knitting method

专利摘要:
KNITTED COMPONENT MANUFACTURING METHOD An article of footwear and several other products may incorporate a knitted component. An embedded filament extends through the knitted component. A feeder in combination can be used to embed the filament within the knitted component. As an example, the feeder in combination may include a feed arm that reciprocates between a recoil position and an extended position. In the manufacture of the knitted component, the feeder embeds the filament when the feed arm is in the extended position, and the filament is absent from the knitted component when the feed arm is in the recoil position.
公开号:BR112013021989B1
申请号:R112013021989-0
申请日:2012-03-09
公开日:2021-02-02
发明作者:Bruce Huffa；Bhupesh Dua
申请人:Nike Innovate C.V.；
IPC主号:

专利说明:

Background
[001] Knitted components that have a wide range of structures, materials and knitting properties can be used in different products. As examples, knitted components can be used in clothing (shirts, pants, socks, jackets, underwear, shoes, for example), athletic equipment (golf bags, baseball and football gloves, ball restraints) football, for example), containers (fillers, bags, for example) and upholstery for furniture (chairs, sofas, car seats, for example). Knitted components can also be used in bed covers (sheets, blankets, for example), table covers, towels, flags, tents, candles and parachutes. Knitted components can be used as technical fabrics for industrial purposes, including structures for automotive and aerospace applications, filter materials, medical fabrics (bandages, cotton wicks, implants, for example), geotextiles to reinforce dikes, agotized for crop protection and industrial clothing that protects and insulates against heat and radiation. Therefore, knitted components can be incorporated into various products for both personal and industrial purposes.
[002] Knitting can generally be classified as weft knitting or warp knitting. In both weft and warp knitting, one or more threads are handled in such a way as to form a plurality of interlaced loops that define different courses and high reliefs. In weft knitting, which is more common, the courses and high reliefs are perpendicular to each other and can be formed from a single thread or many threads. In warp knitting, however, the high reliefs and courses run approximately in parallel and a thread is required for each high relief.
[003] Although knitting can be carried out by hand, the commercial manufacture of knitted components is generally carried out by knitting machines. An example of a knitting machine to produce a weft knitted component is a V-bed flat knitting machine, which includes two needle beds that are angled with respect to each other. Rails extend above and parallel to the needle beds and provide attachment points for feeders, which move along the needle beds and provide yarn to needles within the needle beds. Standard feeders have the ability to provide a yarn that is used to knit, fold and loop. In situations where an inlay yarn is incorporated into a knitted component, an inlay feeder is used. A conventional inlay feeder for a V-bed flat knitting machine includes two components that work together to embed the yarn. Each component of the built-in feeder is attached to separate attachment points on two adjacent rails, thus occupying two attachment points. While standard feeders occupy only one attachment point, two attachment points are generally occupied when a built-in feeder is used to embed a yarn in a knitted component. summary
[004] A knitting method is revealed below. The method includes using a feeder in combination to provide a yarn for knitting, folding and making loops. In addition, the method includes using the feeder in combination to embed the wire.
[005] Another method of knitting includes providing a machine that has a first feeder that dispenses a thread, a second feeder that dispenses a filament and a bed of needles that includes a plurality of needles. At least the first feeder is moved along the bed of needles to form a first course of a knitting component from the yarn. The method also includes moving the first feeder and the second feeder along the bed of needles so as to (a) form a second course of the knitting component from the yarn and (b) embedding the filament in the knitting component. While the first feeder and the second feeder are moved, the second feeder is located in front of the first feeder and the dispenser tip of the second feeder is located below the dispenser tip of the first feeder.
[006] Yet another method of knitting includes providing a three-dimensional machine that has a first feeder that provides a first yarn, a second feeder that provides a second yarn and a bed of needles that includes a plurality of needles. The needle bed defines an intersection at which the planes on which the needles are arranged intersect. The dispensing tip of the first feeder is positioned above the intersection and the dispensing tip of the second feeder is positioned below the intersection. The first feeder and the second feeder are moved along the bed of needles in order to (a) form at least part of a first course of a knitting component from the first yarn and (b) embed the second yarn in part of the first course. The dispensing tip of the second feeder is then positioned above the intersection, and at least the second feeder is moved along the bed of needles to form at least part of the second stroke.
[007] The advantages and features of the aspects characterizing the novelty of the invention are specifically noted in the attached claims. In order to obtain an improved understanding of the advantages and features of novelty, reference can be made to the following description and the attached figures that describe and show various configurations and concepts related to the invention. Description of the figures
[008] The preceding summary and the following detailed description will be better understood when read in conjunction with the accompanying figures.
[009] Figure 1 is a perspective view of a shoe item.
[010] Figure 2 is a side elevation view of the shoe item.
[011] Figure 3 is a side view in median elevation of the shoe item.
[012] Figures 4A-4C are seen in cross section of the shoe article, defined by the cut lines 4A-4C of Figures 2 and 3.
[013] Figure 5 is a top plan view of a first knitted component that forms a part of the upper of the shoe article.
[014] Figure 6 is a base plan view of the first tri-dimensioned component.
[015] Figures 7A-7E are seen in cross section of the first knitted component, defined by the cut lines 7A-7E of Figure 5.
[016] Figures 8A and 8B are seen in plan showing the knitting structures of the first knitted component.
[017] Figure 9 is a top plan view of a second knitted component that can form a part of the upper of the shoe article.
[018] Figure 10 is a base plan view of the second knitted component.
[019] Figure 11 is a schematic top plan view of the second knitted component showing knitting zones.
[020] Figures 12A-12E are seen in cross section of the second knitted component, defined by the cut lines 12A-12E of Figure 9.
[021] Figures 13A-13H are diagrams linking the knitting areas.
[022] Figures 14A-14C are seen in top plan corresponding to Figure 5 and showing other configurations of the first knitted component.
[023] Figure 15 is a perspective view of a knitting machine.
[024] Figures 16-18 are seen in elevation of a feeder in combination with the knitting machine.
[025] Figure 19 is an elevation view corresponding to Figure 16 and showing the internal components of the feeder in combination.
[026] Figures 20A-20C are seen in elevation corresponding to Figure 19 and showing the operation of the feeder in combination.
[027] Figures 21A-21I are seen in schematic perspective of a knitting process that uses the feeder in combination and a conventional feeder.
[028] Figures 22A-22C are schematic cross-sectional views of the knitting process showing positions of the combined feeder and the conventional feeder.
[029] Figure 23 is a schematic perspective view showing another aspect of the knitting process.
[030] Figure 24 is a perspective view of another configuration of the knitting machine. Detailed Description
[031] The following discussion and the accompanying figures reveal several concepts regarding knitted components and the manufacture of knitted components. Although the knitted components can be used in different products, an example of a shoe that incorporates one of the knitted components is shown below. In addition to footwear, the knitted components can be used in other types of clothing (shirts, pants, socks, jackets, underwear, for example), athletic equipment (golf bags, baseball and football gloves, restraint structures soccer ball, for example), containers (fillers, bags, for example) and upholstery for furniture (chairs, sofas, car seats, for example). Knitted components can also be used in bed covers (sheets, blankets, for example), table covers, towels, flags, tents, candles and parachutes. Knitted components can be used as technical fabrics for industrial purposes, including structures for automotive and aerospace applications, filter materials, medical fabrics (bandages, cotton wicks, implants, for example), geotextiles to reinforce dikes, agotized for crop protection and industrial clothing that protects and insulates against heat and radiation. Therefore, knitted components can be incorporated into various products for both personal and industrial purposes. Shoe Configuration
[032] A shoe item 100 is shown in Figures 1-4C as including a sole structure 110 and an upper 120. Although shoe 100 is shown to have a general configuration suitable for operation, the concepts associated with shoe 100 can also be applied to various types of athletic shoes, which include baseball shoes, basketball shoes, cycling shoes, football shoes, tennis shoes, football shoes, training shoes, hiking shoes and walking boots, for example. The concepts can also be applied to types of footwear that are generally considered to be non-athletic, including casual shoes, loafers, sandals and work boots. Therefore, the concepts revealed with respect to footwear 100 apply to a wide variety of footwear types.
[033] For reference purposes, footwear 100 can be divided into three general regions: a front foot region 101, a middle foot region 102 and a heel region 103. The front foot region 101 generally includes parts of the footwear 100 that correspond to the toes and joints that connect the metatarsal bones to the phalanges. The midfoot region 102 generally includes parts of the shoe 100 that correspond to the arch area of the foot. The heel region 103 corresponds generally to the posterior parts of the foot, including the calcaneus bone. Footwear 100 also includes side 104 and middle side 105, which extend through each of regions 101-103 and correspond to opposite sides of footwear 100. More specifically, side 104 corresponds to the outer area of the foot (ie , the surface that faces away from the other foot), and the middle side 105 corresponds to the inner area of the foot (that is, the surface that faces towards the other foot). Regions 101-103 and sides 104-105 are not intended to demarcate precise areas of footwear 100. Instead, regions 101-103 and sides 104-105 are intended to represent general areas of footwear 100 to aid in the discussion Following. In addition to footwear 100, regions 101-103 and sides 104-105 can also be applied to sole structure 110, upper 120 and individual elements thereof.
[034] The sole structure 110 is attached to the upper 120 and extends between the foot and the floor when footwear 100 is worn. The primary elements of the sole structure 110 are the midsole 111, the outer sole 112 and the midsole lining 113. The midsole 111 is attached to the lower surface of the upper 120 and can be formed from a compressible polymer foam element (a foam of polyurethane or ethyl vinyl acetate, for example) that attenuates the forces of reaction to the floor (that is, provides cushioning) when compressed between the foot and the floor during walking, running or other walking activities . In other configurations, the midsole 111 may incorporate plates, moderators, chambers filled with fluid, durable elements or movement control elements that also attenuate forces, increase stability or influence the movements of the foot, or the midsole 21 may basically be formed from a fluid filled chamber. The outer sole 112 is attached to the lower surface of the midsole 111 and can be formed from a wear-resistant rubber material that is woven in order to print traction. The sock lining 113 is located inside the upper 120 and is positioned so that it extends under the bottom surface of the foot to improve the comfort of the shoe 100. Although this configuration for the sole structure 110 is an example of sole structure which can be used in connection with the upper 120, several other conventional or unconventional configurations can also be used for the sole structure 110. Therefore, the features of the sole structure 110 or any sole structure used with the upper 120 can vary considerably.
[035] The upper 120 defines a void within the shoe 100 to accommodate and secure a foot in relation to the sole structure 110. The void is shaped to accommodate the foot and extends to the side of the foot, at the along the median side of the foot, on the foot, around the heel and under the foot. Access to the void is obtained through an opening 121 in the ankle located at least in the heel region 103. A cord 122 extends through several openings of cord 123 in the upper and allows the user to modify the dimensions of the upper 120 in order to accommodate the proportions of the foot. More specifically, the cord 122 allows the user to loosen the upper 120 to facilitate the entry and removal of the foot from the void (i.e., through the opening 121 at the ankle). In addition, the upper 120 includes a tongue 124 that extends under the cord 122 and the cord openings 123 to increase the comfort of the shoe 100. In other configurations, the upper 120 may include additional elements, such as (a) a counter-heel in the heel region 103 that increases stability, (b) a toecap in the front foot region 101 that is made up of a wear-resistant material, and (c) logos, trademarks and posters with care instructions, and information about the material.
[036] Many conventional shoe uppers are formed from various material elements (fabrics, polymeric foam, polymeric sheets, leather, synthetic leather, for example) that are joined together by sewing or binding, for example. In contrast, most of the upper 120 is formed from a knitted component 130, which extends through each of the regions 101-103, along both side 104 and the middle side 105, over the front foot region 101 and around the heel region 103. In addition, the knitted component 130 forms parts of both the outer surface and the opposite inner surface of the upper 120. Thus, the knitted component 130 defines at least a part of the void within the upper 120 In some configurations, the knitted component 130 can also extend under the foot. Referring to Figures 4A-4C, however, a strobe sock 125 is attached to the knitted component 130 and to the upper surface of the sock 111, thereby forming a part of the upper 120 that extends under the sock lining 113. Knitted Component Configuration
[037] Knitted component 130 is shown separate from the remainder of shoes 100 in Figures 5 and 6. Knitted component 130 is formed by a unitary knitting construction. As used herein, a knitted component (knitted component 130, for example) is defined as being formed by a "unitary knitting construction" when formed as an element of a piece through a knitting process. That is, the knitting process substantially forms the various features and structures of the knitted component 130 without the need for significant additional manufacturing steps or processes. Although parts of the knitted component 130 can be joined together (the edges of the knitted component 130 being joined together, for example) following the knitting process, the knitted component 130 remains formed by the construction of unitary knitting since it is formed as a one-piece knitting element. Furthermore, the knitted component 130 remains formed by the construction of unitary knitting when other elements (the cord 122, the tongue 124, logos, trademarks, posters with care instructions and material information, for example) are added next to the knitting process.
[038] The primary elements of the knitted component 130 are a knitting element 131 and a built-in filament 132. The knitting element 131 is formed from at least one thread that is handled (with a knitting machine, for example) from in order to form a plurality of intertwined ties that define different courses and high reliefs. That is, the knitting element 131 has the structure of a knitting fabric. The embedded filament 132 extends through the knitting element 131 and passes between the various loops within the knitting element 131. Although the embedded filament 132 generally extends along strokes within the knitting element 131, the embedded filament 132 can also extend along high reliefs within the knitting element 131. Advantages of the built-in filament 132 include obtaining support, stability and structure. For example, the built-in filament 132 helps to secure the upper 120 around the foot, limits deformation in the areas of the upper 120 (prints stretch resistance, for example) and works in connection with the cord 122 to improve the fit of the shoe 100 .
[039] Knitting element 131 has a generally U-shaped configuration that is outlined by a perimeter edge 133, a pair of heel edges 134 and an inner edge 135. When incorporated into shoes 100, the perimeter edge 133 it is arranged against the upper surface of the midsole 111 and is joined to the strobe sock l25. The heel edges 134 are joined together and extend vertically in the heel region 103. In some shoe configurations 100, a material element can cover a seam between the heel edges 134 in order to reinforce the seam and improving the aesthetic appeal of the shoe 100. The inner edge 135 forms the ankle opening 121 and extends forward to the area where the cord 122, the cord openings 123 and the tongue 124 are located. In addition, the knitting element 131 has a first surface 136 and an opposite second surface 137. The first surface 136 forms a part of the outer surface of the upper 120, while the second surface 137 forms a part of the inner surface of the upper 120, thus defining at least a part of the void within the upper 120.
[040] The embedded filament 132, as noted above, extends through the knitting element 131 and passes between the various loops within the knitting element 131. More specifically, the embedded filament 132 is located within the knitting structure of the element of knitting 131, which can have the configuration of a single textile layer in the area of the embedded filament 132 and between the surfaces 136 and 137, as shown in Figures 7A-7D. When the knitted component 130 is incorporated into the shoe 100, therefore, the embedded filament 132 is located between the outer surface and the inner surface of the upper 120. In some configurations, parts of the embedded filament 132 may be visible or exposed on one or both. surfaces 136 and 137. For example, the embedded filament 132 may be arranged against one of the surfaces 136 and 137, or the knitting element 131 may form indentations or openings through which the embedded filament passes. An advantage of having the embedded filament 132 located between the surfaces 136 and 137 is that the knitting element 131 protects the embedded filament 132 from abrasion and protuberance.
[041] With reference to Figures 5 and 6, the embedded filament 132 extends repeatedly from the perimeter edge 133 towards the inner edge 135 and adjacent to one side of a cord opening 123, at least partially around the opening of the cord 123, to the opposite side, and back to the perimeter edge 133. When the knitted component 130 is incorporated into the shoe 100, the knitting element 131 extends from the throat area of the upper 120 (that is, where the cord 122, the cord openings 123 and the tongue 124 are located) up to the lower area of the upper 120 (i.e., where the knitting element 131 joins the sole structure 110). In this configuration, the embedded filament 132 also extends from the throat area to the lower area. More specifically, the embedded filament passes repeatedly through the knitting element 131 from the throat area to the lower area.
[042] Although the knitting element 131 can be formed in several ways, the strokes of the knitting structure generally extend in the same direction as the embedded filaments 132. That is, the strokes can extend in the direction that extends between the throat area and lower area. Therefore, most of the embedded filament 132 extends along the courses within the knitting element 131. In areas adjacent to the cord openings 123, however, the embedded filament 132 can also extend along high reliefs. within the knitting element 131. More specifically, the sections of the embedded filament 132 that are parallel to the inner edge 135 can extend along the high reliefs.
[043] As discussed above, the embedded filament 132 passes back and forth through the knitting element 131. With reference to Figures 5 and 6, the embedded filament 132 also repeatedly exits the knitting element 131 at the perimeter edge 133 and in it then re-enters the knitting element 131 at another location on the perimeter edge 133, thus forming loops along the perimeter edge 133. An advantage of this configuration is that each section of the embedded filament 132 that extends between the throat area and the lower area can be stretched, loosened independently, or otherwise adjusted during the shoe manufacturing process 100. That is, before fixing the sole structure 110 to the upper 120, the sections of the embedded filament 132 can be adjusted accordingly independently to the appropriate voltage.
[044] In comparison with the knitting element 131, the embedded filament 132 may present greater resistance to stretching. That is, the embedded filament 132 can stretch less than the knitting element 131. Since numerous sections of the embedded filament 132 extend from the throat area of the upper 120 to the lower area of the upper 120, the embedded filament 132 provides resistance to stretching apart the upper 120 between the throat area and the lower area. In addition, putting tension on the cord 122 can put tension on the embedded filament 132, thereby inducing the part of the upper 120 between the throat area and the lower area to be arranged against the foot. Thus, the embedded filament 132 works in connection with the cord 122 in order to improve the fit of the shoe 100.
[045] Knitting element 131 can incorporate several types of yarn that give different properties to separate areas of upper 120. That is, an area of knitting element 131 can be formed from a first type of yarn that prints a first set of properties, and another area of the knitting element 131 can be formed from a second type of yarn that prints a second set of properties. In this configuration, properties can vary across the upper 120 by selecting specific yarns for different areas of the knitting element 131. The properties that a specific type of yarn will print to an area of the knitting element 131 partly depend on the materials that make up the knitting elements. several filaments and fibers within the yarn. Elastane and stretchable polyester each provide substantial stretch and recovery, with the stretchable polyester also providing recyclability. Rayon provides high gloss and moisture absorption. Wool also provides high moisture absorption, in addition to isolating the properties and the ability to biodegrade. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also has relatively high durability. In addition to the materials, other aspects of the yarns selected for the knitting element 131 can affect the properties of the upper 120. For example, a yarn that forms the knitting element 131 can be a monofilament yarn or a multi-filament yarn. The yarn may also include separate filaments that are each formed by different materials. In addition, the yarn may include filaments that are each formed by two or more different materials, such as a two-component yarn with filaments that have a core-sheath configuration or two halves formed by different materials. Different degrees of twisting and pleating, as well as different deniers, can also affect the properties of the upper 120. Therefore, both the materials that form the yarn and other aspects of the yarn can be selected in order to print different properties to separate areas of the upper 120.
[046] With regard to the yarns that form the knitting element 131, the configuration of the embedded filament 132 can also vary significantly. In addition to the yarn, the embedded filament 132 may have the configuration of a filament (monofilament, for example), thread, rope, strips of fabric, cable or chain, for example. In comparison with the yarns forming the knitting element 131, the thickness of the embedded filament 132 may be greater. In some configurations, the embedded filament 132 may have a thickness significantly greater than that of the yarns of the knitting element 131. Although the cross-sectional conformation of the embedded filament 132 may be round, triangular, square, rectangular, elliptical, it can also be used irregular conformations. Furthermore, the materials that form the embedded filament 132 can include any of the materials for the yarn within the knitting element 131, such as cotton, spandex, polyester, rayon, wool and nylon. As noted above, the embedded filament 132 may have greater resistance to stretching than that of the knitting element 131. Therefore, materials suitable for the embedded filament 132 may include several engineering filaments that are used in applications with high tensile strength, including glass, aramides (para-aramid and meta-aramid, for example), ultra-high molecular weight polyethylene and liquid crystal polymer. As another example, a braided polyester thread can also be used as the embedded filament 132.
[047] An example of a suitable configuration for a part of the knitted component 130 is shown in Figure 8A. In this configuration, the knitting element 131 includes a yarn 138 that forms a plurality of interlaced loops that define several horizontal strokes and vertical reliefs. . The embedded filament 132 extends along one of the courses and alternates between being located (a) behind the loops formed from the wire 138 and (b) in front of the loops formed from the wire 138. In effect, the filament embossed 132 is woven through the structure formed by the knitting element 131. Although yarn 138 forms each of the strokes in this configuration, additional yarns may form one or more of the strokes or may form a part of one or more of the strokes.
[048] Another example of a suitable configuration for part of the knitted component 130 is shown in Figure 8B. In this configuration, the knitting element 131 includes a yarn 138 and another yarn 139. Yarns 138 and 139 are coated with metal and form in together, a plurality of interlaced loops that define various horizontal strokes and vertical high reliefs. That is, wires 138 and 139 run parallel to each other. Similar to the configuration of Figure 8A, the embedded filament 132 extends along one of the courses and alternates between being located (a) behind the loops formed from the threads 138 and 139 and (b) in front of the loops formed from yarns 138 and 139. An advantage of this configuration is that the properties of each yarn 138 and 139 can be present in this area of the knitted component 130. For example, yarns 138 and 139 can have different colors, with the color of yarn 138 being basically present on a surface of the various points on the knitting element 131 and the color of yarn 139 being basically present on the reverse surface of the various points on the knitting element 131. As another example, yarn 139 can be formed from a thread that is softer and more comfortable against the foot than thread 138, with thread 138 being basically present on the first surface 136 and thread 139 being basically present on the second surface 137.
[049] Continuing with the configuration of Figure 8B, yarn 138 can be formed from at least one thermostable polymeric material and natural fibers (cotton, wool, silk, for example), while yarn 139 can be formed from from a thermoplastic polymeric material. In general, a thermoplastic polymeric material melts when heated and returns to a solid state when cooled. More specifically, the thermoplastic polymeric material transitions from the solid state to the softening or liquid state when subjected to sufficient heat, and then the thermoplastic polymeric material transitions from the softening or liquid state to the solid state when sufficiently cooled. As such, thermoplastic polymeric materials are often used to join two objects or elements together. In this case, the wire 139 can be used to join (a) a part of the wire 138 to another part of the wire 138, (b) the wire 138 and the embedded filament 132 to each other or (c) another element (logos, brands registered and posters with care instructions and information about the material, for example) to the knitted component 130, for example. Thus, yarn 139 can be considered a fusible yarn since it can be used to fuse or otherwise join parts of the knitted component 130 to one another. Furthermore, yarn 138 can be considered a non-fusible yarn since it is not formed from materials that are generally capable of melting or otherwise joining parts of the knitted component 130 to one another. That is, wire 138 can be a non-fusible wire, whereas wire 139 can be a fusible wire. In some configurations of the knitted component 130, yarn 138 (i.e., non-fusible yarn) can be substantially formed from a thermostable polyester material and yarn 139 (i.e., fusible yarn) can be formed at least partially, from a thermoplastic polyester material.
[050] The use of metal-coated yarns can give advantages to the knitted component 130. When yarn 139 is heated and melted in yarn 138 and embedded filament 132, this process can have the effect of hardening or stiffening the structure of the yarn. knitted component 130. Furthermore, the joining (a) of a part of the yarn 138 with another part of the yarn 138 or (b) of the yarn 138 and the embedded filament 132 with each other has the effect of holding or locking the positions of wire 138 and embedded filament 132, thus imparting stretch resistance and rigidity. That is, parts of yarn 138 may not slip with respect to each other when fused with yarn 139, thereby preventing the knitting element 131 from permanently warping or stretching due to the relative movement of the knitting structure. Another benefit relates to the limitation of unraveling if a part of the knitted component 130 becomes damaged or one of the threads 138 is cut. In addition, the built-in filament 132 may not slide with respect to the knitting element 131, thereby preventing parts of the embedded filament 132 from being pulled out of the knitting element 131. Therefore, areas of the knitted component 130 they can benefit from the use of both the fusible yarn and the non-fusible yarn within the knitting element 131.
[051] Another aspect of knitted component 130 refers to a padded area adjacent to ankle opening 121 and which extends, at least partially, around ankle opening 121. With reference to Figure 7E, the padded area is formed by two superimposed and at least partially coextensive knitted layers 140, which can be formed by a unitary knitting construction, and a plurality of floating threads 141 that extend between the knitted layers 140. Although the sides or edges of the knitted layers 140 are attached each other, the central area is generally not fixed. Thus, the knitted layers 140 effectively form a tube or tubular structure, and the floating threads 141 can be located or embedded between the knitted layers 140 so as to pass through the tubular structure. That is, the floating yarns 141 extend between the knitted layers 140, are generally parallel to the surfaces of the knitted layers 140 and also pass through and fill an internal volume between the knitted layers 140. While most of the knitting element 131 is formed from threads that are mechanically handled so as to form interlaced loops, the floating threads 141 are generally free or otherwise embedded within the internal volume between the knitted layers 140. In addition, the knitted layers 140 can be formed, at least partially, from a stretchable thread. An advantage of this configuration is that the knitted layers will effectively compress the floating threads 141 and provide an aesthetic aspect to the padded area adjacent to the ankle opening 121. That is, the stretchable thread within the knitted layers 140 can be put under tension during the knitting process that forms the knitted component 130, thereby inducing the knitted layers 140 to compress the floating yarns 141. Although the degree of stretching in the stretch-able yarn can vary significantly, the stretch-able yarn it can be extended one hundred percent in many configurations of the knitted component 130.
[052] The presence of the floating threads 141 gives a compressible appearance to the padded area adjacent to the ankle opening 121, thereby increasing the comfort of the shoe 100 in the area of the ankle opening 121. Many conventional footwear incorporate polymeric or other foam elements compressible materials to areas adjacent to an ankle opening. In contrast to conventional footwear, parts of the knitted component 130 formed by a unitary knitting construction with the remainder of the knitted component 130 can form the padded area adjacent to the ankle opening 121. In other shoe configurations 100, padded areas similar ones can be located in other areas of the knitted component 130. For example, similar quilted areas can be located in an area that corresponds to the joints between the metatarsal bones and the proximal phalanges in order to fill the joints. Alternatively, a plush loop structure can also be used to print some degree of fill to areas of the upper 120.
[053] Based on the above discussion, the knitted component 130 prints several features to the upper 120. In addition, the knitted component 130 provides several advantages compared to some conventional upper configurations. As noted above, conventional shoe uppers are formed from various material elements (fabrics, polymeric foam, polymer sheets, leather, synthetic leather, for example) that are joined by stitch stitching or bonding, for example. As the number and types of material elements incorporated into the upper increase, the time and expense associated with transporting, storing, cutting and joining the material elements may increase as well. Residual material from the cutting and sewing processes also accumulates considerably as the number and types of material elements incorporated in the upper increase. Furthermore, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from a smaller number of material elements. By decreasing the number of material elements used in the upper, therefore, waste can be reduced by increasing the manufacturing efficiency and recycling capacity of the upper. For this, the knitted component 130 forms a substantial part of the upper 120, at the same time increasing the manufacturing efficiency, decreasing the residues and simplifying the recycling capacity. Other Knitted Component Settings
[054] A knitted component 150 is shown in Figures 9 and 10 and can be used in place of knitted component 130 in footwear 100. The basic elements of knitted component 150 are a knitting element 151 and a built-in filament 152. The knitting element knitting 151 is formed from at least one thread that is handled (a knitting machine, for example) in order to form a plurality of interlocking loops that define different courses and high reliefs. That is, the knitting element 151 has the structure of a knitting fabric. The built-in filament 152 extends through the knitting element 151 and passes between the various loops within the knitting element 151. Although the built-in filament 152 generally extends along strokes within the knitting element 151, the built-in filament 152 can also extend along high reliefs within the knitting element 151. Like the embedded filament 132, the embedded filament 152 provides resistance to stretching and, when incorporated into the shoe 100, works in connection with the cord 122 in order to perfect shoe fit 100.
[055] Knitting element 151 has a generally U-shaped configuration that is outlined by a perimeter edge 153, a pair of heel edges 154 and an inner edge 155. In addition, knitting element 151 has a first surface 156 and an opposing second surface 157. The first surface 156 can form a part of the outer surface of the upper 120, while the second surface 157 can form a part of the inner surface of the upper 120, thus defining at least a part of the void within the upper 120. In many configurations, knitting element 151 can be configured as a single textile layer in the area of embedded filament 152. That is, knitting element 151 can be a single textile layer between surfaces 156 and 157. In addition, the element of knitting 151 defines a plurality of drawstring openings 158.
[056] Similar to the embedded filament 132, the embedded filament 152 extends repeatedly from the perimeter edge 153 towards the inner edge 155, at least partially around one of the cord openings 158 and back to the perimeter edge 153 In contrast to the built-in filament 132, however, some parts of the built-in filament 152 slope back and extend to the heel edges 154. More specifically, the parts of the built-in filament 152 associated with the later drawstring openings 158 extend. from one of the heel edges 154 towards the inner edge 155, at least partially around one of the more posterior drawstring openings 158 and back to one of the heel edges 154. In addition, some parts of the embedded filament 152 do not extend around one of the bead openings 158. More specifically, some sections of the embedded filament 152 extend in the direction of the inner edge 155, saw in area They are adjacent to one of the drawstring openings 158 and extend backwards towards the perimeter edge 153 or one of the heel edges 154.
[057] Although the knitting element 151 can be formed in several ways, the strokes of the knitting structure generally extend in the same direction as the built-in filaments 152. In areas adjacent to the cord openings 153, however, the built-in filament 152 can also extend along high reliefs within the knitting element 151. More specifically, the sections of the embedded filament 152 which are parallel to the inner edge 155 can extend along the high reliefs.
[058] In comparison with the knitting element 151, the embedded filament 152 may have greater resistance to stretching. That is, the embedded filament 152 can stretch less than the knitting element 151. Since numerous sections of the embedded filament 152 extend through the knitting element 151, the embedded filament 152 can impart resistance to stretching to the upper parts 120 between the throat area and the lower area. In addition, putting tension on the cord 122 can put tension on the embedded filament 152, thereby inducing the parts of the upper 120 between the throat area and the lower area to be arranged against the foot. In addition, given that numerous sections of the embedded filament 152 extend towards the heel edges 154, the embedded filament 152 can provide resistance to stretching to parts of the upper 120 in the heel region 103. Furthermore, put tension on the cord 122 can induce the upper part 120 in the heel region 103 to be arranged against the foot. Thus, the embedded filament 152 works in connection with the cord 122 in order to improve the fit of the shoe 100.
[059] Knitting element 151 can incorporate any of the several types of yarn discussed above for knitting element 131. Embedded filament 152 can also be formed from any of the configurations and materials discussed above for embedded filament 132 In addition, the various knitting configurations discussed with respect to Figures 8A and 8B can also be used in the knitted component 150. More specifically, the knitting element 151 may have areas formed from a single yarn, two metal-coated yarns or a fusible wire and a non-fusible wire, with the fusible wire joining (a) a part of the non-fusible wire to another part of the non-fusible wire or (b) the non-fusible wire and the embedded filament 152 to each other.
[060] Most knitting element 131 is shown to be formed from relatively nonwoven fabric and a common or single knitting structure (a tubular knitting structure, for example). In contrast, the knitting element 151 incorporates several knitting structures that give specific properties and advantages to different areas of the knitted component 150. Furthermore, by combining different types of yarn with the knitting structures, the knitted component 150 you can print a range of properties to different areas of the upper 120. Referring to Figure 11, a schematic view of the knitted component 150 shows several zones 160-169 that have different knitting structures, each of which will now be discussed in detail. For reference purposes, each of the regions 101-103 and sides 104 and 105 is shown in Figure 11 in order to obtain reference to the locations of the knitting zones 160-169 when the knitted component 150 is incorporated into the shoe 100.
[061] A tubular knitting zone 160 extends along most of the perimeter edge 153 and through each of the regions 101-103 on both sides 104 and 105. The tubular knitting zone 160 also extends to inside from each side 104 and 105 in an area located approximately in the interface regions 101 and 102 so as to form the front of the inner edge 155. The tubular knitting zone 160 forms a relatively nonwoven knitting configuration . With reference to Figure 12A, a cross section is shown through an area of the tubular knitting zone 160, and the surfaces 156 and 157 are substantially parallel to each other. The tubular knitting zone 160 gives several advantages to footwear 100. For example, the tubular knitting zone 160 has greater durability and wear resistance than some other knitting structures, especially when the yarn in the tubular knitting zone 160 is coated with metal with a fusible wire. In addition, the relatively non-woven aspect of the tubular knitting zone 160 simplifies the process of joining the strobile sock 125 with the perimeter edge 153. That is, the part of the tubular knitting zone 160 located along the edge of the 153 facilitates the shoe duration process 100. For reference purposes, Figure 13A shows a circuit diagram of the way in which the tubular knitting zone 160 is formed with a knitting process.
[062] Two stretchable knitting zones 161 extend inwardly from the perimeter edge 153 and are located to correspond to the location of the joints between the metatarsal bones and the proximal phalanges of the foot. That is, the stretchable zones extend inwardly from the perimeter edge in the area located approximately in the interface regions 101 and 102. Similar to the tubular knitting zone 160, the knitting configuration in the knitting zones liable to stretch can be a tubular knitting structure. In contrast to the tubular knitting zone 160, however, the stretchable knitting zones 161 are formed from a stretchable yarn that imparts stretch and recovery properties to the knitted component 150. In spite of the degree of stretching in the Stretchable yarn can vary significantly, the stretchable yarn can stretch at least one hundred percent in many configurations of the knitted component 150.
[063] A tubular folding and interlocking knitting area 162 extends along part of the inner edge 155 at least in the middle foot region 102. The tubular folding and interlocking knitting area 162 also forms a configuration relatively nonwoven knitting, but thicker than the tubular knitting zone 160. In cross section, the tubular folding and interlock knitting zone 162 is similar to that of Figure 12A, in which the surfaces 156 and 157 are substantially parallel to each other. The tubular folding and interlocking knitting area 162 gives several advantages to shoes 100. For example, the tubular folding and interlocking knitting area 162 has greater resistance to stretching than that of some other knitting structures, which is beneficial when cord 122 puts the tubular pleating and interlock knitting zone 162 and the embedded filaments 152 in tension. For reference purposes, Figure 13B shows a circuit diagram of the way in which the tubular folding and interlocking knitting zone 162 is formed with the knitting process.
[064] A 1x1 mesh knitting area 163 is located in the front foot region 101 and spaced into the perimeter edge 153. The 1x1 mesh knitting area has a C-shaped configuration and forms a plurality of openings extending through the knitting element 151 and the first surface 156 to the second surface 157, as shown in Figure 12B. The openings increase the permeability of the knitted component 150, which allows air to enter the upper 120 and moisture to escape from the upper 120. For reference purposes, Figure 13C shows a circuit diagram of the way in which the knitting area of 1x1 163 mesh is formed with a knitting process.
[065] A 2x2 164 knitting zone extends adjacent to the 1x1 163 knitting zone. Compared to the 1x1 163 knitting zone, the 2x2 164 knitting zone forms larger openings, the which can further increase the permeability of the knitted component 150. For reference purposes, Figure 13D shows a circuit diagram of the way in which the 2x2 mesh knitting zone 164 is formed with a knitting process.
[066] A 3x2 165 knitting zone is located within the 2x2 164 knitting zone, and another 3x2 165 knitting zone is located adjacent to one of the stretchable 161 zones. knitting 1x1 163 and the knitting zone 2x2 164, the knitting zone 3x2 165 forms even larger openings, which can further increase the permeability of the knitted component 150. For reference purposes, Figure 13E shows a circuit diagram of the way in which the 3x2 165 knitting zone is formed with a knitting process.
[067] A 1x1 166 imitation knitting zone is located in the front foot region 101 and extends around the 1x1 163 knitting zone. In contrast to the 163-165 knitting zones, which they form openings through knitting element 151, the 1x1 imitation knitting zone 166 forms indentations on the first surface 156, as shown in Figure 12C. In addition to improving the aesthetic appearance of footwear 100, the 1x1 imitation knitting zone 166 can increase flexibility and decrease the total mass of the knitted component 150. For reference purposes, Figure 13F shows a circuit diagram of the way which the 1x1 166 imitation knitting zone is formed with a knitting process.
[068] Two 2x2 imitation knitting zones 167 are located in the heel 103 region and adjacent to the heel edges 154. In comparison to the 1x1 166 imitation knitting zone, the knitting zones of 2x2 imitation 167 form larger indentations on the first surface 156. In areas where the embedded filaments 152 extend through indentations in the 2x2 imitation knitting zones 167, as shown in Figure 12D, the embedded filament 152 can be visible and exposed in the lower indentations area. For reference purposes, Figure 13G shows a circuit diagram of the way in which imitation 2x2 167 knitting zones are formed with a knitting process.
[069] Two 2x2 168 hybrid knitting zones are located in the midfoot 102 region and in front of the imitation 2x2 167 knitting zones. The 2x2 168 hybrid knitting zones share the characteristics of the 2x2 knitting zone 164 and the imitation 2x2 167 knitting zones. More specifically, the 2x2 168 hybrid knitting zones form openings that are the size and configuration of the 2x2 164 knitting zone, and the 2x2 hybrid knitting zones 168 form indentations. that have the size and configuration of the imitation 2x2 167 knitting zones. In areas where the embedded filaments 152 extend through indentations in the 2x2 168 hybrid knitting zones, as shown in Figure 12E, the embedded filaments 152 are visible and exposed. For reference purposes, Figure 13H shows a circuit diagram of the way in which the 2x2 168 hybrid knitting zones are formed with a knitting process.
[070] Knitted component 150 also includes two padded areas 169 that have the general configuration of the padded area adjacent to ankle opening 121 and which extends, at least partially, around ankle opening 121, which was discussed above for the knitted component 130. Therefore, the quilted areas 169 are formed by two superimposed knitted layers and at least partially coextensive, which can be formed by a unitary knitting construction and a plurality of floating threads that extend between the knitted layers .
[071] A comparison between Figures 9 and 10 reveals that most of the warp in knitting element 151 is located on the first surface 156, and not on the second surface 157. That is, the indentations formed by the knitting areas of imitation mesh 166 and 167, as well as indentations in the 2x2 hybrid knitting zones 168, are formed on the first surface 156. This configuration has the advantage of increasing the comfort of the shoe 100. More specifically, this configuration places the configuration relatively of the second surface 157 against the foot. Another comparison between Figures 9 and 10 reveals that parts of the embedded filament 152 are exposed on the first surface 156, but not on the second surface 157. This configuration also has the advantage of increasing the comfort of the shoe 100. More specifically, by the spacing of the built-in filament 152 of the foot in a part of the knitting element 151, the built-in filaments 152 will not come into contact with the foot.
[072] Additional configurations of the knitted component 130 are shown in Figures 14A-14C. Although discussed with respect to the knitted component 130, the concepts associated with each of these configurations can also be used with the knitted component 150. With reference to Figure 14A, the embedded filaments 132 are absent from the knitted component 130. Although the embedded yarns 132 print stretch resistance to areas of the knitted component 130, some configurations may not require the stretch resistance of the embedded filaments 132. Furthermore, some configurations may benefit from greater stretching in the upper 120. With reference to Figure 14B, the knitting element 131 includes two flaps 142 which are formed by a unitary knitting construction with the remainder of knitting element 131 and extend along the length of knitted component 130 at the perimeter edge 133. When incorporated into footwear 100, flaps 142 they can replace the strobe sock 125. That is, the flaps 142 can together form a part of the upper 120 that is extended from under the sock lining 113 and is attached to the upper surface of the sock 111. With reference to Figure 14C, the knitted component 130 has a configuration that is limited to the middle foot region 102. In this configuration, other material elements (fabrics , polymeric foam, polymeric sheets, leather, synthetic curing, for example) can be joined to the knitted component 130 by sewing or bonding, for example, to form the upper 120.
[073] Based on the above discussion, each of the knitted components 130 and 150 can have different configurations that give features and advantages to the upper 120. More specifically, the knitting elements 131 and 151 can incorporate different knitting structures and types of yarn that print specific properties to areas other than the upper 120, and the embedded filaments 132 and 152 can extend through the knitting structures in order to impart resistance to stretching to the upper area 120 and work in connection with the cord 122 for improve the fit of shoes 100. Knitting Machine and Feeder Settings
[074] Although knitting can be carried out by hand, the commercial manufacture of knitted components is generally carried out by knitting machines. An example of a knitting machine 200 that is suitable for producing either one or the other of the knitted components 130 and 150 is shown in Figure 15. The knitting machine 200 has the configuration of a flat knitting machine with a V-bed for the purposes of exemplification, but both knitted components 130 and 150 or aspects of knitted components 130 and 150 can be produced on other types of knitting machine.
[075] The knitting machine 200 includes two needle beds 201 which are inserted with respect to each other, thus forming a V-bed. Each of the needle beds 201 includes a plurality of individual needles 202 which are arranged in a common plan. That is, the needles 202 of a bed of needles 201 are arranged in a foreground, and the needles 202 of the other bed of needles 201 are arranged in a background. The first plane and the second plane (i.e., the two needle beds 201) are angled with respect to each other and meet so as to form an intersection that extends over most of the width of the knitting machine 200. As described in more detail below, needles 202 each have a first position in which they retract and a second position in which they extend. In the first position, the needles 202 are moved away from the intersection where the first plane and the second plane meet. In the second position, however, the needles 202 pass through the intersection at which the first plane and the second plane meet.
[076] A pair of rails 203 extends above and parallel to the intersection of the needle beds 201 and provides attachment points for several standard feeders 204 and feeders in combination 220. Each rail 203 has two sides, each of which which accommodates either a standard feeder 204 or a feeder in combination 220. Thus, the knitting machine 200 can include a total of four feeders 204 and 220. As shown, the front rail 203 includes a feeder in combination 220 and a standard feeder 204 on opposite sides, and the rear rail 203 includes two standard feeders 204 on opposite sides. Although two rails 203 are shown, other configurations of the knitting machine 200 may incorporate additional rails 203 to provide attachment points for more feeders 204 and 220.
[077] Due to the action of a car 205, the feeders 204 and 220 move along the rails 203 and the needle beds 201, thus supplying threads to the needles 202. In Figure 15, a thread 206 is supplied to the feeder in combination 220 by a 207 spool. More specifically, the yarn 206 extends from the spool 207 to several yarn guides 208, a return spring 209 and a yarn tensioner 210 before entering the feeder in combination 220. Although not shown, spools Additional 207 can be used to supply wires to feeders 204.
[078] Standard feeders 204 are conventionally used in a flat V-bed knitting machine, such as the 200 knitting machine. That is, existing knitting machines incorporate standard 204 feeders. Each standard 204 feeder has the ability to supply a yarn that needles 202 handle to knit, fold and loop. As a comparison, feeders in combination 220 have the ability to supply a yarn (yarn 206, for example) that needles 202 knit, sew and loop with, and the feeder in combination 220 has the ability to embed the wire. In addition, the 220 feeder in combination has the ability to embed several different filaments (filament, thread, rope, fabric strips, cable, chain or wire). Therefore, the combination feeder 220 has greater versatility than each standard feeder 204.
[079] As noted above, the 220 feeder in combination can be used when embedding a thread or other filament, in addition to knitting, folding and looping with the thread. Conventional knitting machines, which do not incorporate the 220 combination feeder, can also embed a thread. More specifically, conventional knitting machines that are supplied with a built-in feeder can also embed a yarn. A conventional inlay feeder for a V-bed flat knitting machine includes two components that work together to embed the yarn. Each component of the built-in feeder is attached to separate attachment points on two adjacent rails, thus occupying two attachment points. While a standard 204 individual feeder occupies only one fixing point, two fixing points are generally occupied when a built-in feeder is used to embed a yarn in a knitted component. In addition, while a feeder in combination 220 occupies only one fixing point, a conventional feeder occupies two fixing points.
[080] Since the knitting machine 200 includes two rails 203, four fixing points are available on the knitting machine 200. If a conventional inlay feeder were used with the knitting machine 200, only two fixing points would be available for the standard feeders 204. When using the combination feeder 220 on the knitting machine 200, however, three attachment points are available for the standard feeders 204. Therefore, the combination feeder 220 can be used when embedding a thread or another filament, and the feeder in combination 220 has the advantage of occupying only one fixing point.
[081] The combination feeder 220 is shown individually in Figures 16-19 as including a conveyor 230, a feed arm 240 and a pair of actuating elements 250. Although most of the combination feeder 220 can be formed from metal materials (steel, aluminum, titanium, for example), parts of the conveyor 230, the feeding arm 240 and the actuating elements 250 can be formed from polymeric, ceramic or composite materials, for example. As discussed above, the combination feeder 220 can be used when embedding a thread or other filament, in addition to knitting, folding and looping with a thread. With reference to Figure 16 specifically, a part of the wire 206 is shown in order to exemplify the way in which a wire interfaces with the feeder in combination 220.
[082] The conveyor 230 has a generally rectangular configuration and includes a first cover element 231 and a second cover element 232, which are connected by four screws 233. The cover elements 231 and 232 define an internal cavity in which parts of the feed arm 240 and actuating elements 250 are located. The conveyor 230 also includes a fastener 234 which extends outwardly from the first cover element 231 to secure the feeder 220 to one of the rails 203. Although the configuration of the fastener 234 may vary, the fastener 234 is shown to include two protruding areas spaced apart that form a dovetail conformation, as shown in Figure 17. An inverse dovetail configuration on one of the rails 203 may extend into the dovetail conformation of the fixing element 234 in order to effectively connect the feeder in combination 220 to the trimming machine 200. It should also be noted that the second cover element 234 forms an elongated centrally located slot 235, as shown in Figure 18 .
[083] The feed arm 240 has a generally elongated configuration that extends through the conveyor 230 (i.e., the cavity between the cover elements 231 and 232) and outwardly from the underside of the conveyor 230. In addition to others elements, the feed arm 240 includes an actuating screw 241, a spring 242, a pulley 243, a loop 244 and a dispensing area 245. The actuating screw 241 extends outward from the feed arm 240 and is located inside the cavity between the cover elements 231 and 232. One side of the actuation screw 242 is also located inside the slot 235 in the second cover element 232, as shown in Figure 18. The spring 242 is attached to the conveyor 230 and the feed arm 240. More specifically, one end of spring 242 is attached to conveyor 230, and the opposite end of spring 242 is attached to feed arm 240. Pulley 243, loop 244 and dispensing area 245 are present on the arm from food 240 so as to form an interface with thread 206 or another filament. In addition, pulley 243, loop 244 and dispensing area 245 are configured to ensure that wire 206 or other filament passes smoothly through the feeder in combination 220, thus being supplied securely to needles 202. Again with Referring to Figure 16, wire 206 extends around pulley 243, through loop 244 and into dispensing area 245. In addition, wire 206 extends out of a dispensing tip 246, which is a region end of the feeding arm 240, to then supply the needles 202.
[084] Each of the actuating elements 250 includes an arm 251 and a plate 252. In many configurations of the actuating elements 250, each arm 251 is formed as a one-piece element with one of the plates 252. While the arms 251 are located outside the conveyor 230 and on the upper side of the conveyor 230, the plates 252 are located within the conveyor 250. Each of the arms 251 has an elongated configuration that defines an outer end 253 and an opposite inner end 254, and the arms 251 are positioned to define a space 255 between both internal ends 254. That is, the arms 252 are spaced apart. The plates 252 have a generally planar configuration. Referring to Figure 19, each of the plates 252 defines an opening 256 with an inclined edge 257. Furthermore, the actuating screw 241 of the feed arm 240 extends into each opening 256.
[085] The combination feeder configuration 220 discussed above provides a structure that facilitates the translation movement of the feeding arm 240. As discussed in more detail below, the translation movement of the feeding arm 240 selectively positions the dispensing tip - dora 246 at a location above or below the intersection of the needle beds 201. That is, the dispensing tip 246 has the ability to reciprocate through the intersection of the needle beds 201. An advantage of the translation movement of the feed arm 240 is that the feeder in combination 220 (a) provides yarn 206 for knitting, folding and looping when dispensing tip 246 is positioned above the intersection of needle beds 201 and (b) provides the thread 206 or other filament for embedding when the dispensing tip 246 is positioned below the intersection of the needle beds 201. Furthermore, the feed arm 240 performs m shuttle movement between the two positions, depending on the way in which the combination feeder 220 is being used.
[086] When reciprocating through the intersection of the needle beds 201, the feed arm 240 is moved from a retracted position to an extended position. When in the retracted position, the dispensing tip 246 is positioned above the intersection of the needle beds 201. When in the extended position, the dispensing tip 246 is positioned below the intersection of the needle beds 201. The dispensing tip 246 is closer conveyor 230 when the feed arm 240 is in the retracted position than when the feed arm 240 is in the extended position. Likewise, the dispensing tip 246 is further away from the conveyor 230 when the feed arm 240 is in the extended position than when the feed arm 240 is in the retracted position. In other words, the dispensing tip 246 moves away from the conveyor 230 when in the extended position, and the dispensing tip 246 moves closer to the conveyor 230 when in the recoil position.
[087] For reference purposes in Figures 16-20C, as well as in other figures discussed below, an arrow 221 is positioned adjacent to dispensing area 245. When arrow 221 points upward or in the direction of conveyor 230, the arm feed 240 is in the retract position. When arrow 221 points down or away from conveyor 230, the feed arm 240 is in the extended position. Therefore, by reference to the position of the arrow 221, the position of the feed arm 240 can be readily verified.
[088] The natural state of the feed arm 240 is the retraction position. That is, when no significant force is applied to the feeder areas in combination 220, the feed arm remains in the recoil position. With reference to Figures 16-19, for example, no forces or other influences are shown to interact with the feeder in combination 220, and the feed arm 240 is in the recoil position. The translational movement of the feed arm 240 can occur, however, when sufficient force is applied to one of the arms 251. More specifically, the translational movement of the feed arm 240 occurs when sufficient force is applied to one end. external units 253 and is directed to space 255. With reference to Figures 20A and 20B, a force 222 acts on one of the outer ends 253 and is directed to space 255, and the feed arm 240 is shown as having moved to the extended position. When removing force 222, however, the feed arm 240 will return to the retracted position. It should also be noted that Figure 20C shows the force 222 acting on the inner ends 254 and being directed outwards, and the feed arm 240 remains in the recoil position.
[089] As discussed above, feeders 204 and 220 move along rails 203 and needle beds 201 due to the action of carriage 205. More specifically, a drive screw inside carriage 205 comes into contact with feeders 204 and 220 in order to push the feeders 204 and 220 along the needle beds 201. With respect to the feeder in combination 220, the drive screw can come into contact either with one of the outer ends 253 or with one of the inner ends 254 of in order to push the feeder in combination 220 along the needle beds 201. When the drive screw comes into contact with one of the outer ends 253, the feed arm 240 is moved to the extended position and the dispensing tip 246 passes below the intersection of the needle beds 201. When the drive screw contacts one of the inner ends 254 and is located within space 255, the feed arm 24 0 remains in the recoil position and the dispensing tip 246 is above the intersection of the needle beds 201. Therefore, the area where the carriage 205 comes into contact with the feeder in combination 220 determines whether the feed arm 240 is in the position of recoil or in the extended position.
[090] The mechanical action of the feeder in combination 220 will now be discussed. Figures 19-20B show the feeder in combination 220 with the first cover element 231 removed, thus exposing the elements within the cavity in the conveyor 230. By comparing the Figure 19 with Figures 20A and 20B, it may be evident the way in which force 222 induces the feed arm 240 to translate. When force 222 acts on one end 253, one of the actuation elements 250 slides in the direction that is perpendicular to the length of the feed arm 240. That is, one of the actuation elements 250 slides horizontally in Figures 19-20B. The movement of one of the actuating elements 250 causes the drive screw 241 to contact one of the inclined edges 257. Since the movement of the actuating elements 250 is restricted to the direction that is perpendicular to the length of the feed arm 240 , the drive screw 241 rolls or slides against the inclined edge 257 and induces the feed arm 240 to move to the extended position. When removing the force 222, the spring 242 pulls the feed arm 240 from the extended position to the recoil position.
[091] Based on the above discussion, the feeder in combination 220 reciprocates between the recoil position and the extended position, depending on whether a thread or other filament is being used for knitting, tying and making loops or being used for inlay. Combination feeder 220 has a configuration in which the application of the force 222 induces the feed arm 240 to move from the recoil position to the extended position, and the removal of the power 222 induces the feed arm 240 to translate - from the extended position to the retraction position. That is, the combination feeder 220 has a configuration in which the application and removal of force 222 causes the feed arm 240 to reciprocate between the opposite sides of the needle beds 201. In general, the outer ends 253 actuation areas can be considered, which induce movement in the feed arm 240. In other feeder configurations in combination, the actuation areas can be in other locations or can respond to other stimuli in order to induce movement in the feed arm 240. For example, the actuation areas can be electrical inputs coupled to servo mechanisms that control the movement of the feeding arm 240. Therefore, the feeder in combination 220 can have several structures that work in the same general way as the configuration discussed above. Knitting Process
[092] The way in which the knitting machine 200 works to manufacture a knitted component will now be discussed in detail. Furthermore, the following discussion will demonstrate the operation of the feeder in combination 220 during a knitting process. Referring to Figure 21A, a part of the knitting machine 200 is shown that includes several needles 202, a rail 203, a standard feeder 204 and the feeder in combination 220. While the feeder in combination 220 is attached to the front side of the rail 203, the standard feeder 204 is attached to the rear side of rail 203. Wire 206 passes through the feeder in combination 220, and one end of wire 206 extends outward from dispensing tip 246. Although wire 206 is shown , any other filament (filament, thread, rope, fabric band, cable, chain or yarn, for example) can pass through the feeder in combination 220. Another yarn 211 passes through the standard feeder 204 and forms a part of a knitted component 260, and the loops of the yarn 211 that form the upper course of the knitted component 260 are retained by hooks located at the ends of the needles 202.
[093] The knitting process discussed here refers to the formation of the knitted component 260, which can be any knitted component, including knitted components that are similar to the knitted components 130 and 150. For the purposes of the discussion, only a relatively small section of the knitted component 260 is shown in the figures in order to allow the knitting structure to be shown. Furthermore, the scale or proportions of the various elements of the knitting machine 200 and the knitting component 260 can be improved in order to better show the knitting process.
[094] The standard feeder 204 includes a feeding arm 212 with a dispensing tip 213. Feeding arm 212 is angled to position the dispensing tip 213 in a location that is (a) centered between needles 202 and (b ) above the intersection of the needle beds 201. Figure 22A shows a schematic cross-sectional view of this configuration. Note that the needles 202 are arranged in different planes, which are inclined towards each other. That is, the needles 202 of the needle beds 201 are arranged in different planes. The needles 202 each have a first position and a second position. In the first position, which is shown in full line, the needles 202 are recessed. In the second position, which is shown in dashed line, the needles 202 are extended. In the first position, the needles 202 are moved away from the intersection in which the planes in which the needle beds 201 are arranged are located. In the second position, however, the needles 202 are extended and pass through the intersection at which the planes on which the needle beds 201 meet. That is, the needles 202 cross each other when extended to the second position. It should be noted that the dispensing tip 213 is located above the intersection of the planes. In this position, the dispensing tip 213 supplies the yarn 211 to the needles 202 for the purpose of knitting, folding and making loops.
[095] The feeder in combination 220 is in the recoil position, as evidenced by the orientation of arrow 221. The feed arm 240 extends downwards from the conveyor 230 in order to position the dispensing tip 246 in a location which is (a) centered between needles 202 and (b) above the intersection of needle beds 201. Figure 22B shows a schematic cross-sectional view of this configuration. Note that the dispensing tip 246 is positioned in the same relative location as the dispensing tip 213 of Figure 22A.
[096] With reference now to Figure 21B, the standard feeder 204 moves along the rail 203 and a new stroke is formed in the knitted component 260 from the yarn 211. More specifically, the needles 202 pull sections of the yarn 211 through the ties from the previous course, thus forming the new course. Therefore, strokes can be added to the knitted component 260 by moving the standard feeder 204 along the needles 202, thus allowing the needles 202 to handle the yarn 211 and form additional loops from the yarn 211.
[097] Continuing with the knitting process, the feed arm 240 now moves from the recoil position to the extended position, as shown in Figure 21C. In the extended position, the feed arm 240 extends downwardly from the conveyor 230 in order to position the dispensing tip 246 in a location that is (a) centralized between the needles 202 and (b) below the intersection of the needles 201. Figure 22C shows a schematic cross-sectional view of this configuration. Note that the dispensing tip 246 is positioned above the location of the dispensing tip 246 in Figure 22B due to the translation movement of the feeding arm 240.
[098] With reference now to Figure 21D, the feeder in combination 220 moves along rail 203 and yarn 206 is placed between loops of knitted component 260. That is, yarn 206 is located in front of some loops and behind other loops of an alternating pattern. In addition, yarn 206 is placed in front of loops that are held by needles 202 on one bed of needles 201, and yarn 206 is placed behind loops that are held by needles 202 on the other bed of needles 201. Note- the feed arm 240 remains in the extended position so as to arrange the thread 206 in the area below the intersection of the needle beds 201. This effectively places the thread 206 within the newly formed course by the standard feeder 204 in Figure 21B.
[099] In order to complete the inlay of the wire 206 in the tri-dimensioned component 260, the standard feeder 204 moves along the rail 203 in order to form a new course from the wire 211, as shown in Figure 21E . By forming the new course, yarn 206 is effectively knitted within or otherwise integrated into the structure of knitted component 260. At this stage, the feed arm 240 can also be moved from the extended position to the retracted position.
[0100] Figures 21D and 21E show separate movements of feeders 204 and 220 along rail 203. That is, Figure 21D shows a first movement of the feeder in combination 220 along rail 203, and Figure 21E shows a second and subsequent movement of the standard feeder 204 along rail 203. In many knitting processes, feeders 204 and 220 can effectively move simultaneously to embed yarn 206 and form a new course from yarn 211. The feeder in combination 220, however, it moves in front of or in front of the standard feeder 204 so as to position the wire 206 before the new course is formed from the wire 211.
[0101] The knitting process outlined in the discussion above provides an example of the way in which the embedded filaments 132 and 152 can be located on the knitting elements 131 and 151. More specifically, the knitted components 130 and 150 can be formed using the combination feeder 220 in order to effectively embed the embedded filaments 132 and 152 in the knitting elements 131. Given the reciprocating action of the feed arm 240, the embedded filaments can be located within a previously formed course before the formation of a new course.
[0102] Continuing with the knitting process, the feed arm 240 now moves from the recoil position to the extended position, as shown in Figure 21F. The combination feeder 220 then moves along the rail 203 and the yarn 206 is placed between the loops of the knitted component 260, as shown in Figure 21G. This effectively places the wire 206 into the course formed by the standard feeder 204, as shown in Figure 21E. In order to complete the embedding of the yarn 206 in the knitted component 260, the standard feeder 204 moves along the rail 203 in order to form a new course from the yarn 211, as shown in Figure 21H. By forming the new course, yarn 206 is effectively knitted within or otherwise integrated into the structure of knitted component 260. At this stage, the feed arm 240 can also be moved from the extended position to the retracted position.
[0103] With reference to Figure 21H, wire 206 forms a loop 214 between the two embedded sections. In the discussion above of the knitted component 130, it was observed that the embedded filament 132 repeatedly leaves the knitting element 131 at the perimeter edge 133 and then re-enters the knitting element 131 at another location of the perimeter edge 133, thus forming loops along the perimeter edge 133, as shown in Figures 5 and 6. Loop 214 is formed in a similar manner. That is, loop 214 is formed where the yarn 206 leaves the knitting structure of the knitted component 260 and then enters the knitting structure again.
[0104] As discussed above, the standard feeder 204 has the ability to supply a yarn (yarn 211, for example) that needles 202 handle for knitting, folding and making loops. The combination feeder 220, however, has the ability to provide a thread (thread 206, for example) that needles 202 knit, fold or loop with, as well as embed the thread. The above discussion of the knitting process describes the way in which the combination feeder 220 embeds a thread while in the extended position. The combination feeder 220 can also supply the yarn for knitting, folding and making loops while in the recoil position. Referring to Figure 21I, for example, the feeder in combination 220 moves along the rail 203 while in the recoil position and forms a course of the knitted component 260 while in the recoil position. Therefore, by the reciprocating movement of the feed arm 240 between the recoil position and the extended position, the feeder in combination 220 can supply the thread 206 for the purposes of knitting, pleating, looping and embedding. An advantage of the combination feeder 220 is, therefore, its versatility in providing a yarn that can be used in a greater number of functions than those of the standard feeder 204.
[0105] The capacity of the feeder in combination 220 to provide yarn for knitting, pleating, looping and inlay is based on the reciprocating action of the feed arm 240. With reference to Figures 22A and 22B, the dispensing tips 213 and 246 are in identical positions with respect to needles 202. Therefore, both feeders 204 and 220 can provide a thread for knitting, folding and making loops. Referring to Figure 22C, the dispensing tip 241 is in a different position. As such, the 220 combination feeder can provide wire or other filament for inlay. An advantage of the 220 feeder in combination, therefore, refers to its versatility in providing a yarn that can be used in knitting, nailwork, looping and inlaying. Other Considerations for the Knitting Process
[0106] Additional aspects regarding the knitting process will now be discussed. Referring to Figure 23, the upper course of the knitted component 260 is formed from both yarns 206 and 211. More specifically, the left side of the course is formed from yarn 211, while the right side of the course is formed from wire 206. In addition, wire 206 is embedded in the left side of the stroke. In order to form this configuration, the standard feeder 204 can initially form the left side of the stroke from the wire 211. The combined feeder 220 then inserts the wire 206 on the right side of the stroke while the feed arm 240 is in the extended position. Then, the feed arm 240 moves from the extended position to the recoil position and forms the right side of the stroke. Therefore, the feeder in combination can embed a thread in one part of a course and then supply the thread for the purpose of knitting the rest of the course.
[0107] Figure 24 shows a knitting machine configuration 200 that includes four feeders in combination 220. As discussed above, the feeder in combination 220 has the ability to provide a yarn (yarn 206, for example) for knitting, pleating , execution of loops and inlay. Given this versatility, standard feeders 204 can be replaced by several feeders in combination 220 on knitting machines 200 or on several conventional knitting machines.
[0108] Figure 8B shows a configuration of the knitted component 130 in which two threads 138 and 139 are coated with metal to form the knitting element 131, and the embedded filament 132 extends through the knitting element 131. The The general knitting process discussed above can also be used to form this configuration. As shown in Figure 15, the knitting machine 200 includes several standard feeders 204, and two of the standard feeders 204 can be used to form the knitting element 131, with the feeder in combination 220 depositing the embedded filament 132. Therefore, the The knitting process discussed above in Figures 21A-21I can be modified with the addition of another standard feeder 204 to provide an additional yarn. In configurations in which yarn 138 is a non-fusible yarn and yarn 139 is a fusible yarn, the knitted component 130 can be heated after the knitting process to melt the knitted component 130.
[0109] The part of the knitted component 260 shown in Figures 21A-21I has the configuration of a knit fabric in the form of rib with regular and uninterrupted strokes and embossments. That is, the part of the knitted component 260 does not, for example, have mesh areas similar to the 163165 mesh knitting areas or imitation mesh areas similar to the imitation knitting areas 166 and 167. In order to form the knitting zones 163-165 in one or other of the knitted components 150 and 160, a combination of a bed of needles arranged on shelves 201 and a transfer of sewing loops from the previous bed of needles 201 to the back and back to the previous 201 needle beds in different shelf positions. In order to form imitation mesh areas similar to the imitation knitting zones 166 and 167, a combination of needle bed arranged on shelves and a transfer of sewing loops from the previous 201 needle beds to the posterior ones is used.
[0110] Strokes within a knitted component are generally parallel to each other. Since most of the embedded filament 152 follows courses within the knitting element 151, it can be suggested that the various sections of the embedded filament 152 are parallel to each other. With reference to Figure 9, for example, some sections extend between the edges 153 and 154. Several sections of the embedded filament 152 are therefore not parallel. The concept of basting can be used to print this configuration not parallel to the embedded filament 152. More specifically, strokes of variable length can be formed to effectively insert wedge-shaped structures between the sections of the embedded filament 152. The structure formed in the knitted component 150, therefore, in which several sections of the embedded filament 152 are not parallel, can be obtained through the process of forming basting.
[0111] Although most of the embedded filaments 152 follow courses within the knitting element 151, some sections of the embedded filament 152 follow high reliefs. For example, the sections of the embedded filament 152 that are adjacent and parallel to the inner edge 155 follow high reliefs. This can be achieved by first inserting a section of the embedded filament 152 along a part of a course and to the point at which the embedded filament 152 is intended to follow a high relief. The built-in filament 152 is then driven back so as to move the built-in filament 152 out of the way at the point where the built-in filament 152 is intended to follow the emboss, and the course is completed. This process is repeated until the embedded filament 152 extends along the desired distance along the relief. Similar concepts can be used for parts of the embedded filament 132 in the knitted component 130.
[0112] Several procedures can be used to reduce the relative movement between (a) the knitting element 131 and the embedded filament 132 or (b) the knitting element 151 and the embedded filament 152. That is, several procedures can be used to prevent embedded filaments 132 and 152 from sliding, moving, being pulled out or otherwise being displaced from knitting elements 131 and 151. For example, the merging of one or more yarns that are formed from thermoplastic polymeric materials into the embedded filaments 132 and 152 can prevent movement between the embedded filaments 132 and 152 and the knitting elements 131 and 151. In addition, the embedded filaments 132 and 152 can be attached to the knitting elements 131 and 151 when periodically fed to knitting needles such as a pleating element. That is, the embedded filaments 132 and 152 can be formed at folding points at points along their lengths (one per centimeter, for example) in order to attach the embedded filaments 132 and 152 to the knitting elements 131 and 151 and prevent movement of the embedded filaments 132 and 152.
[0113] Following the knitting process described above, several operations can be performed to improve the properties of both knitted components 130 and 150. For example, a water-repellent coating or other water-resistant treatment can be applied to limit the ability of knitting structures to absorb and retain water. As another example, the knitted components 130 and 150 can be steam treated in order to improve the molding room and induce the melting of the threads. As discussed above with reference to Figure 8B, wire 138 can be a non-fusible wire and wire 139 can be a fusible wire. When treated with steam, wire 139 may fuse or otherwise soften in order to transition from the solid state to the softening or liquid state and then transition from the softening or liquid state to the solid state when sufficiently cooled. Accordingly, yarn 139 can be used to join (a) a part of yarn 138 to another part of yarn 138, (b) yarn 138 and embedded filament 132 to each other or (c) another element (logos, brands registered and posters with care instructions and information about the material, for example) to the knitted component 130, for example. Therefore, a steam treatment process can be used to induce the melting of the yarns in the knitted components 130 and 150.
[0114] Although the procedures associated with the steam treatment process can vary considerably, one method involves pinning one of the knitted components 130 and 150 to a mold during steam treatment. An advantage of pinning one of the knitted components 130 and 150 to a mold is that the dimensions resulting from specific areas of the knitted components 130 and 150 can be controlled. For example, the pins in the mold can be located to hold areas that correspond to the perimeter edge 133 of the knitted component 130. By retaining specific dimensions for the perimeter edge 133, the perimeter edge 133 will have the correct length for a part of the process of duration that joins the upper 120 to the sole structure 110. Therefore, the attachment areas of the knitted components 130 and 150 can be used to control the resulting dimensions of the knitted components 130 and 150 following the steam treatment process.
[0115] The knitting process described above to form the knitted component 260 can be applied to the manufacture of the knitted components 130 and 150 for the footwear 100. The knitting process can also be applied to the manufacture of several other knitted components. That is, the knitting processes that use one or more feeders in combination or other feeders with reciprocating movement can be used to form several knitted components. Therefore, the knitted components formed by the knitting process described above, or by a similar process, can also be used in other types of clothing (shirts, pants, socks, jackets, underwear, shoes, for example), athletic equipment (golf bags, baseball and football gloves, football restraint structures, for example), containers (fillers, bags, for example) and upholstery for furniture (chairs, sofas, car seats, for example ). Knitted components can also be used in bed covers (sheets, blankets, for example), table covers, towels, flags, tents, candles and parachutes. Knitted components can be used as technical fabrics for industrial purposes, including structures for automotive and aerospace applications, filter materials, medical fabrics (bandages, cotton wicks, implants, for example), geotextiles to reinforce dikes, agotized for crop protection and industrial clothing that protects and insulates against heat and radiation. Therefore, knitted components can be incorporated into various products for both personal and industrial purposes.
[0116] The invention is revealed above and in the attached figures with reference to various configurations. The purpose of the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. Those skilled in the art will recognize that numerous variations and modifications can be made in the configurations described above without abandoning the scope of the present invention, defined by the appended claims.

权利要求:
Claims (5)
[0001]
1. Method for knitting including the steps of: using a knitting machine (200) that has a first feeder (204) that dispenses a thread (206), a second feeder (220) that dispenses a filament and a bed of needles ( 201) which includes a plurality of needles (202); moving at least the first feeder (204) along the bed of needles (201) to form a first course of a knitting component (150) from the yarn (206); move the first feeder and the second feeder (220) along the needle bed (201) to (a) form a second course of the knitting component (150) from the yarn and (b) embedding the filament in the knitting component (150), the second feeder (220) being located in front of the first feeder (204), where a dispenser tip (246) of the second feeder (220) is located below a dispenser tip (213) of the first feeder ( 204); the method being CHARACTERIZED by: reciprocating from a position of the dispensing tip (246) of the second feeder (220) from a position that is on one side of an area where the needles (202) cross each other up to a opposite side of the area where the needles (202) cross each other.
[0002]
2. Method according to claim 1, CHARACTERIZED by the fact that it additionally includes a step of reciprocating movement from a position of the dispensing tip (246) of the second feeder (220) in a vertical direction.
[0003]
3. Method, according to claim 1, CHARACTERIZED by the fact and that additionally includes a step of selecting the thread (206) to be formed, at least partially, from a thermoplastic polymeric material.
[0004]
4. Method according to claim 3, CHARACTERIZED by the fact that the knitting machine (200) additionally includes having a third feeder (204) that dispenses a thread (206) entirely formed from at least one of a material thermostable polymer and natural fibers.
[0005]
5. Method according to claim 1, CHARACTERIZED by the fact that the knitting machine (200) additionally includes a third feeder (204) that dispenses with a second yarn (206), and additionally includes a step of incorporating the second yarn (206) within at least one of the first course and the second course.

类似技术:

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公开号 | 公开日 | 专利标题

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BR112013021989B1|2021-02-02|knitting method

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US20180168276A1|2018-06-21|Article of footwear incorporating a knitted component

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US20190082790A1|2019-03-21|Knitted footwear component with an inlaid ankle strand

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US9481953B2|2016-11-01|Combination feeder for a knitting machine

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US9445640B2|2016-09-20|Article of footwear incorporating a knitted component with a tongue

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TWI598051B|2017-09-11|Knitted footwear component with an inlaid ankle strand

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TWI634849B|2018-09-11|Knitted component with adjustable inlaid strand for an article of footwear

同族专利:

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公开号 | 公开日

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KR20140019373A|2014-02-14|

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CN103518011A|2014-01-15|

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EP3333291A1|2018-06-13|

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CN105671765A|2016-06-15|

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WO2012125490A2|2012-09-20|

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EP2686468A2|2014-01-22|

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US20170145604A1|2017-05-25|

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US9567696B2|2017-02-14|

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CN105671765B|2018-01-19|

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US20120234052A1|2012-09-20|

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US10822729B2|2020-11-03|

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JP6029182B2|2016-11-24|

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HK1225765B|2017-09-15|

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BR112013021989A2|2016-11-16|

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CN103518011B|2016-02-10|

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US20210047762A1|2021-02-18|

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US9060570B2|2015-06-23|

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EP2686468B1|2018-04-25|

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WO2012125490A3|2012-11-15|

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US20140245544A1|2014-09-04|

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HK1190762A1|2014-07-11|

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KR101521038B1|2015-05-15|

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JP2014514464A|2014-06-19|

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法律状态:
2017-07-04| B25A| Requested transfer of rights approved|Owner name: NIKE INNOVATE C.V. (US) |

---

2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

---

2019-07-16| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|

---

2020-07-21| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

---

2020-11-24| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

---

2021-02-02| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 09/03/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US13/048,540|US9060570B2|2011-03-15|2011-03-15|Method of manufacturing a knitted component|

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US13/048,540|2011-03-15|

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