(12) United States Patent
`Meir et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 9,060,562 B2
`Jun. 23, 2015
`
`US009060562B2
`
`(54) METHOD OF KNITTING A KNITTED
`COMPONENT WITH AN INTEGRAL KNIT
`TONGUE
`
`(71) Applicant: Nike, Inc., Beaverton, OR (US)
`
`(72) Inventors: Adrain Meir, Portland, OR (US);
`Daniel A. Podhajny, Beaverton, OR
`(US); Daren P. Tatler, Hillsboro, OR
`US
`(US)
`(73) Assignee: NIKE, Inc., Beaverton, OR (US)
`(*) Notice:
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 141 days.
`
`(21) Appl. No.: 13/781,551
`(22) Filed:
`Feb. 28, 2013
`
`(65)
`
`Prior Publication Data
`
`US 2013/0239.625A1
`
`Sep. 19, 2013
`
`Related U.S. Application Data
`(63) Continuation-in-part of application No. 13/400,511,
`filed on Feb. 20, 2012, now Pat. No. 8,448,474.
`51) Int. C
`(51) E. 730
`A43B I/04
`
`(2006.01)
`ol)
`C
`t
`(Continued)
`
`(52) U.S. Cl.
`CPC. A.43B I/04 (2013.01): D04B 1/24 (2013.01);
`A43B 23/0245 (2013.01); A43B 23/0265
`(2013.01); A43B 23/26 (2013.01): D04B I/22
`(2013.01): D04B 15/56 (2013.01); D10B
`2403/02411 (2013.01); D10B2403/032
`(2013.01); D10B 2501/043 (2013.01); A43B
`23/0205 (2013.01): D04B 7/28 (2013.01);
`D10B2403/01 13 (2013.01)
`
`(58) Field of Classification Search
`CPC ............... D04B 1/24: D04B 2401/043: D04B
`2403/032: A43B 1/04; A43B 23/0245; A43B
`23/26
`USPC ....... 66/169 R, 170, 171, 177; 2/3 R, 3 A, 84,
`2/114,47
`See application file for complete search history.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`601,192 A
`3, 1898 Woodside
`1,215, 198 A
`2f1917 Rothstei
`OS
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`CN
`CN
`
`6, 2006
`17821.56
`12/2011
`102271548
`(Continued)
`OTHER PUBLICATIONS
`
`Declaration of Dr. Edward C. Frederick from the US Patent and
`Trademark Office Inter Partes Review of US Patent No. 7,347,011
`(178 pp).
`
`(Continued)
`
`Primary Examiner — Danny Worrell
`(74) Attorney, Agent, or Firm — Plumsea Law Group, LLC
`(57)
`ABSTRACT
`Methods of manufacturing a knitted component for an article
`of footwear that include knitting an upper with an integral knit
`tongue during a knitting process on a knitting machine are
`described. The knitting process forms the integral knittongue
`of unitary knit construction with the upper so that the integral
`knit tongue extends through a throat area of the knitted com
`ponent. The integral knit tongue can include raised elements
`formed of unitary knit construction with the tongue.
`23 Claims, 28 Drawing Sheets
`
`
`
`
`
`
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`
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`1008
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`(51) Int. C.
`D04EB I/24
`
`A43B 23/26
`D04B I/22
`D04B .5/56
`D04B 7/28
`
`(2006.01)
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`(56)
`
`References Cited
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`2012fOO 11744 A1
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`2012fO233882 A1
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`2012fO233884 A1
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`2012,0240429 A1
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`2012fO255.201 A1 10, 2012 Little
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`FOREIGN PATENT DOCUMENTS
`
`RE
`DE
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`
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`8, 2013
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`OTHER PUBLICATIONS
`
`David J. Spencer, Knitting Technology: A Comprehensive Handbook
`and Practical Guide (Third ed., Woodhead Publishing Ltd. 2001)
`(413 pp).
`Excerpt of Hannelore Eberle et al., Clothing Technology (Third
`English ed., Beuth-Verlag GmnH 2002) (book cover and back; pp.
`2-3, 83).
`
`Skechers EX1001-p.2
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`US 9,060,562 B2
`Page 3
`
`(56)
`
`References Cited
`
`OTHER PUBLICATIONS
`
`Letter from Bruce Huffa dated Dec. 23, 2013 (71 pages).
`Non-Final Office Action mailed Oct. 17, 2012 in U.S. Appl. No.
`13/400,511.
`Non-Final Office Action mailed Dec. 19, 2012 in U.S. Appl. No.
`13/474,531.
`Notice of Allowance mailed Jan. 31, 2013 in U.S. Appl. No.
`13/400,511.
`
`International Search Report and Written Opinion mailed Jul. 30.
`2014 in International Application No. PCT/US2014/018845.
`Taiwanese Office Action dated Nov. 14, 2014 in Taiwanese Patent
`Application No. 102105769.
`International Search Report and Written Opinion mailed Jun. 20.
`2014 in International Application No. PCT/US2014/018852.
`
`* cited by examiner
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`US 9,060,562 B2
`
`1.
`METHOD OF KNITTING A KNITTED
`COMPONENT WITH AN INTEGRAL KNIT
`TONGUE
`
`CROSS-REFERENCE TO RELATED
`APPLICATION
`
`This application is a continuation-in-part of co-pending
`U.S. patent application Ser. No. 13/400,511, entitled “Article
`Of Footwear Incorporating A Knitted Component With A
`10
`Tongue’, filed on Feb. 20, 2012, which application is hereby
`incorporated by reference in its entirety.
`
`BACKGROUND
`
`15
`
`25
`
`30
`
`35
`
`The present invention relates generally to methods of
`manufacturing articles of footwear, and, in particular, to a
`knitting process for a knitted component with an integral knit
`tongue for an article of footwear.
`Conventional articles of footwear generally include two
`primary elements, an upper and a sole structure. The upper is
`secured to the sole structure and forms a void on the interior
`of the footwear for comfortably and securely receiving a foot.
`The sole structure is secured to a lower area of the upper,
`thereby being positioned between the upper and the ground.
`In athletic footwear, for example, the sole structure may
`include a midsole and an outsole. The midsole often includes
`a polymer foam material that attenuates ground reaction
`forces to lessen stresses upon the foot and leg during walking,
`running, and other ambulatory activities. Additionally, the
`midsole may include fluid-filled chambers, plates, modera
`tors, or other elements that further attenuate forces, enhance
`stability, or influence the motions of the foot. The outsole is
`secured to a lower surface of the midsole and provides a
`ground-engaging portion of the sole structure formed from a
`durable and wear-resistant material, such as rubber. The sole
`structure may also include a sockliner positioned within the
`void and proximal a lower surface of the foot to enhance
`footwear comfort.
`The upper generally extends over the instep and toe areas of
`40
`the foot, along the medial and lateral sides of the foot, under
`the foot, and around the heel area of the foot. In some articles
`of footwear, such as basketball footwear and boots, the upper
`may extend upward and around the ankle to provide Support
`or protection for the ankle. Access to the void on the interior
`of the upper is generally provided by an ankle opening in a
`heel region of the footwear. A lacing system is often incor
`porated into the upper to adjust the fit of the upper, thereby
`permitting entry and removal of the foot from the void within
`the upper. The lacing system also permits the wearer to
`modify certain dimensions of the upper, particularly girth, to
`accommodate feet with varying dimensions. 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 a heel counter to limit movement of the heel.
`A variety of material elements (e.g., textiles, polymer
`foam, polymer sheets, leather, synthetic leather) are conven
`tionally used in manufacturing the upper. In athletic footwear,
`for example, the upper may have multiple layers that each
`include a variety of joined material elements. As examples,
`the material elements may be selected to impart stretch-resis
`tance, wear-resistance, flexibility, air-permeability, com
`pressibility, comfort, and moisture-wicking to different areas
`of the upper. In order to impart the different properties to
`different areas of the upper, material elements are often cut to
`desired shapes and then joined together, usually with Stitch
`ing or adhesive bonding. Moreover, the material elements are
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`often joined in a layered configuration to impart multiple
`properties to the same areas. As the number and type of
`material elements incorporated into the upper increases, the
`time and expense associated with transporting, Stocking, cut
`ting, and joining the material elements may also increase.
`Waste material from cutting and Stitching processes also
`accumulates to a greater degree as the number and type of
`material elements incorporated into the upper increases.
`Moreover, uppers with a greater number of material elements
`may be more difficult to recycle than uppers formed from
`fewer types and numbers of material elements. By decreasing
`the number of material elements used in the upper, therefore,
`waste may be decreased while increasing the manufacturing
`efficiency and recyclability of the upper.
`Therefore, there exists a need for an article of footwear that
`incorporates a knitted component with an integral knit
`tongue.
`
`SUMMARY
`
`Various configurations of an article of footwear may have
`an upper and a sole structure secured to the upper. A knitted
`component including the upper and an integral knit tongue is
`incorporated into the article of footwear. The upper and the
`integral knit tongue are formed as a one-piece knit element.
`The knit element defines a portion of an exterior surface of the
`upper and an opposite interior Surface of the upper, with the
`interior surface defining a void for receiving a foot. The
`integral knit tongue is formed of unitary knit construction
`with the upper as a one-piece knit element and extends
`through a throat area of the upper. The integral knit tongue
`incorporates raised elements providing lace apertures for a
`lacing System.
`In one aspect, the invention provides a method of manu
`facturing a knitted component for an article of footwear, the
`method comprising: knitting a portion of the knitted compo
`nent defining an upper with a knitting machine, the upper
`including a portion of at least one of an exterior Surface of the
`knitted component and an opposite interior Surface of the
`knitted component; and knitting an integral knit tongue that is
`of unitary knit construction with the upper with the knitting
`machine, the integral knit tongue extending through a throat
`area of the knitted component; and wherein the integral knit
`tongue is joined by knitting with the knitting machine to a
`forward portion of the throat area and at least along a portion
`of a lateral side and a medial side of the throat area of the
`knitted component extending from the forward portion to an
`ankle opening of the upper.
`In another aspect, the invention provides a method of
`manufacturing a knitted component for an article of footwear,
`the method comprising: knitting a first portion of the knitted
`component defining an upper with a first feeder of a knitting
`machine, the upper including a portion of at least one of an
`exterior Surface of the knitted component and an opposite
`interior Surface of the knitted component; knitting a second
`portion of the knitted component defining the upper with a
`second feeder of the knitting machine; and knitting an integral
`knit tongue that is of unitary knit construction with the upper
`with at least one of the first feeder and the second feeder of the
`knitting machine, the integral knit tongue extending through
`a throat area of the knitted component; and wherein the inte
`gral knit tongue is joined by knitting with the knitting
`machine to a forward portion of the throat area and at least
`along a portion of a lateral side and a medial side of the throat
`area of the knitted component extending from the forward
`portion to an ankle opening of the upper.
`
`Skechers EX1001-p.32
`Skechers v Nike
`
`

`

`US 9,060,562 B2
`
`3
`In another aspect, the invention provides a method of
`manufacturing a knitted component for an article of footwear,
`the method comprising: knitting a first portion of the knitted
`component defining an upper with a first feeder of a knitting
`machine, the upper including a portion of at least one of an
`exterior Surface of the knitted component and an opposite
`interior Surface of the knitted component; knitting a second
`portion of the knitted component defining the upper with a
`second feeder of the knitting machine; and knitting an integral
`knit tongue that is of unitary knit construction with the upper
`with a third feeder of the knitting machine, the integral knit
`tongue extending through a throat area of the knitted compo
`nent; and wherein the integral knittongue is joined by knitting
`with the knitting machine to a forward portion of the throat
`area and at least along a portion of a lateral side and a medial
`side of the throat area of the knitted component extending
`from the forward portion to an ankle opening of the upper.
`Other systems, methods, features and advantages of the
`invention will be, or will become, apparent to one of ordinary
`skill in the art upon examination of the following figures and
`detailed description. It is intended that all such additional
`systems, methods, features and advantages be included
`within this description and this Summary, be within the scope
`of the invention, and be protected by the following claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
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`The invention 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 invention.
`Moreover, in the figures, like reference numerals designate
`corresponding parts throughout the different views.
`FIG. 1 is an isometric view of an exemplary embodiment of
`an article of footwear;
`35
`FIG. 2 is a lateral side view of an exemplary embodiment of
`an article of footwear;
`FIG. 3 is a medial side view of an exemplary embodiment
`of an article of footwear;
`FIG. 4A is across-sectional view of the article of footwear,
`as defined by section lines 4A in FIGS. 2 and 3;
`FIG. 4B is a cross-sectional view of the article of footwear,
`as defined by section lines 4B in FIGS. 2 and 3;
`FIG. 5 is a top plan view of an exemplary embodiment of a
`knitted component with an integral knit tongue;
`FIG. 6 is a cross-sectional view of the knitted component
`with the integral knit tongue, as defined by section line 6 in
`FIG. 5;
`FIG. 7 is an enlarged schematic view of the integral knit
`tongue of the knitted component;
`FIG. 8 is a top plan view of an alternate embodiment of a
`knitted component with an integral knit tongue;
`FIG. 9 is a cross-sectional view of the knitted component
`with the integral knit tongue, as defined by section line 9 in
`FIG. 8:
`FIG. 10 is a top plan view of an alternate embodiment of a
`knitted component with an integral knit tongue having a
`partially integral portion;
`FIG. 11 is an enlarged schematic view of the integral knit
`tongue of the knitted component having a partially integral
`portion;
`FIG. 12 is a cross-sectional view of the knitted component
`with the integral knit tongue having a partially integral por
`tion, as defined by section line 12 in FIG. 11;
`FIG. 13 is a top plan view of an alternate embodiment of a
`knitted component with an integral knit tongue having par
`tially decoupled knit elements;
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`60
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`FIG. 14 is a cross-sectional view of the integral knit tongue
`of the knitted component having partially decoupled knit
`elements, as defined by section line 14 in FIG. 13;
`FIG. 15 is a cross-sectional view of the integral knittongue
`of the knitted component having partially decoupled knit
`elements, as defined by section line 15 in FIG. 13;
`FIG. 16 is a loop diagram of an exemplary embodiment of
`an integral knit tongue;
`FIG. 17 is an isometric view of an exemplary embodiment
`of a knitting machine;
`FIG. 18 is a schematic view of internal components of the
`knitting machine in operation;
`FIG. 19 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue;
`FIG. 20 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue;
`FIG. 21 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue;
`FIG.22 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tonguehaving a partially integral
`portion;
`FIG. 23 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tonguehaving a partially integral
`portion;
`FIG. 24 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue having a partially integral
`portion;
`FIG.25 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tonguehaving a partially integral
`portion;
`FIG. 26 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue having partially
`decoupled knit layers;
`FIG. 27 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue having partially
`decoupled knit layers;
`FIG. 28 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue having partially
`decoupled knit layers; and
`FIG. 29 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted com
`ponent with an integral knit tongue having partially
`decoupled knit layers.
`
`DETAILED DESCRIPTION
`
`The following discussion and accompanying figures dis
`close a variety of concepts relating to knitted components and
`the manufacture of knitted components. Although the knitted
`components may be used in a variety of products, an article of
`footwear that incorporates one of the knitted components is
`disclosed below as an example. In addition to footwear, the
`knitted components may be used in other types of apparel
`(e.g., shirts, pants, socks, jackets, undergarments), athletic
`equipment (e.g., golfbags, baseball and football gloves, Soc
`cer ball restriction structures), containers (e.g., backpacks,
`bags), and upholstery for furniture (e.g., chairs, couches, car
`
`Skechers EX1001-p.33
`Skechers v Nike
`
`

`

`US 9,060,562 B2
`
`10
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`15
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`5
`seats). The knitted components may also be used in bed
`coverings (e.g., sheets, blankets), table coverings, towels,
`flags, tents, sails, and parachutes. The knitted components
`may be used as technical textiles for industrial purposes,
`including structures for automotive and aerospace applica
`tions, filter materials, medical textiles (e.g. bandages, Swabs,
`implants), geotextiles for reinforcing embankments, agrotex
`tiles for crop protection, and industrial apparel that protects or
`insulates against heat and radiation. Accordingly, the knitted
`components and other concepts disclosed herein may be
`incorporated into a variety of products for both personal and
`industrial purposes.
`Footwear Configurations
`FIGS. 1 through 15 illustrate various footwear configura
`tions according to the principles described and illustrated
`herein. In particular, FIGS. 1-4B illustrate an exemplary
`embodiment of an article of footwear incorporating a knitted
`component including an upper and an integral knit tongue.
`FIGS. 1 through 4B illustrate an exemplary embodiment of
`an article of footwear 100, also referred to simply as footwear
`100. In some embodiments, article of footwear 100 may
`include a sole structure 110 and an upper 120. Although
`footwear 100 is illustrated as having a general configuration
`suitable for running, concepts associated with footwear 100
`may also be applied to a variety of other athletic footwear
`types, including baseball shoes, basketball shoes, cycling
`shoes, football shoes, tennis shoes, Soccer shoes, training
`shoes, walking shoes, and hiking boots, for example. The
`concepts may also be applied to footwear types that are gen
`erally considered to be non-athletic, including dress shoes,
`loafers, sandals, and work boots. Accordingly, the concepts
`disclosed with respect to footwear 100 may be applied to a
`wide variety of footwear types.
`For reference purposes, footwear 100 may be divided into
`three general regions: a forefoot region 101, a midfoot region
`102, and a heel region 103, as shown in FIGS. 1, 2, and 3.
`Forefoot region 101 generally includes portions of footwear
`100 corresponding with the toes and the joints connecting the
`metatarsals with the phalanges. Midfoot region 102 generally
`includes portions of footwear 100 corresponding with an arch
`area of the foot. Heel region 103 generally corresponds with
`rear portions of the foot, including the calcaneuS bone. Foot
`wear 100 also includes a lateral side 104 and a medial side
`105, which extend through each of forefoot region 101, mid
`foot region 102, and heel region 103 and correspond with
`45
`opposite sides of footwear 100. More particularly, lateral side
`104 corresponds with an outside area of the foot (i.e., the
`surface that faces away from the other foot), and medial side
`105 corresponds with an inside area of the foot (i.e., the
`surface that faces toward the other foot). Forefoot region 101,
`midfoot region 102, and heel region 103 and lateral side 104,
`medial side 105 are not intended to demarcate precise areas of
`footwear 100. Rather, forefoot region 101, midfoot region
`102, and heel region 103 and lateral side 104, medial side 105
`are intended to represent general areas of footwear 100 to aid
`in the following discussion. In addition to footwear 100,
`forefoot region 101, midfoot region 102, and heel region 103
`and lateral side 104, medial side 105 may also be applied to
`sole structure 110, upper 120, and individual elements
`thereof.
`In an exemplary embodiment, sole structure 110 is secured
`to upper 120 and extends between the foot and the ground
`when footwear 100 is worn. In some embodiments, the pri
`mary elements of sole structure 110 are a midsole 111, an
`outsole 112, and a sockliner 113 (shown in FIGS. 4A and 4B).
`Midsole 111 is secured to a lower surface of upper 120 and
`may be formed from a compressible polymer foam element
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`6
`(e.g., a polyurethane or ethylvinylacetate foam) that attenu
`ates ground reaction forces (i.e., provides cushioning) when
`compressed between the foot and the ground during walking,
`running, or other ambulatory activities. In other embodi
`ments, midsole 111 may incorporate plates, moderators,
`fluid-filled chambers, lasting elements, or motion control
`members that further attenuate forces, enhance stability, or
`influence the motions of the foot, or midsole 111 may be
`primarily formed from a fluid-filled chamber. Outsole 112 is
`secured to a lower surface of midsole 111 and may be formed
`from a wear-resistant rubber material that is textured to
`impart traction. Sockliner 113 is located within upper 120 and
`is positioned to extend under a lower surface of the foot to
`enhance the comfort of footwear 100. Although this configu
`ration for sole structure 110 provides an example of a sole
`structure that may be used in connection with upper 120, a
`variety of other conventional or nonconventional configura
`tions for sole structure 110 may also be used. Accordingly, in
`other embodiments, the features of sole structure 110 or any
`sole structure used with upper 120 may vary.
`In some embodiments, upper 120 defines a void within
`footwear 100 for receiving and securing a foot relative to sole
`structure 110. The void is shaped to accommodate the foot
`and extends along a lateral side of the foot, along a medial side
`of the foot, over the foot, around the heel, and under the foot.
`Access to the Void is provided by an ankle opening 121
`located in at least heel region 103. In some embodiments, a
`throat area 123 extends from ankle opening 121 inheel region
`103 over an area corresponding to an instep of the foot to an
`area adjacent to forefoot region 101. In an exemplary embodi
`ment, an integral knit tongue 140 is formed of unitary knit
`construction with upper 120 and extends through throat area
`123 of upper 120 between lateral side 104 and medial side
`105.
`A lace 122 extends through various lace apertures 143 in
`raised elements 142 of integral knit tongue 140 and permits
`the wearer to modify dimensions of upper 120 to accommo
`date proportions of the foot. More particularly, lace 122 per
`mits the wearer to tighten upper 120 around the foot, and lace
`122 permits the wearer to loosen upper 120 to facilitate entry
`and removal of the foot from the void (i.e., through ankle
`opening 121). In addition, integral knit tongue 140 of upper
`120 extends under lace 122 to enhance the comfort of foot
`wear 100. In further configurations, upper 120 may include
`additional elements, such as (a) a heel counter in heel region
`103 that enhances stability, (b) a toe guard in forefoot region
`101 that is formed of a wear-resistant material, and (c) logos,
`trademarks, and placards with care instructions and material
`information.
`Many conventional footwear u