FIELD OF THE INVENTION

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is generally secured to the sole structure and may form a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is generally 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 may form 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 and in some instances under the foot. Access to the void in the interior of the upper is generally provided by an ankle opening in and/or adjacent to a heel region 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. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate other structures such as, for example, a heel counter to provide support and limit movement of the heel.

BRIEF DESCRIPTION OF THE DRAWING

The embodiments of the present disclosure may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, with emphasis instead being placed upon illustrating the principles of the present disclosure. Moreover, in the figures, like referenced numerals designate similar or identical features. FIG. 1 is a perspective view of an article of footwear having a knitted component with exposed expandable yarns in accordance with certain aspects of the present disclosure.

FIG. 1A is a magnified view of an area of FIG. 1.

FIG. 2 is a top view showing an upper for an article of footwear prior to manipulation into a wearable shape in view of certain aspects of the present disclosure.

FIG. 3 is a bottom view showing the upper of FIG. 2.

FIG. 4 is a back perspective view of a bra at least partially formed with a knitted component having exposed expandable yarns in accordance with certain aspects of the present disclosure.

FIG. 5 is magnified view of the bra from FIG. 4 showing exposed portions of the expandable yam in accordance with certain aspects of the present disclosure.

FIG. 6 is a knit diagram representing an example knitting technique that may be used to form certain embodiments discussed herein in accordance with certain aspects of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects are described below with reference to the drawings in which like elements generally are identified by like numerals. The relationship and functioning of the various elements of the aspects may better be understood by reference to the following detailed description. However, aspects are not limited to those illustrated in the drawings or explicitly described below. It also should be understood that the drawings are not necessarily to scale, and in certain instances details may have been omitted that are not necessary for an understanding of aspects disclosed herein, such as conventional fabrication and assembly.

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. FIG. 1 is an illustration showing an example of an article of footwear 100 having an upper 102 that is secured to a sole structure 104. The area where the sole structure 104 joins the upper 102 may be referred to as a biteline 106. The upper 102 may be at least partially formed by a knitted component 122, and be joined to the sole structure 104 in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, etc. The sole structure 104 may define the bottom surface of a void 105 for receiving and accommodating a user’s foot. The void 105 may be accessible through an ankle opening 108.

Referring to FIG. 2, which shows the knitted component 122 as it may appear after knitting but prior to being manipulated into a wearable shape to form the upper 102 (and also FIG. 3, showing a reverse view of FIG. 2), the upper 102 may include a lateral side 110 and a medial side 112. A throat area 114 may be included between the lateral side 110 and the medial side 112, and the throat area 114 may be positioned to cover the top (dorsal) surface of the foot during typical use. A midfoot area 116 of the upper 102 may be located between a heel area 118 and a toe area 120. The throat area 114 may be primarily located in the midfoot area 116. In some embodiments, an optional tongue may be disposed at least partially in the throat area 114.

At least a portion of the upper 102 may be formed with a knitted component 122 (or another suitable textile component). For example, the upper 102 may be formed primarily as an integral and seamless 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 components without the need for significant post-knitting processes or steps. Alternatively, the knitted component 122 may be formed separately as distinct integral one-piece elements and then the respective elements attached (e.g., via sewing).

Forming the upper with a knitted component 122 may impart 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 weight of the upper 102, and thus the overall weight of the article of footwear 100, may be reduced with respect to alternative uppers and/or other components that are typically used in footwear. The knitted component 122 may also provide desirable aesthetic characteristics by incorporating yams having different colors, textures or other visual properties arranged in a particular pattern. The yams themselves and/or the knit stmcture formed by one or more of the yarns of the knitted components may be varied at different locations to provide different knit portions with different properties (e.g., a portion forming the throat area 114 of the knitted component 122 may be relatively elastic while a portion forming the heel area 118 or another area may be relatively inelastic).

In some embodiments, the knitted component 122 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, as described in more detail below, the knitted component 122 may include yarns formed of a thermoplastic polymer material (e.g., a polyurethane, polyamide, polyolefin, and/or nylon) 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 122 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.

The upper 102 may include one or more expandable yams. For example, the expandable yams may each include one or more expandable yarns inlaid within knitted component 122. An expandable yarn may have a full diameter (e.g., when not restricted or compressed) of about 1/16” or larger, for example, though other expandable yams may have other diameters (e.g., 1/8”, 1/4", or even larger). Two non-limiting exemplary examples of expandable yams are a 5500 denier version and a 3500 denier version of multifilament polyester yarn that has been texturized to loft. Particular examples are marketed as “LILY” yams and are sold by Sawada Hong Kong Co. Ltd., though other yarns from other manufacturers may also be expandable yams.

As described in more detail below, at least a portion of one or more yarns (including the expandable yarns 140) may be inlaid between certain loops of the knitted component 122 on a knitting machine during the manufacturing of the knitted component 122. The expandable yarns 140 are illustrated in the magnified view of FIG. 1A. For example, an expandable yam 140 may be placed within the loops of a course (e.g., between loops on the front side and loops on the back side of the knitted component 122 and/or weaving in front of and in back of loops within a course), and/or be inserted within a tube during a knitting process, such as by utilizing an inlay process and/or a tubular knit construction insertion process. For example, such a process may include using an inlay feeder or other mechanical inlay device on a knitting machine (e.g., a combination feeder) to place the expandable yarn 140 between two needle beds (e.g., front and back needle beds) during a knitting process. One example of an inlay process, along with a combination feeder for enabling such a process, is described in U.S. Patent Application Publication No. 2013/0145652, published Jun 13, 2013, and having an applicant of NIKE, Inc., which is hereby incorporated by reference in its entirety. Alternatively, the expandable yarn 140 may be fed through the tubes or other channels of the knitted component 122 by hand. It is contemplated that the expandable yam 140 may be attached to the remainder of the upper 102 in a different way (e.g., other than being located in a tube or inlaid), such as by using an adhesive to secure the expandable yam 140 directly to the exterior surface 130 of the upper 102.

The knitted component 122 may have multiple expandable yarns inlaid within the knitted component 122. For example, a first expandable yam 140A, a second expandable yam 140B, a third expandable yarn 140C, a fourth expandable yam 140D, etc. are included in the knitted component 122, and are respectively inlaid in separate courses (although it is contemplated that two or more yarns may be inlaid within one course). While not shown, it is also contemplated that a yam without substantial expanding properties (e.g., a common polyester yarn) may be inlaid in a location of the knitted component 122.

In the embodiment of FIGS. 1-3 (and referring to FIG. 1A), each expandable yam 140 includes an inlaid portion 142 that is inlaid between a first surface 130 (which may be an exterior surface) and a second surface 144. Optionally, the second surface 144 may be an interior surface, though in other embodiments the ultimate interior surface of the article of footwear 100 may be formed by a liner that is coextensive with the second surface 144.

By contrast, an exposed portion 146 of each expandable yarn 140 may be exposed and/or otherwise located outside the loops 150 of the knitted component 122. For example, the exposed portion 146 of the first expandable yam 140 may be located on at least one of the first surface 130 and the second surface 144 (e.g., such that it is not sandwiched between these two surfaces). In the depicted embodiment, the exposed portion 146 is exposed on the first surface 130 such that it is accessible and/or viewable from an exterior vantage point of the article of footwear 100. In other words, the exposed portion 146 protrudes outwardly from the first surface 130.

The inlaid portion 142 of the expandable yam 140 may have a diameter that is different than a diameter of the exposed portion 146. For example, when unsecured (e.g., when exposed such that it is not constrained by knitted loops on each side), the exposed portion 146 of the first expandable yarn 140 may be free to expand to, or remain in, a lofted or expanded state such that a maximum diameter may be reached. That is, the exposed portions 146 have the freedom to extend radially outward to reach their respective maximum diameters and/or default diameters (particularly when a “LILY” yarn is used, as discussed above). By contrast, portions of the expandable yarn 140 that are inlaid, such as the inlaid portions 142, may be in a relatively restricted or compressed state due to containment provided by knitted loops on each side of the inlaid portions 142. As a result, the maximum diameter of the expandable yarn 140 cannot be reached in the inlaid portions 142. The degree of restriction/compression in the inlaid portions 142 may be varied by varying the stitch density of the knitted component 122, by varying the elasticity of the yarns forming the knitted component 122, etc. In some embodiments, the diameter of the expandable yam 140 in the exposed areas and/or other unsecured areas (e.g., the exposed portions 146) is at least 50% larger than its diameter in the secured areas (e.g., inlaid portions 142), such as twice as large, 3 times as large, 5 times as large, or even larger. In this manner, the exposed portions 146 may protrude outwardly from the respective knitted surfaces (e.g., the first surface 130) a distance substantially equal to the diameter of the exposed portions 146, thereby forming a bump-like projection on the knitted surface.

In view of the above, the inlaid portion 142 of each expandable yarn 140 may have a first diameter 152, the exposed portion 146 of each expandable yarn 140 may have a second diameter 154, and the second diameter 154 may be larger than the first diameter 152. When comparing respective diameters, the second diameter 154 may be measured at the midway point between the ends of the exposed portion 146 (in the lengthwise direction of the expandable yarn 140).

The exposed portions 146 of the expandable yam(s) may be located in any suitable position. Additionally, more than one expandable yam 140 may be included such that the exposed portions 146 are selectively located on the upper 102. For example, in the instance of an article of footwear as shown in FIGS. 1-3, the exposed portions 146 may be located in the throat area 114 of the upper 102, and specifically in an area that generally includes a tongue 115 (which is an optional feature). Advantageously, these exposed portions 146 may provide cushioning in the throat area 114, and in particular they may protect the user’s foot from the shoelace 160 and/or another fastening element (e.g., a strap, buckle, cable, air pocket, or any other suitable fastening element), thereby reducing pressure points and/or areas of discomfort otherwise experienced by a user.

While the exposed portions 146 are primarily described as protruding from the first surface 130 forming an exterior surface of the upper in the depicted embodiment, it is also contemplated that the exposed portions 146 may be located on the second surface 144, which may be the interior surface of the upper (e.g., such that they protrude into the void 105 of the article of footwear 100, assuming the ultimate interior surface of the article of footwear 100 is formed by the knitted component 122). This is shown in FIG. 3. Advantageously, such interior-facing exposed portions may form cushion-like features that increase the comfort of the upper 102 when in use. Further, it is contemplated that the exposed portions 146 of the expandable yam 140 may be located on both sides of the knitted component 122 such that they protrude from both opposite-facing surfaces of the knitted component 122. If exposed portions 146 are included on both sides, a single expandable yarn 140 may have exposed portions 146 on each of these sides, and/or different expandable yarns 140 may isolate their respective exposed portions 146 on opposite sides.

In addition to articles of footwear, a variety of other articles may incorporate aspects disclosed here. 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) may include or more of the features discussed above, where compatible. As an example, FIG. 4 shows a bra 202 that is at least partially formed with a knitted component 222. The knitted component 222 includes features similar to the knitted component 122 discussed above. In particular, the bra 202 includes a plurality of expandable yarns 240 that have inlaid portions 242 and exposed portions 246 as shown in FIG. 5. Exposed portions 246 may protrude from an exterior surface of the bra 202 such that an area of cushioning is formed. In the depicted example, the cushioning provided by the exposed portions 246 of the expandable yam 240 is located on the interior, concave surface of the bra cup. Alternative locations are also contemplated (e.g., in any other location of a bra, a different article of apparel, and/or any other textile article where such a feature may be advantageous).

FIG. 5 shows a magnified view of an area of the bra 202. As shown, the expandable yarns 240 generally extend in the course-wise direction 250 of the knitted component 222, and the exposed portions 246 of adjacent expandable yarns 240 may generally be offset from each other from the perspective of the wale-wise direction 252 (which is perpendicular to the course-wise direction). Advantageously, this arrangement may provide optimal coverage of the exposed portions 246 on a first surface 230 of the knitted component 222. Other arrangements are also contemplated.

Further, the exposed portions 246 may be different sizes. In particular, a length of a first exposed portion 246A may be greater than a length of a second exposed portion 246B. This length may be controlled by the knitted process, and particularly based on how many loops an exposed portion “skips” after a transfer step, during knitting. An example knitting process for forming the exposed portions 246 of the expandable yarns 240 is discussed in more detail below. In certain aspects, the first exposed portion 246A may be at least 50% larger than the second exposed portion 246B, for example, such as at least 75% larger, at least 100% larger, or even larger.

It is also contemplated that different exposed portions 246 may protrude different distances from the first surface 230, which may be caused by using different yarn types (e.g., certain yarns may expand more than others), by altering the length of the exposed portions (to provide more expansion space), or by any other suitable method. Advantageously, exposed portions 246 of different sizes may be used to accomplish different functions. For example, larger exposed portions 246 may be better for cushioning in areas of high pressure (e.g., in the throat area of an article of footwear), whereas smaller exposed portions 246 may provide less cushioning but may have enhanced durability (e.g., for use in areas that typically experience a high degree of abrasiveness). To enhance durability, it is further contemplated that the exposed portions 246 may be treated in a post-knitting step, such as sprayed or otherwise coated with a coating layer, at least partially fused in a heat processing step, etc. Any of the features of the bra 202 may be applied to the article of footwear 100, where compatible, and vice versa.

To form a knitted component having exposed portions of an expandable yam, the knitting method may include a unique set of transfer steps during the knitting process to move the inlaid portions 142 from a location between knitted loops to a location outside of the knitted loops (thereby exposed). FIG. 6 shows a knit diagram 170 of an example knitting technique that may be used to expose certain portions of an inlaid foamable (i.e., expandable) yam on a surface of a knitted component. As shown by FIG. 6, for example, an inlay jacquard procedure may be used to inlay an expandable yarn 140 within knitted loops of a second yam 141 (e.g., comprising a polyester and elastane in the depicted embodiment, though other suitable yarn types are also contemplated). The second yam 141 may refer to any yam that is knit on needles, rather than being inlaid. As shown, a unique transfer process may be utilized, which is key to ensuring that a length of the expandable yarn 140 will be exposed on a resulting surface. In particular, each transfer 143 (also represented by arrows in the knit diagram 170) causes certain loops of a course (e.g., loops of the second yarn 141) that would otherwise cover the expandable yarn 140 (e.g., where it is eventually exposed) to move to an opposite needle bed, thereby providing a hole or an “opening” where a plurality of needles are skipped on one needle bed such that nothing covers a portion of the expandable yam 140 to form the exposed portions (e.g., exposed portions 146 and/or exposed portions 246).

FIG. 6 is provided only as an example, and other knitting techniques are additionally or alternatively contemplated. For example, as described in U.S. Patent Application 16/951,249, filed November 18, 2020, several knitting techniques are described for exposing a particular inlaid yam on the surface of a knitted component, in a manner similar to what is described here. While this application deals with a foamable yam, the present expandable yams 140 may be knitted in a similar (or identical) manner, where compatible, to provide surface exposure. U.S. Patent Application 16/951,249 is hereby incorporated by reference in its entirety.

Having described various aspects of the subject matter above, additional disclosure is provided below that may be consistent with the claims originally filed with this disclosure. In describing this additional subject matter, reference may be made to the previously described figures. In a first aspect, the present disclosure describes an upper for an article of footwear. The upper may include a knitted component that at least partially forms a throat area of the upper and has a first surface and a second surface with at least one course of knitted loops; a first expandable yarn being at least partially inlaid within a first course of the at least one course of knitted loops, the first expandable yam having an inlaid portion that is between the first surface and the second surface; and a second yam forming the knitted loops of the at least one course, where the first expandable yam includes an exposed portion that is exposed on the first surface of the knitted component, and where the inlaid portion of the first expandable yam has a first diameter, and where the exposed portion of the first expandable yam has a second diameter that is larger than the first diameter.

[0035] In a second aspect, the upper of aspect 1 may have the first expandable yam extending through the throat area of the upper, where the exposed portion of the first expandable yarn is exposed in the throat area.

In a third aspect, the upper of any of the previous aspects may further include the first expandable yam comprising a plurality of inlaid portions and a plurality of exposed portions extending lengthwise on the first expandable yam, each inlaid portion within the plurality of inlaid portions extending between two exposed portions within the plurality of exposed portions.

In a fourth aspect, the upper of any of the previous aspects may have the first surface being an exterior surface of the upper.

In a fifth aspect, the upper of any of the previous aspects may have the exposed portion of the first expandable yam being located on the exterior surface in the throat area such that is configured to provide cushioning between a fastening element of the article of footwear and a user’s foot.

In a sixth aspect, the upper of any of the previous aspects may have the first surface being an interior surface of the upper, where the exposed portion of the first expandable yarn is located on the interior surface such that it extends into a void of the article of footwear.

In a seventh aspect, the upper of any of the previous aspects may have the second diameter being at least 50% larger than the first diameter.

In an eighth aspect, the upper of any of the previous aspects may have the second diameter being at least 100% larger than the first diameter.

In a ninth aspect, the upper of any of the previous aspects may further include a second expandable yam being at least partially inlaid within a second course of the knitted component, the second course being substantially parallel to the first course, where the second expandable yarn has an inlaid portion that is between the first surface and the second surface of the knitted component, and where the second expandable yam includes an exposed portion that is exposed on the first surface of the knitted component. In a tenth aspect, the upper of aspect 9 may have the inlaid portion of the second expandable yam having a first diameter, where the exposed portion of the second expandable yam has a second diameter, and where the second diameter is larger than the first diameter.

In an eleventh aspect, the upper of any of aspects 9-10 may have the first expandable yarn having a plurality of first exposed portions that are exposed on the first surface, where the second expandable yam has a plurality of second exposed portions that are exposed on the first surface, and where the first exposed portions are offset relative to the second exposed portions in a direction perpendicular to a coursewise direction.

In a twelfth aspect, a knitted component may include one or more of the following: a first surface and a second surface, the first surface and the second surface including a set of knitted loops within a first course; a first expandable yarn being at least partially inlaid within a first course of the knitted component; and a second yam forming the set of knitted loops of the first course, where the first expandable yarn includes an inlaid portion that is positioned between the first surface and the second surface of the knitted component, where the first expandable yam includes an exposed portion that is exposed on the first surface of the knitted component, where the inlaid portion of the first expandable yam has a first diameter, and where the exposed portion of the first expandable yam has a second diameter that is larger than the first diameter.

In a thirteenth aspect, the knitted component of aspect 12 may further include the first expandable yam having a plurality of inlaid portions and a plurality of exposed portions extending lengthwise on the first expandable yam, each inlaid portion within the plurality of inlaid portions extending between two exposed portions within the plurality of exposed portions.

In a fourteenth aspect, the knitted component of any of aspects 12-13 may further include a second expandable yam being at least partially inlaid within a second course of the knitted component, the second course being parallel to the first course, where the second expandable yarn has an inlaid portion that is between the first surface and the second surface of the knitted component, and where the second expandable yam includes an exposed portion that is exposed on the first surface of the knitted component.

In a fifteenth aspect, the knitted component of aspect 14 may include the inlaid portion of the second expandable yam having a first diameter, where the exposed portion of the second expandable yarn has a second diameter, and where the second diameter is larger than the first diameter.

In a sixteenth aspect, the knitted component of any of aspects 12-15 may include the second diameter being at least 50% larger than the first diameter.

In a seventeenth aspect, the knitted component of any of aspects 12-16 may include the first expandable yam having a second exposed portion that is exposed on the second surface of the knitted component.

In an eighteenth aspect, the knitted component of any of aspects 12-17 may at least partially form an article of apparel.

A nineteenth aspect includes a method, which may include one or more of the following steps: knitting a knitted component having a first surface and a second surface that include knitted loops in at least a first course, the knitted component comprising: a first expandable yarn being at least partially inlaid within a first course of the knitted component; and a second yam forming the knitted loops in at least the first course, where the first expandable yarn includes an inlaid portion that is positioned between a first surface and a second surface, where the first expandable yam includes an exposed portion that is exposed on the first surface, and where the inlaid portion of the first expandable yarn has a first diameter, where the exposed portion of the first expandable yarn has a second diameter, and where the second diameter is larger than the first diameter.

In a twentieth aspect, the method of aspect 19 may include inlaying a plurality of inlaid portions and a plurality of exposed portions on a knitting machine, the plurality of inlaid portions and the plurality of exposed portions extending lengthwise on the first expandable yam, each inlaid portion within the plurality of inlaid portions extending between two exposed portions within the plurality of exposed portions.

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. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims. 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.