g., each having a different color for visual effect or each having a different material composition.

Referring still toFIGS.1-3, knit-in tensile area20may include one or more tensile structures24, each of which may include a plurality of intersecting portions26a-dand a plurality of arterial portions28a-dthat surround an opening30. Each tensile structure24also includes at least one course of tensile material22that extends across opening30and is interlooped with at least one of intersecting portions26a-d. Each intersecting portion26a-dexists at a nexus of arterial portions28a-d. Opening30may extend through knit component10. Course of tensile material22includes a float32that spans opening30between adjacent intersecting portions26b,26d. In other embodiments, the float of tensile material need not span the opening across its largest dimension, and in other embodiments, a plurality of courses of tensile material may span the opening.

Course of tensile material22is integrally knitted into knit component10, e.g., interlooped with at least one of intersecting portions26a-dby one or more knit stitches as a result of the knitting process. The interlooping of course of tensile material22may be contrasted with an inlaying process that does not interloop the inlaid course with knit component. Integrally knitting course of tensile material22into knit component10advantageously secures it within knit component10; otherwise, course of tensile material22could translate in the course-wise direction relative to knit component10, e.g., due to a tensile force. In knit component10however, course of tensile material22may include a first stitch34that is interlooped with intersecting portion26b, and an optional second stitch36that is interlooped with intersecting portion26d. In other embodiments, course of tensile material22may include additional stitches that interloop with each intersecting portion. For example, in other embodiments, each course of tensile material may include two, three, or a greater number of stitches that interloop with each intersecting portion. As another example, in other embodiments, each course of tensile material may interloop with every other intersecting portion through which it passes. Generally, a course of tensile material may be integrally knitted with any aspect of an intersecting portion, e.g., portions of the first and/or the second layer that form the intersecting portion. Depending on how courses of tensile material are integrally knitted into the knit component, intersecting portions may conceal one or more stitches of course of tensile material from one or more viewpoints. For example, in the embodiment ofFIGS.1-3, first stitch34of course22is knitted into first layer12; therefore first stitch34may be substantially or completely concealed from a viewpoint from which second layer14is visible. By comparison, stitch38is knitted into second layer14, and therefore may substantially concealed from another viewpoint from which first layer12is visible.

Referring still toFIGS.1-3, course of tensile material22includes float32that spans opening30. Generally, each course of tensile material may include one or more floats that span one or more openings. Advantageously, float32may contribute to stretch resistance in the direction of the course of tensile material22, and may also prevent passage of objects through opening30while preserving breathability of knit component10. Float32is straight across opening30(e.g., taut); although in other embodiments (such as inFIG.5), floats may not be straight (e.g., may have slack). Generally, a straight float may increase stretch resistance of the knit component because it limits mechanical stretch (as compared to a knit stitch or a float with slack, which may allow mechanical stretch, i.e., straightening of the course due to application of a tensile force). The distance along a float between stitches adjacent may define the float length, which may coincide with the distance along a float between adjacent intersecting portions. For example, inFIGS.1-2, float32has a float length equal to the distance along float32between the first and second stitches34,36, which approximately coincides with the distance along float32between intersecting portions26b, d.

Given its potentially higher stiffness and larger diameter relative to other materials that may form the knit component, the tensile material may be relatively difficult to knit on a knitting machine as compared to other materials. For example the course of tensile material22may be more difficult to knit than materials used to form first and second layers12,14. To alleviate these challenges and to facilitate knitting the tensile material, the float length of each course of tensile material may range from a small number of floated needles, e.g., two to three needles, up to a larger number of floated needles, e.g., five to ten needles. In embodiments such asFIGS.1-3where each course of tensile material (such as course22) includes a plurality of floats (i.e., where the same course of tensile material extends across more than one opening), each float may have the same or different float length, e.g., to tailor the stretch resistance of the knit-in tensile area at particular location along the course of tensile material.

In some embodiments, a second float (e.g., a float of non-tensile material forming part of the first or second layers, or a float of tensile material) may also be integrally knitted with one or more intersecting portions and span the opening. From some viewpoints, the float of tensile material may obscure the second float of non-tensile material. The second float may further contribute to stretch resistance of the knit component. In other embodiments (as inFIG.4), a plurality of courses of tensile material may span each opening between adjacent intersecting portions, and one or more of the plurality of courses of tensile material may be knitted into one or both of the adjacent intersecting portions. Additional courses of tensile material may contribute to greater stretch resistance.

In the embodiments ofFIGS.1-3, arterial portions28a-dconnect adjacent intersecting portions26a-d. Each arterial portion28a-dgenerally has an elongate shape, although the length of each arterial portion28a-dmay vary significantly between embodiments and within embodiments. For example, arterial portions28a-dofFIG.2have a relatively short length, as intersecting portions26a-dare relatively large. In other embodiments, the length of arterial portions may vary, even within the same embodiment. For example, a knit component may include a first knit-in tensile area including arterial portions with a relatively short first length, and a second knit-in tensile area including arterial portions with a longer second length. As the arterial portion length increases, the size of the openings in the knit-in tensile area tends to increase also, contributing to greater breathability and visibility through the knit component. Other embodiments may include arterial portions with more than one length.

Generally, arterial portions may intersect each other at a wide range of angles. For example, inFIGS.1-2, arterial portions28f, gmay form an interior angle of approximately one hundred degrees, while arterial portions28e, fform an interior angle of approximately forty degrees. In other embodiments, intersecting portions may form an angle ranging from approximately 30 degrees to up to approximately one hundred fifty degrees, e.g., 40, 50, 60, 70, 110, 120, or 130 degrees. Referring still toFIGS.1-3, each arterial portion28a-dmay include yarns of first and second layers12,14formed into knit loops. In other embodiments, arterial portions may not appear to include knit loops, but rather taught yarns due to tensile forces imparted by the knitting process. Although arterial portions28a-dofFIGS.1-3are free of tensile material, in other embodiments, arterial portions may include one or more integrally-knitted courses of tensile material.

Referring still toFIGS.1-3, each intersecting portion26a-dmay include yarns of the first and second layers12,14, and may have multi-bed knit construction. In each intersecting portion26a-d, the first layer12may be predominantly visible from a first viewpoint41, and the second layer14may be predominantly visible from a second viewpoint42. Intersecting portions26b, dsubstantially conceal stitches34,36of tensile material from second viewpoint42(from which the second layer14is visible) because stitches34,36are knitted into first layer12. However, intersecting portion26csubstantially conceals stitch38from first viewpoint41(from which the first layer12is visible).

The appearance, dimensions, and structures of each intersecting portion may vary. In the embodiment ofFIGS.1-3, each intersecting portion (e.g.,26a-d) may have an elongate, web-like structure with a width, w, that exceeds a height, h, and a thickness, t, that approximates or exceeds the diameter of arterial portions28a-d. Generally, height, h may increase with the number of courses of first and second layers contained within each intersecting portion. For example intersecting portions may include four to ten total courses of the first and second layers, e.g., eight courses. In the embodiment ofFIGS.1-3, intersecting portions26b, deach includes eight courses: four double-bed courses of each of the first and second layers12,14, although courses of the first layer12are predominantly visible inFIGS.1-2. Generally, the width, w, may increase with the number of wales of the first and second layers contained within intersecting portion. For example, an intersecting portion may include two to ten wales of the first and or second layers, e.g., four wales. InFIGS.1-2, intersecting portions26b, deach include four wales. Generally, thickness, t, of intersecting portion may approximate or exceed the diameter of arterial portions as a result from the interlooping of at least one course of tensile material with the first and/or second layers within each intersecting portion, as shown inFIG.3. Loft inherent to the materials and structures forming the intersecting portions may also contribute to increased thickness relative to arterial portions.

Generally, the intersecting portions and arterial portions surround circular, oblong, or elliptical openings. Referring toFIGS.1-3, opening30has an approximately square or pentagonal shape that is bounded by intersecting portions26a-dand arterial portions28a-d. Second opening44ofFIGS.1-2has a roughly triangular shape, but in other embodiments, the openings may have a roughly circular, elliptical, oblong, square, rectangular, hexagonal, or other shape depending upon the dimensions of the intersecting portions and arterial portions. In other embodiments, an opening may have a first size (i.e., area) and may be bounded by three intersecting portions and three arterial portions. In still other embodiments, an opening may be bounded by a greater number of intersecting portions and arterial portions, e.g., five, six, or greater number. In other embodiments, a plurality of openings within a knit-in tensile area may have the same or different shapes and sizes.

Referring now toFIG.4, another knit component46is shown that includes a knit in tensile area48, which is formed from a plurality of first tensile structures. Exemplary first tensile structure50includes intersecting portions52a-dand arterial portions54a-d, which surround a square-shaped opening56. A course of tensile material58spans opening56and interloops with intersecting portions52b, d. Each intersecting portion52a-dmay have a knot-like structure with a height that is similar to its width, either or both of which may exceed the diameter of arterial portions50a-d. That is, intersecting portions52a-dmay appear as a knot-like mass of yarns compared to relatively slender arterial portions54a-d. Course of tensile material58includes a float60that spans opening56between intersecting portions52b, d. Knit in tensile area48also includes a plurality of second tensile structures61, which are similar to the first tensile structures50except that at least two courses of tensile material (e.g., courses62,63) span each opening. In other tensile structures of knit component46, at least one course of non-tensile material (e.g., course64) may span the opening, e.g., for the advantage of greater stretch resistance in the course-wise direction.

InFIG.5an alternative knit-in tensile area65is illustrated that including a plurality of first tensile structures (that are similar to tensile structures50shown inFIG.4), in addition to a plurality of second tensile structures66that each include a non-strait float (e.g., float67, which may have slack or a U-shaped appearance) and intersecting portions68a-chaving a greater height and width relative to other intersecting portions (e.g., intersecting portion69). However, intersecting portions68a-cand69are similar in construction and in the fact that each intersecting portion may interloop with one or more courses of tensile material.

The foregoing knit components are merely exemplary and not intended to limit the scope of the present disclosure. Rather, other knit components of the present disclosure may include knit in tensile areas having different characteristics, including intersecting portions and openings with different shapes and sizes, arterial portions with multiple and different lengths, greater numbers of courses of tensile material spanning each opening, knit in tensile areas with different orientations relative to other knit in tensile areas, etc.

Knit components constructed with knit-in tensile areas according to the above structures may advantageously benefit from high stretch resistance in the direction parallel to the orientation of courses of tensile material. This stretch resistance is heightened by knitting the one or more courses of tensile material into at least one intersecting portion, as opposed to inlaying the courses of tensile material through the intersecting portions. Moreover, the float portions of the tensile material may further increase stretch resistance of the knit component by limiting mechanical stretch in the knit-in tensile area. Additionally, the knit component may also have high stretch resistance in the directions parallel to the arterial portions, which generally may extend straight between adjacent intersecting portions (e.g., may be taut between adjacent intersecting portions). Further, the knit component may have relatively high strength and resistance to tearing, owing to the intersecting portions which may secure the relative positions of intersecting arterial portions. As yet another advantage, the knit component may advantageously provide relatively high visibility and permeability due to the one or more openings formed in the knit-in tensile area. Additional advantages will be apparent to those skilled in the art.

Referring now toFIG.6, an upper70for an article of footwear may include a knit component72having one or more knit-in tensile areas, especially where it is desirable to limit stretch, improve ventilation, or improve visibility through knit component72. Each knit-in tensile area may include one or more tensile structures as described above. Upper70resembles a U-shape, however, it shall be understood that the “horseshoe-shape” or “U-shape” shape is merely exemplary, and other uppers embodying the disclosure of this application may be knitted with edges in different locations, for example a “C-shaped” uppers or a multiple-piece uppers. Knit component72includes a first layer74and a second layer (not shown). For reference purposes, upper70may be divided generally along a longitudinal direction (heel-to-toe) into three general regions: a forefoot region78having a forefoot edge region79, a midfoot region80, and a rearfoot region82. Forefoot region78may generally include portions of upper70that may eventually cover (when incorporated into an article of footwear) the toes and the joints connecting the metatarsals with the phalanges. The midfoot region80may generally include portions corresponding with an arch area of the foot, and may include a throat region81. The rearfoot region82may generally correspond with rear portions of the foot, including areas that cover the calcaneus bone (which comprises a portion of a wearer's heel). Additionally, the rearfoot region82may cover some or all of the wearer's malleoli and talus (which comprise a portion of the ankle). The rearfoot region82may coincide with a collar region83. Upper70may also include a medial side84having a medial edge86and a medial edge region88, and a lateral side90having a lateral edge92and a lateral edge region94. Each of the medial and lateral sides84,90may extend through each of the forefoot region78, midfoot region80, and rearfoot region82, and may correspond with opposite sides. More particularly, lateral side90may correspond with an outside area of the foot (i.e., the surface that faces away from the other foot), and medial side84may correspond with an inside area of the foot (i.e., the surface that faces toward the other foot). The forefoot region78, midfoot region80, rearfoot region82, medial side84, and lateral side90are not intended to demarcate precise areas of upper70or knit component72, but rather are intended to represent general areas to aid in the following discussion.

Referring still toFIG.6, first layer74may eventually correspond with an exterior layer and the second layer may eventually correspond with an inner layer. Upper70also includes first knit-in tensile area96located in rearfoot region82, a second knit-in tensile area100located in midfoot region80, and a third knit-in tensile area102located in forefoot region78. It shall be understood that knit structures present in any region of upper70may also be suitable in any other region of any upper.

First knit-in tensile area96is located on medial side84of knit component72and extends from collar region83to medial edge region88. Courses of tensile material (e.g., course106) extend from a rear edge region to midfoot region80. Courses of first knit-in tensile area96may have a different orientation than courses of other knit-in tensile areas due to the use of gores or wedges (e.g., wedge108) in the knit component72. Generally, gores or wedges may be utilized to adjust the orientation of any knit-in tensile area.

First knit-in tensile area96may have similar knit structures (e.g., tensile structure104) constructed as described above, with each tensile structure104including at least one portion of a course of tensile material (e.g., course106) that is oriented in a longitudinal direction (which may correspond with a weft direction and a forefoot-rearfoot orientation) with a float that spans an opening (e.g., opening107, which has a first float length). Arterial portions (such as arterial portion109) extend from collar region83, diagonally downward toward medial edge region88. Other arterial portions extend diagonally upward. When incorporated into an article of footwear, first knit-in tensile area96may secure upper70around the rear of a wearer's foot by preventing longitudinal stretch. As first knit-in tensile area96may experience relatively low tensile forces as compared to other knit-in tensile areas, materials selected for these areas may differ from other knit-in tensile areas. For example, first knit-in tensile area96may include tensile material with a lower maximum tensile strength than tensile material utilized in other knit-in tensile areas. Similarly, due to relatively high abrasive forces that may be experienced in rearfoot region82, materials utilized for first layer74may differ from other materials utilized elsewhere in knit component72.

Second knit-in tensile area100, located in midfoot region80, includes a plurality of first tensile structures (e.g., structure110with a float having a second float length) and second tensile structures (e.g., structure112with a strait float having a third float length), both constructed as described above. Second knit-in tensile area100includes one or more courses of tensile material (e.g., course113) extending from medial edge region88(including medial edge86) to lateral edge region94(including lateral edge92), and may also include one or more partial courses of tensile material (e.g., course114) that extend from throat region81to lateral edge region94(including lateral edge92) or medial edge region88(including medial edge86). This medial-lateral orientation may correspond with a weft direction. Courses of tensile material may extend beyond medial and lateral edges86,92, e.g., to facilitate securing those courses to other structure, such as a sole structure, for the advantage of increased stretch resistance and strength. This medial-lateral configuration of tensile material in midfoot region80may advantageously contribute to a high degree of “lock down” or medial-lateral stability when upper70is incorporated into an article of footwear. In other embodiments, courses of tensile material in midfoot region80need not have a strictly medial-lateral orientation, but may extend diagonally (e.g., upward and forward) or may have another orientation. Given that midfoot region80will likely experience relatively high tensile forces, materials utilized in third knit-in tensile area100may differ from other materials used in knit component72. For example, tensile material utilized in third knit-in tensile area100may have greater maximum tensile strength than tensile materials utilized in other knit-in tensile areas.

Third knit-in tensile area102, located in forefoot region78, includes a plurality of first tensile structures116and a plurality of second tensile structures118. First tensile structures116may be spaced apart by one or more openings120that are free of tensile material. Spacing apart tensile structures may advantageously save weight and materials costs while increasing breathability and visibility through knit component72. Second tensile structures118may each include more than one float of tensile material spanning each opening, e.g., for increased stretch resistance. Each course of tensile material extends from medial edge region88(including medial edge86) to lateral edge region94(including lateral edge92), while third knit-in tensile area102extends from forefoot edge region79to midfoot region80.

The foregoing knit-in tensile structures are exemplary and not intended to limit the scope of the present disclosure. Rather, other knit-in tensile structures in other embodiments may utilize one or more features of any of the foregoing examples, and may have additional differences. For example, a knit component may include first and second knit-in tensile areas. Floats in the first knit-in tensile area may have a first float length and the openings may have a first shape (e.g., square, circular, elliptical, triangular, etc.) and a first size, whereas floats in the second knit-in tensile area may have a second float length that is the same or different from the first float length. Likewise, openings in the second knit-in tensile area may have openings with the same or different shapes and sizes as the first knit-in tensile area. In the same or other embodiments, along each course of tensile material, the float length of different floats may differ.

InFIG.7an article of footwear122is shown that includes an upper124at least partially formed with a knit component126. Article122has a general configuration suitable for walking or running. Concepts associated with footwear, including upper124and knit component126, may also be applied to a variety of other athletic footwear types, including but not limited to baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, soccer shoes, sprinting shoes, tennis shoes, and hiking boots. 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 herein apply, therefore, to a wide variety of footwear types. In the embodiment ofFIG.7, upper124may generally provide a comfortable and secure covering for a wearer's foot. As such, upper124may define a void128to effectively receive and secure a foot within article122. Moreover, an optional sole structure130may be secured to a lower area of upper124and may extend between a wearer's foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence the motions of the foot.

Article122may include one or more knit-in tensile areas, utilizing aspects from any of the knit component and upper examples described above. For example, knit component126of article122includes a first knit-in tensile area132positioned on a lateral side134, and may also include a second knit-in tensile area positioned on a medial side (not shown). Courses of tensile material (e.g., course135) may extend across an overfoot portion136of article122, e.g., from a lateral edge region138(including lateral edge140) to a medial edge region (including a medial edge). Additionally or alternatively, courses of tensile material (e.g., course142) may extend partially over article122, e.g., from lateral edge region138to a throat region144. One or more courses of tensile material may be secured to sole structure130, e.g., at lateral edge region138, such as with adhesives or other joining methods. Securing one or more courses of tensile material to sole structure130may advantageously improve the media-lateral stability of article122by preventing movement of a wearer's foot within void128. Courses of tensile material may also cooperate with a fastening system146. For example, a lace may traverse an opening of a tensile structure, i.e., utilize the opening as a lace loop. Alternatively, fastening system146may attach to knit-in tensile area132, e.g., for the benefit of providing a secure anchor point.

Referring now toFIG.8a knitting sequence is illustrated that may be utilized to form integrally-knit components as described above, such as through a weft knitting process (e.g., with a flat knitting machine with one, two, or more needle beds). The non-limiting sequence ofFIG.8is illustrated on a weft knitting machine having a first needle bed150and a second needle bed152. The knitting sequence illustrates the formation of a knit-in tensile area that utilizes courses of a tensile material154, along with courses of a first material156and a second material158to form a first and a second layer.

At a first step160, the knitting machine forms a course162of tensile material154by periodically knitting stitches on second needle bed152, separated by floats. Each stitch may be knitted into an intersecting portion, and each float may span an opening formed in previous knitting steps (not shown). The floats each skip a number of needles between knit stitches, e.g., two to ten needles. In other words, the floats may have a float length of at least two needles. InFIG.8, for example, the floats formed during course162each skip five needles. In other embodiments, the float length may be longer or shorter, for example, depending upon the properties of the tensile material (e.g., diameter and stiffness) that influence how easily it knits on the knitting machine, or depending upon whether the float will be straight or not (e.g., whether it is taut or slack), or depending upon the size of the openings in the knit component. In still other embodiments, a single course of tensile material may include floats having more than one float length. In first step160, the knitting machine fixes the position of course162within the knit component by interlooping with one or more previously-knitted courses, and prepares course162to interloop with intersecting portions of the knit component in subsequent steps. In first step160, all stitches of course162(of tensile material154) are formed on second needle bed152, where they will interloop with stitches of the second layer in subsequent steps. Alternatively, stitches of courses of tensile material may be formed entirely or in part on first needle bed150to prepare for subsequent interlooping with stitches of the first layer. By forming all stitches of course162on a single needle bed, the finished knit component may conceal those stitches from at least one viewpoint. For example, by knitting loops of course162on second needle bed152where those stitches will interloop with one or more courses of the second layer, those stitches of course162may be concealed from a first viewpoint where the first layer is visible.

At a second step164, the knitting machine closes course162of tensile material154knitted at first step160by knitting courses of first and second materials156,158, respectively. For example, inFIG.8, courses166,168form an interlock knit structure of first and second materials156,158. Both of courses166,168include stitches formed on both the first and second needle beds150,152. In this step, at least one of courses166,168interloops with stitches of course162of tensile material154knitted during first step160. For example, inFIG.8, course168of second material158interloops with each loop of course162of tensile material154. However, in other embodiments, the first and/or second layers need not interloop with all loops of the tensile material.

Following first and second steps162,164the knitting machine will have knitted one or more intersecting portions at each location where the interlocking courses of first and second materials156,158interloop with knit stitches of tensile material154. Additionally, the knitting machine will have knitted one or more floats of tensile material154across openings formed by previous knitting steps (not shown).

At a third step170, the knitting machine begins to form intersecting portions, openings, and arterial portions in the knit component by alternating between knitting additional courses of first and second materials156,158and by executing inter-needle transfers of stitches of those courses. InFIG.8, course172of first material156and course174of second material158form a multi-bed knit structure that initially does not form part of an opening. For example, courses172,174may form a tubular knit structure. Subsequently however, the knitting machine executes transfer steps176,178that move knit stitches of courses172,174to other needles. The locations of these transfers coincide with floats of tensile material154that will be knitted in subsequent steps. More specifically, transfer steps176,178pull stitches of courses172,174apart from each other, thereby creating openings and forming arterial portions of the knit component around the openings. Following transfer steps176,178, the knitting machine knits optional courses180-186and executes additional transfer steps188,190to further widen the openings and lengthen arterial portions. In other embodiments having smaller openings and shorter arterial portions, courses180-186and transfers188,190may not be necessary. Likewise, in other embodiments having larger openings and longer arterial portions, third step170may include additional courses and transfers. Following first through third steps160,164,170, the knitting machine will have knitted one or more intersecting portions and one or more partial openings in the knit component.

At a fourth step192, the knitting machine knits another course194of tensile material154by periodically knitting stitches on second needle bed152, separated by floats that span the partial openings formed during third step170. Where course194of tensile material154forms stitches on second needle bed152, it forms part of additional intersecting portions of the knit component.

At a fifth step196, the knitting machine completes the openings started in third step170by alternating between knitting additional courses of first and second materials156,158and executing additional inter-needle transfers. InFIG.8, courses198,202of first material156and courses200,204of second material158form a multi-bed knit structure (e.g., tubular knit), similar to third step170. Subsequently, the knitting machine executes transfer steps206,208that move knit stitches of courses198-204to other needles. Unlike third step170, when transfers pulled stitches apart (making the openings larger), transfer steps206,208of fifth step196pull stitches together (making the openings smaller). In other words, third step170forms the widening part of the openings, whereas fifth step196forms the narrowing part of the openings. More specifically, transfer steps206,208pull spaced-apart stitches of courses198-204toward each other, thereby narrowing the openings. Also, third step170may form arterial portions oriented a first direction, whereas fifth step196may form arterial portions oriented in a second direction. Following transfer steps206,208, the knitting machine knits optional courses210-216and executes additional transfer steps218,220to further narrow the opening. In other embodiments having smaller openings, courses210-216and transfers218,220may not be necessary. Likewise, in other embodiments having larger openings, fifth step196may include additional courses and transfers. Following first through fifth steps160,164,170,192, and196, the knitting machine will have knitted a knit component with intersecting portions that are interlooped with tensile material, one or more complete openings spanned by floats of the tensile material, and one or more arterial portions.

Although the foregoing knitting sequence describes five steps for the sake of comprehensive description, fewer steps may be necessary to form a tensile structure. For example, a first step may involve forming a widening part of an opening, arterial portions, and intersecting portions (as in third step170discussed above). A second step may involve knitting a course of tensile material, including at least one stitch and a float that spans the opening, and continuing to form intersecting portions on either side of the float that may be integrally knitted with the tensile material (as described in fourth step192above). A third step may involve forming a narrowing part of an opening and additional arterial portions (as in fifth step196discussed above).

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 and their equivalents. Rather, the embodiments discussed were chosen and described to provide the best illustration of the principles of the present disclosure and its practical application to thereby enable one of ordinary skill in the art to utilize the present disclosure in various forms and with various modifications as are suited to the particular use contemplated. It is intended and will be appreciated that embodiments may be variously combined or separated without departing from the present disclosure and all exemplary features described herein are applicable to all aspects of the present disclosure described herein. Moreover, the advantages described herein are not necessarily the only advantages of the present disclosure and it is not necessarily expected that every embodiment of the present disclosure will achieve all of the advantages described.