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`US 20120233882Al
`
`c19) United States
`c12) Patent Application Publication
`Huffa et al.
`
`c10) Pub. No.: US 2012/0233882 Al
`Sep. 20, 2012
`(43) Pub. Date:
`
`(54) ARTICLE OF FOOTWEAR INCORPORATING
`A KNITTED COMPONENT
`
`(52) U.S. Cl. ............................................................ 36/45
`
`(75)
`
`Inventors:
`
`Bruce Buffa, Encino, CA (US);
`Dua Bhupesh, Portland, OR (US)
`
`(57)
`
`ABSTRACT
`
`(73)
`
`Assignee:
`
`NIKE. Inc., Beaverton, OR (US)
`
`(21)
`
`Appl. No.:
`
`13/048,514
`
`(22)
`
`Filed:
`
`Mar. 15, 2011
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`A43B 23100
`
`(2006.01)
`
`An article of footwear may include an upper incorporating a
`knitted component. An inlaid strand extends through the knit(cid:173)
`ted component. A combination feeder may be utilized to inlay
`the strand within the knitted component. As an example, the
`combination feeder may include a feeder arm that recipro(cid:173)
`cates between a retracted position and an extended position.
`In manufacturing the knitted component, the feeder inlays the
`strand when the feeder arm is in the extended position, and the
`strand is absent from the knitted component when the feeder
`arm is in the retracted position.
`
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`
`Skechers EX1019-p.25
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 25 of 46
`
`US 2012/0233882 Al
`
`200
`~
`
`Figure 15
`
`Skechers EX1019-p.26
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 26 of 46
`
`US 2012/0233882 Al
`
`220
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`Skechers EX1019-p.27
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 27 of 46
`
`US 2012/0233882 Al
`
`220
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`
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`
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`Skechers EX1019-p.28
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 28 of 46
`
`US 2012/0233882 Al
`
`220
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`Skechers EX1019-p.29
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 29 of 46
`
`US 2012/0233882 Al
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`220
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`
`Skechers EX1019-p.30
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 30 of 46
`
`US 2012/0233882 Al
`
`250
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`Skechers EX1019-p.31
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 31 of 46
`
`US 2012/0233882 Al
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`Skechers EX1019-p.32
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 32 of 46
`
`US 2012/0233882 Al
`
`253
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`Skechers EX1019-p.33
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 33 of 46
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`US 2012/0233882 Al
`
`200
`/
`
`Figure 21A
`
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`
`Skechers EX1019-p.34
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 34 of 46
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`US 2012/0233882 Al
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`200
`
`/
`
`Figure 21 B
`
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`
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`Skechers EX1019-p.35
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 35 of 46
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`US 2012/0233882 Al
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`200
`/
`
`Figure 21C
`
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`
`Skechers EX1019-p.36
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 36 of 46
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`US 2012/0233882 Al
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`200
`✓
`
`Figure 21 D
`
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`
`Skechers EX1019-p.37
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 37 of 46
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`US 2012/0233882 Al
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`200
`
`/
`
`Figure 21 E
`
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`
`Skechers EX1019-p.38
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 38 of 46
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`US 2012/0233882 Al
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`200
`/
`
`Figure 21 F
`
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`
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`
`Skechers EX1019-p.39
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 39 of 46
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`US 2012/0233882 Al
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`200
`/
`
`Figure 21G
`
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`
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`
`Skechers EX1019-p.40
`Skechers v Nike
`
`

`

`Patent Application Publication
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`Sep. 20, 2012 Sheet 40 of 46
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`US 2012/0233882 Al
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`200
`
`/
`
`Figure 21 H
`
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`
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`Skechers EX1019-p.41
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 41 of 46
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`US 2012/0233882 Al
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`200
`/
`
`Figure 211
`
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`
`260
`
`Skechers EX1019-p.42
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 42 of 46
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`US 2012/0233882 Al
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`203
`
`204
`
`212
`
`211
`
`Figure 22A
`
`Skechers EX1019-p.43
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 43 of 46
`
`US 2012/0233882 Al
`
`220
`250
`~
`230
`
`203
`
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`
`206
`
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`
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`
`Skechers EX1019-p.44
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 44 of 46
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`US 2012/0233882 Al
`
`220
`250
`~
`230
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`203
`
`221~
`
`206
`
`Figure 22C
`
`Skechers EX1019-p.45
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 45 of 46
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`US 2012/0233882 Al
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`200
`
`/
`
`Figure 23
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`211
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`260
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`Skechers EX1019-p.46
`Skechers v Nike
`
`

`

`Patent Application Publication
`
`Sep. 20, 2012 Sheet 46 of 46
`
`US 2012/0233882 Al
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`200
`~
`
`Figure 24
`
`Skechers EX1019-p.47
`Skechers v Nike
`
`

`

`US 2012/0233882 Al
`
`Sep.20,2012
`
`1
`
`ARTICLE OF FOOTWEAR INCORPORATING
`A KNITTED COMPONENT
`
`fore, waste may be decreased while increasing the manufac(cid:173)
`turing efficiency and recyclability of the upper.
`
`BACKGROUND
`
`SUMMARY
`
`[0001] 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 receiv(cid:173)
`ing 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 reac(cid:173)
`tion ~orces to_ lessen stresses upon the foot and leg during
`walking, runnmg, and other ambulatory activities. Addition(cid:173)
`ally, the midsole may include fluid-filled chambers plates
`moderators, or other elements that further attenuat: forces'
`enhance stability, or influence the motions of the foot. Th~
`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 posi(cid:173)
`tioned within the void and proximal a lower surface of the foot
`to enhance footwear comfort.
`[0002] The upper generally extends over the instep and toe
`areas of the foot, along the medial and lateral sides of the foot
`under the foot, and around the heel area of the foot. In som~
`articles of footwear, such as basketball footwear and boots
`the upper may extend upward and around the ankle to provid~
`support or protection for the ankle. Access to the void on the
`)nte:ior of the u~per is generally provided by an ankle open(cid:173)
`mg ma heel reg10n of the footwear. A lacing system is often
`incorporated 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
`syste_m to enhance adjustability of the footwear, and the upper
`may mcorporate a heel counter to limit movement of the heel.
`[0003] A variety of material elements ( e.g., textiles, poly(cid:173)
`mer foam, polymer sheets, leather, synthetic leather) are con(cid:173)
`ventionally utilized 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-resistance, wear-resistance, flexibility, air-permeabil(cid:173)
`ity, compressibility, comfort, and moisture-wicking to differ(cid:173)
`ent_ areas ~f the upper. In order to impart the different prop(cid:173)
`erties to different areas of the upper, material elements are
`often cut to desired shapes and then joined together, usually
`with stitching or adhesive bonding. Moreover, the material
`elements are often joined in a layered configuration to impart
`multiple properties to the same areas. As the number and type
`of 111;aterial elements incorporated into the upper increases,
`the time and expense associated with transporting, stocking,
`cutting, 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 utilized in the upper, there-
`
`[0004] An article of footwear is disclosed below as having
`an upper and a sole structure secured to the upper. A knitted
`component of the upper includes a fusible yarn and a non(cid:173)
`~sible yam that are knitted together to form a plurality of
`mtermeshed loops defining courses and wales. The knitted
`component also includes an inlaid strand extending along at
`least one of the courses.
`[0005] The discussion below also discloses an article of
`footwear having an upper that includes a knit element an
`inlaid strand, and a lace. The knit element defines a portio~ 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 knit element extends from a throat
`area of the upper to a lower area of the upper, and the knit
`element defines a plurality of apertures located within the
`throat area. The inlaid strand extends through the knit element
`from the throat area to the lower area. The inlaid strand also
`extends at least partially around the apertures in the throat
`area, and the inlaid strand is located between the exterior
`surface and the interior surface in the throat area. The lace
`extends through the apertures.
`[0006] Additionally, an article of footwear is disclosed
`below as having an upper that includes a first knitted layer, a
`second knitted layer, and a plurality of floating yams. The first
`knitted layer forms at least a portion of an exterior surface of
`the upper. The second knitted layer is formed of unitary knit
`construction with the first knitted layer, and the second knit(cid:173)
`ted layer is positioned adjacent to the first knitted layer and at
`least partially coextensive with the first knitted layer to define
`a tube between the first knitted layer and the second knitted
`layer. The floating yarns are located within the tube and
`extend in a direction that is substantially parallel to the first
`knitted layer and the second knitted layer. Moreover, the first
`knitted layer and the second knitted layer are at least partially
`formed from a yarn that stretches at least one hundred per(cid:173)
`cent.
`[0007] The advantages and features of novelty characteriz(cid:173)
`)ng aspects of the invention are pointed out with particularity
`m the appended claims. To gain an improved understanding
`of the advantages and features of novelty, however, reference
`may be made to the following descriptive matter and accom(cid:173)
`pm_iying figures that describe and illustrate various configu(cid:173)
`rat10ns and concepts related to the invention.
`
`FIGURE DESCRIPTIONS
`
`[0008] The foregoing Summary and the following Detailed
`J?escription will be better understood when read in conjunc(cid:173)
`t10n with the accompanying figures.
`[0009] FIG. 1 is a perspective view of an article of footwear.
`[0010] FIG. 2 is a lateral side elevational view of the article
`of footwear.
`[0011] FIG. 3 is a medial side elevational view of the article
`of footwear.
`[0012] FIGS. 4A-4C are cross-sectional views of the article
`of footwear, as defined by section lines 4A-4C in FIGS. 2 and
`3.
`[0013] FIG. 5 is a top plan view of a first knitted component
`that forms a portion of an upper of the article of footwear.
`
`Skechers EX1019-p.48
`Skechers v Nike
`
`

`

`US 2012/0233882 Al
`
`Sep.20,2012
`
`2
`
`[0014] FIG. 6 is a bottom plan view of the first knitted
`component.
`[0015] FIGS. 7 A-7E are cross-sectional views of the first
`knitted component, as defined by section lines 7 A-7E in FIG.
`5.
`[0016] FIGS. SA and 8B are plan views showing knit struc(cid:173)
`tures of the first knitted component.
`[0017] FIG. 9 is a top plan view of a second knitted com(cid:173)
`ponent that may form a portion of the upper of the article of
`footwear.
`[0018] FIG. 10 is a bottom plan view of the second knitted
`component.
`[0019] FIG. 11 is a schematic top plan view of the second
`knitted component showing knit zones.
`[0020] FIGS. 12A-12E are cross-sectional views of the sec(cid:173)
`ond knitted component, as defined by section lines 12A-12E
`in FIG. 9.
`[0021] FIGS.13A-13H are loop diagrams of the knit zones.
`[0022] FIGS. 14A-14C are top plan views corresponding
`with FIG. 5 and depicting further configurations of the first
`knitted component.
`[0023] FIG. 15 is a perspective view of a knitting machine.
`[0024] FIGS. 16-18 are elevational views of a combination
`feeder from the knitting machine.
`[0025] FIG. 19 is an elevational view corresponding with
`FIG.16 and showing internal components of the combination
`feeder.
`[0026] FIGS. 20A-20C are elevational views correspond(cid:173)
`ing with FIG. 19 and showing the operation of the combina(cid:173)
`tion feeder.
`[0027] FIGS. 21A-21I are schematic perspective views of a
`knitting process utilizing the combination feeder and a con(cid:173)
`ventional feeder.
`[0028] FIGS. 22A-22C are schematic cross-sectional
`views of the knitting process showing positions of the com(cid:173)
`bination feeder and the conventional feeder.
`[0029] FIG. 23 is a schematic perspective view showing
`another aspect of the knitting process.
`[0030] FIG. 24 is a perspective view of another configura(cid:173)
`tion of the knitting machine.
`
`DETAILED DESCRIPTION
`
`[0031] The following discussion and accompanying figures
`disclose a variety of concepts relating to knitted components
`and the manufacture of knitted components. Although the
`knitted components may be utilized 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 utilized in other
`types of apparel ( e.g., shirts, pants, socks, jackets, undergar(cid:173)
`ments), athletic equipment ( e.g., golf bags, baseball and foot(cid:173)
`ball gloves, soccer ball restriction structures), containers
`(e.g., backpacks, bags), and upholstery for furniture (e.g.,
`chairs, couches, car seats). The knitted components may also
`be utilized in bed coverings ( e.g., sheets, blankets), table
`coverings, towels, flags, tents, sails, and parachutes. The knit(cid:173)
`ted components may be utilized as technical textiles for
`industrial purposes, including structures for automotive and
`aerospace applications, filter materials, medical textiles ( e.g.
`bandages, swabs, implants), geotextiles for reinforcing
`embankments, agrotextiles for crop protection, and industrial
`apparel that protects or insulates against heat and radiation.
`Accordingly, the knitted components and other concepts dis-
`
`closed herein may be incorporated into a variety of products
`for both personal and industrial purposes.
`[0032] Footwear Configuration
`[0033] An article of footwear 100 is depicted in FIGS. l-4C
`as including 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(cid:173)
`erally considered to be non-athletic, including dress shoes,
`loafers, sandals, and work boots. Accordingly, the concepts
`disclosed with respect to footwear 100 apply to a wide variety
`of footwear types.
`[0034] 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. Forefoot region
`101 generally includes portions of footwear 100 correspond(cid:173)
`ing 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. Footwear
`100 also includes a lateral side 104 and a medial side 105,
`which extend through each of regions 101-103 and corre(cid:173)
`spond with 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). Regions
`101-103 and sides 104-105 are not intended to demarcate
`precise areas of footwear 100. Rather, regions 101-103 and
`sides 104-105 are intended to represent general areas of foot(cid:173)
`wear 100 to aid in the following discussion. In addition to
`footwear 100, regions 101-103 and sides 104-105 may also be
`applied to sole structure 110, upper 120, and individual ele(cid:173)
`ments thereof.
`[0035] Sole structure 110 is secured to upper 120 and
`extends between the foot and the ground when footwear 100
`is worn. The primary elements of sole structure 110 are a
`midsole 111, an outsole 112, and a sockliner 113. Midsole
`111 is secured to a lower surface of upper 120 and may be
`formed from a compressible polymer foam element (e.g., a
`polyurethane or ethylvinylacetate foam) that attenuates
`ground reaction forces (i.e., provides cushioning) when com(cid:173)
`pressed between the foot and the ground during walking,
`running, or other ambulatory activities. In further configura(cid:173)
`tions, midsole 111 may incorporate plates, moderators, fluid(cid:173)
`filled chambers, lasting elements, or motion control members
`that further attenuate forces, enhance stability, or influence
`the motions of the foot, or midsole 21 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 trac(cid:173)
`tion. Sockliner 113 is located within upper 120 and is posi(cid:173)
`tioned to extend under a lower surface of the foot to enhance
`the comfort of footwear 100. Although this configuration 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 configurations for sole
`
`Skechers EX1019-p.49
`Skechers v Nike
`
`

`

`US 2012/0233882 Al
`
`Sep.20,2012
`
`3
`
`structure 110 may also be utilized. Accordingly, the features
`of sole structure 110 or any sole structure utilized with upper
`120 may vary considerably.
`[0036] 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. A lace 122 extends through various lace
`apertures 123 in upper 120 and permits the wearer to modify
`dimensions of upper 120 to accommodate proportions of the
`foot. More particularly, lace 122 permits 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,
`upper 120 includes a tongue 124 that extends under lace 122
`and lace apertures 123 to enhance the comfort of footwear
`100. In further configurations, upper 120 may include addi(cid:173)
`tional 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.
`[0037] Many conventional footwear uppers are formed
`from multiple material elements ( e.g., textiles, polymer foam,
`polymer sheets, leather, synthetic leather) that are joined
`through stitching or bonding, for example. In contrast, a
`majority of upper 120 is formed from a knitted component
`130, which extends through each ofregions 101-103, along
`both lateral side 104 and medial side 105, over forefoot region
`101, and around heel region 103. In addition, knitted compo(cid:173)
`nent 130 forms portions of both an exterior surface and an
`opposite interior surface of upper 120. As such, knitted com(cid:173)
`ponent 130 defines at least a portion of the void within upper
`120. In some configurations, knitted component 130 may also
`extend under the foot. Referring to FIGS. 4A-4C, however, a
`strobe! sock 125 is secured to knitted component 130 and an
`upper surface of midsole 111, thereby forming a portion of
`upper 120 that extends under sockliner 113.
`[0038] Knitted Component Configuration
`[0039] Knitted component 130 is depicted separate from a