USOO951 0636B2
`
`(12) United States Patent
`Dua et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 9,510,636 B2
`Dec. 6, 2016
`
`(54) ARTICLE OF FOOTWEAR
`NCORPORATING A KNITTED
`COMPONENT WITH AN INTEGRAL KNIT
`TONGUE
`OR (US
`B
`71) Appli
`: Nike, I
`(71) Applicant: Nike, Inc., Beaverton,
`(US)
`(72) Inventors: Bhupesh Dua, Portland, OR (US);
`Bruce Huffa, Encino, CA (US); Adrian
`Meir, Portland, OR (US); Benj amin A.
`Shaffer, Portland, OR (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 703 days.
`
`(21) Appl. No.: 13/781.525
`
`(22) Filed:
`
`Feb. 28, 2013
`
`(65)
`
`Prior Publication Data
`US 2013/0239.438 A1
`Sep. 19, 2013
`Related U.S. Application Data
`(63) Continuation-in-part of application No. 13/474,531,
`filed on May 17, 2012, now Pat. No. 8,621,891, which
`(Continued)
`
`(51) Int. Cl.
`D04B I/22
`A43B I/04
`
`(2006.01)
`(2006.01)
`(Continued)
`
`(52) U.S. Cl.
`CPC ............. A43B I/04 (2013.01); A43B 23/0205
`(2013.01); A43B 23/0245 (2013.01);
`it is
`• us
`(Continued)
`(58) Field of Classification Search
`CPC ............. D04B 1/126: D04B 1/22: D04B 1/24:
`D04B 7/24: D04B 15/56
`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 Rothstein
`(Continued)
`
`CN
`CN
`
`FOREIGN PATENT DOCUMENTS
`1317061
`10, 2001
`17821.56
`6, 2006
`(Continued)
`
`OTHER PUBLICATIONS
`Taiwanese Office Action dated Nov. 14, 2014 in Taiwanese Patent
`Application No. 102105769.
`International Preliminary Report on Patentability (including Written
`Opinion of the ISA) mailed Sep. 4, 2014 in International Applica
`tion No. PCT/US2013/0266.18.
`Non-Final Office Action mailed Dec. 19, 2012 in U.S. Appl. No.
`13/474,531.
`
`(Continued)
`
`Primary Examiner — Danny Worrell
`(74) Attorney, Agent, or Firm — Brinks Gilson & Lione
`
`ABSTRACT
`(57)
`Articles of footwear are described that incorporate a knitted
`component that has an upper and an integral knit tongue. The
`integral knit tongue is formed of unitary knit construction
`with the upper and extends through a throat area of the
`knitted component. The integral knit tongue includes raised
`elements formed of unitary knit construction with the
`tongue. Methods of manufacturing a knitted component for
`an article of footwear may include knitting the upper and the
`integral knit tongue during a knitting process on a knitting
`machine.
`
`27 Claims, 28 Drawing Sheets
`
`1800
`
`1601( — / / / /
`12(–
`:
`-
`to (-
`1604 - A / / /
`(
`- Q Q Q QQQQQQ Q.
`1606 ( -
`>
`f / / /
`1807{-
`S.
`1808{->
`y
`1609 -
`>
`1st
`
`A / A A
`Q Q Q Q Q Q Q Q Q Q.
`
`Skechers EX1001-p.1
`Skechers v Nike
`
`

`

`US 9,510,636 B2
`Page 2
`
`Related U.S. Application Data
`is a continuation of application No. 13/400.511, filed
`on Feb. 20, 2012, now Pat. No. 8,448,474.
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`(51) Int. Cl.
`A43B 23/02
`A43B 23/26
`D04B .5/56
`D04EB I/24
`D04B 7/28
`(52) U.S. Cl.
`CPC .......... A43B 23/0265 (2013.01); A43B 23/26
`(2013.01): D04B 1/22 (2013.01): D04B I/24
`(2013.01): D04B 7/28 (2013.01): D04B 15/56
`(2013.01); D10B 2403/01 13 (2013.01); D10B
`2403/0243 (2013.01); D10B 2403/02411
`(2013.01); D10B 2403/032 (2013.01); D10B
`2501/043 (2013.01)
`
`(56)
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`
`Skechers EX1001-p.2
`Skechers v Nike
`
`

`

`US 9,510,636 B2
`Page 3
`
`(56)
`
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`* cited by examiner
`
`Skechers EX1001-p.3
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`888)
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`909
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`Z09
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`Z08
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`Z00||
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`U.S. Patent
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`US 9,510,636 B2
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`(Y)
`V
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`9
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`1600
`
`1601 (— / / / /
`1602 – S
`too ( — Y
`1604 (- A / / /
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`US 9,510,636 B2
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`1.
`ARTICLE OF FOOTWEAR
`NCORPORATING A KNITTED
`COMPONENT WITH AN INTEGRAL KNIT
`TONGUE
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation-in-part of co-pending
`U.S. patent application Ser. No. 13/474,531, entitled
`“Article Of Footwear Incorporating A Knitted Component
`With A Tongue’, filed on May 17, 2012, which application
`is a continuation of U.S. patent application Ser. No. 13/400,
`511, entitled “Article Of Footwear Incorporating A Knitted
`Component With A Tongue’, filed on Feb. 20, 2012, which
`applications are hereby incorporated by reference in their
`entirety.
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`BACKGROUND
`
`The present invention relates generally to articles of
`footwear, and, in particular, to an article of footwear incor
`porating a knitted component with an integral knit tongue.
`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
`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
`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, moderators, 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 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 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 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 foot
`wear, 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-perme
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`ability, compressibility, 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 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 material elements incorporated into the
`upper increases, the time and expense associated with trans
`porting, 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 mate
`rial 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 an article of foot
`wear having an upper and a sole structure secured to the
`upper, the article of footwear incorporating a knitted com
`ponent comprising: a portion of the knitted component
`defining the upper, 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, the
`interior Surface defining a void for receiving a foot; and an
`integral knit tongue formed of unitary knit construction with
`the upper and extending through a throat area of the knitted
`component; and wherein the integral knit tongue is joined 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 por
`tion to an ankle opening of the upper.
`In another aspect, the invention provides a knitted com
`ponent for an article of footwear, the knitted component
`comprising: a portion of the knitted component defining the
`upper, 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, the interior surface
`configured to define a void for receiving a foot; and an
`integral knit tongue formed of unitary knit construction with
`the upper and extending through a throat area of the knitted
`component; and wherein the integral knit tongue is joined 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 por
`tion to an ankle opening of the upper.
`
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`In another aspect, the invention provides a knitted com
`ponent for an article of footwear, the knitted component
`comprising: an upper and an integral knit tongue formed of
`unitary knit construction with the upper and extending
`through a throat area of the knitted component; the knitted
`component comprising at least two knit element layers,
`including: a first knit element layer comprising a portion of
`an exterior Surface of the knitted component; and a second
`knit element layer comprising a portion of an interior Surface
`of the knitted component, the interior Surface disposed
`opposite to the exterior Surface and the interior Surface being
`configured to define a void for receiving a foot; and wherein
`the integral knit tongue is joined 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.
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`FIG. 13 is a top plan view of an alternate embodiment of
`a knitted component with an integral knit tongue having
`partially decoupled knit elements;
`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 knit
`tongue 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
`component with an integral knit tongue:
`FIG. 20 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted
`component with an integral knit tongue:
`FIG. 21 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted
`component with an integral knit tongue:
`FIG.22 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted
`component with an integral knit tongue having a partially
`integral portion;
`FIG. 23 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted
`component with an integral knit tongue having a partially
`integral portion;
`FIG. 24 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted
`component 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
`component with an integral knit tongue having a partially
`integral portion;
`FIG. 26 is a schematic view of internal components of the
`knitting machine in operation to manufacture a knitted
`component 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
`component 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
`component 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
`component with an integral knit tongue having partially
`decoupled knit layers.
`
`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 inven
`tion. 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;
`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 a cross-sectional view of the article of foot
`wear, as defined by section lines 4A in FIGS. 2 and 3;
`FIG. 4B is a cross-sectional view of the article of foot
`wear, 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;
`55
`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
`portion, as defined by section line 12 in FIG. 11;
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`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).
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`athletic equipment (e.g., golf bags, baseball and football
`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
`used in bed coverings (e.g., sheets, blankets), table cover
`ings, towels, flags, tents, sails, and parachutes. The knitted
`components may be used 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 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 configu
`rations 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
`generally 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
`40
`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, includ
`ing the calcaneus bone. Footwear 100 a