DOUBLE KNIT UPPER COMPRISING FUNCTIONAL TUCKED-IN YARNS

Abstract

A double layer knitted element includes a first layer comprising a first yarn, a second layer comprising a second yarn, and a third yarn arranged at least in part between the first and second layer. The third yarn is attached to at least one of the first layer and the second layer by a plurality of tuck stitches, wherein there is at least one miss stitch between two successive tuck stitches of the third yarn.

Claims

1. A double layer knitted element comprising: a first layer comprising a first yarn; a second layer comprising a second yarn; and a third yarn arranged at least in part between the first and second layer, wherein the third yarn is attached to at least one of the first layer and the second layer by a plurality of tuck stitches, and wherein there is at least one miss stitch between two successive tuck stitches of the third yarn.

2. The double layer knitted element of claim 1, wherein the third yarn comprises a functional yarn.

3. The double layer knitted element of claim 2, wherein the functional yarn is at least one of a melting yarn, thermoplastic polyurethane yarn, water repellent yarn, volume yarn, puff yarn, natural fiber yarn, cellulose yarn, hybrid yarn, anti-microbial yarn, or a conductive yarn.

4. The double layer knitted element of claim 2, wherein the functional yarn is a yarn with at least one of the following properties: heat resistance, UV protection, moisture absorbance, water resistance, heat retention, chemical resistance, flame resistance, or moisture wicking capability.

5. The double layer knitted element of claim 2, wherein the functional yarn is a yarn with at least one of the following properties: compression, shrinkability, cushioning, conduction, insulation, or durability.

6. The double layer knitted element of claim 1, wherein the third yarn is attached to only one of the first and second layer by tuck stitches in the respective layer.

7. The double layer knitted element of claim 1, wherein the third yarn is attached to at least one of the first and the second layer by immediately successive tuck stitches.

8. The double layer knitted element of claim 1, wherein a ratio between the number of tuck stitches and the number of miss stitches varies within a course.

9. The double layer knitted element of claim 1, wherein the ratio between the number of tuck stitches and the number of miss stitches is 1:1, 1:2, or 1:3.

10. The double layer knitted element of claim 1, wherein a distance between two successive tuck stitches is less than 2.54 cm.

11. The double layer knitted element of claim 1, wherein the first yarn of the first layer is attached to the second layer by tuck or loop stitches, or the second yarn of the second layer is attached to the first layer by tuck or loop stitches.

12. The double layer knitted element of claim 1, wherein the third yarn is knitted at least twice in between two knitting rows.

13. The double layer knitted element of claim 1, wherein the third yarn is partially knitted in a certain portion of the knitting row.

14. The double layer knitted element of claim 1, wherein the third yarn is attached to the first layer by a plurality of tuck stitches, and wherein the third yarn is not visible at the second layer.

15. The double layer knitted element of claim 1, wherein the thickness of the third yarn varies within the knitted element.

16. The double layer knitted element of claim 1, wherein the third yarn is provided in repetitive structures, jacquard structures, or in spacer-based structures.

17. The double layer knitted element of claim 1, wherein the element is manufactured by intarsia, interlock, plating, inverted plating, or inlay techniques.

18. An upper for a shoe comprising a double layer knitted element of claim 1.

19. A shoe comprising: the upper of claim 18; and a sole attached to the upper.

20. A method of manufacturing a double layer knitted element, the method comprising the steps of: providing a first layer comprising a first yarn; providing a second layer comprising a second yarn; and arranging a third yarn at least in part between the first and second layer, wherein the third yarn is attached to at least one of the first and second layer by a plurality of tuck stitches, and wherein there is at least one miss stitch between two successive tuck stitches of the third yarn.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Aspects of the present disclosure will be described in more detail with reference to the following figures:

[0043] FIGS. 1A-C show a knitting scheme for a double layer knitted element with two layers and a third tucked-in yarn according to some embodiments.

[0044] FIG. 2 shows a knitting scheme for a double layer knitted element with two layers and a third tucked-in yarn knitted twice in between two knitting rows according to some embodiments.

[0045] FIGS. 3A-B show a knitting scheme for a double layer knitted element with two layers and a third tucked-in yarn with a different ratio between the number of tuck stitches and the number of miss stitches according to some embodiments.

[0046] FIG. 4 shows a knitting scheme for a double layer knitted element with a third tucked-in yarn knitted twice in between two knitting rows according to some embodiments.

[0047] FIG. 5 shows a knitting scheme for a double layer knitted element with jacquard structures and a third tucked-in yarn according to some embodiments.

[0048] FIGS. 6A-C show a knitting scheme for a double layer knitted element using different knitting techniques according to some embodiments.

[0049] FIG. 7 shows a knitting scheme for a double layer knitted element with a spacer and a third tucked-in yarn according to some embodiments.

[0050] FIG. 8 shows a knitting scheme for a double layer knitted element and a third tucked-in yarn with a varying ratio between the number of tuck stitches and the number of miss stitches within the same course according to some embodiments.

[0051] FIG. 9 shows a knitting scheme for a double layer knitted element and a partially tucked-in third yarn according to some embodiments.

[0052] FIGS. 10A-B show a knitting scheme and section of a double layer knitted element and a tucked-in third yarn using Intarsia knitting technique according to some embodiments.

[0053] FIG. 11 shows a flow diagram illustrating a method of manufacturing a double layer knitted element of the present disclosure according to some embodiments.

[0054] FIG. 12 shows an isometric view of a shoe having a double layer knitted element according to some embodiments.

DETAILED DESCRIPTION

[0055] In the following, embodiments of the present disclosure are described in more detail referring to a double layer knitted element, in particular for a sports article. While specific combinations of features are described in relation to the exemplary embodiments of the present disclosure, it is to be understood that the disclosure is not limited to such embodiments. In particular, not all features need to be present in order to realize the present disclosure, and the embodiments may be modified by combining certain features of one embodiment with one or more features of another embodiment. For example, the present disclosure can be used for a shoe upper, clothing, or accessories where various functional properties like stiffness, elasticity, stretch, recovery or compression are required, without influencing the appearance.

[0056] The use of a third tucked-in yarn enables a double knitted element that comprises desired functional properties while it still has an uninfluenced outward appearance. The various functional properties comprise stiffness, elasticity, stretch, recovery, or compression, for example. The techniques used in order to achieve such properties or functions will be described in the following.

[0057] The described techniques include suitable knitting techniques comprising different combinations of the number of tuck and miss stitches of the third yarn, as well as the selection of fibers and yarns. These and other techniques will be explained in the following, before embodiments of shoe uppers will be described in which these techniques are applied.

[0058] FIGS. 1A-C show knitting schemes of a double layer knitted structure, wherein the dots represent the needle positions of a knitting machine in a knitting row. In particular, the knitting scheme of FIGS. 1A-C comprises two lines of needles provided within a row.

[0059] FIG. 1A illustrates a first layer 100 (e.g. the front layer) comprising a first yarn 110, a second layer 200 (e.g. the back layer) comprising a second yarn 210, and a third yarn 310 arranged at least in part between the first layer 100 and the second 200 layer, wherein the third yarn 310 is attached to the second 200 layer by a plurality of tuck stitches 311. In some embodiments, the third yarn 310 may be attached to the first layer 100 by a plurality of tuck stitches 311. As illustrated in FIG. 1A there is at least one miss stitch 312 between two successive tuck stitches 311 of the third yarn 310. In some embodiments, for example in FIG. 1A, the ratio between the number of tuck stitches and the number of miss stitches, which corresponds to the tuck-miss ratio, is 1:1.

[0060] In some embodiments, the main double layer knit structure is independent of the tucked-in yarn. The tucked-in yarn is an addition to the existing structure and is sandwiched in between the two layers.

[0061] FIG. 1A illustrates that the third yarn 310 is only attached to the second layer 200 by immediately successive tuck stitches 311, wherein the third yarn 310 is not attached to the first layer 100.

[0062] In some embodiments, when using melt or TPU yarns as the third yarn 310, stiffness can be applied to only one of the two layers.

[0063] In some embodiments, stiffness is achieved within the fabric without affecting its external appearance.

[0064] In some embodiments, the first 110 and second 210 yarns may be different. In some embodiments, the first 110 and second 210 yarns may be equal.

[0065] In some embodiments, as illustrated in FIG. 1A, the first layer 100 is connected to the second layer 200 by tuck stitches.

[0066] FIG. 1B illustrates a section of a front layer 100 of an exemplary double knitted element comprising a first yarn 110, wherein FIG. 1C illustrates a section of a back layer 200 comprising a second yarn 210. In FIGS. 1B and 1C, a melting yarn 310 is connected (tucked) to the back layer 200. In particular, the melting yarn 310 is absorbed mostly by the back layer 200 (a bit also by the inner side of the front layer 100) after thermal activation. The external side of the front layer 100 does not present melting yarn 310 (e.g., melting yarn 310 is not exposed at the front layer 100), as shown in FIG. 1B. Thus, further post processes can be applied to the front side of the fabric, without using or reactivating the melted yarn 310 underneath the front layer 100. As shown, for example, in FIG. 1C, the first yarn 110 of the front layer 100 may be attached to the back layer 200 by tuck or loop stitches.

[0067] In some embodiments, the third yarn is locked to the fabric because of the tucks. Compared to the tucked-in third yarn of the present disclosure, inlay strands would be free floating inside the double layer fabric and could be removed from the knitted fabric if pulled.

[0068] Further, in various embodiments of the present disclosure, the third yarn may comprise a functional yarn.

[0069] In some embodiments, the functional yarn can be at least one of a melting yarn, thermoplastic polyurethane (TPU) yarn, water repellent yarn, volume/puff yarn, natural fiber yarn (e.g. wool and cotton), cellulose yarn, hybrid yarn, anti-microbial (anti-bacterial) yarn (e.g. copper, zinc, silver, etc.), elastic yarn, conductive yarn, or at least one of a yarn with at least one of a heat resistance, UV protection, heat retention, moisture absorbance, water resistance, chemical resistance, flame resistance, moisture wicking capability, or at least one of a yarn with a compression, shrinkability, cushioning, conductive, insulation, durability property.

[0070] In some embodiments, applications of knitting a conductive yarn could be heating certain parts of the upper or for transferring electricity to LED lights in the upper or tooling, wherein wool yarns can heat up the upper and cotton yarns can absorb moisture.

[0071] FIG. 2 shows an exemplary embodiment wherein the third yarn 310a can be tucked in the first layer 100, e.g. on the front stitches from row 110, in a first knitting step, and the third yarn 310b can be tucked in the second layer 200, e.g. on the back stitches from the previous row 210, not shown here, in a second knitting step, by immediately successive tuck stitches.

[0072] FIGS. 3A and 3B illustrate knitting schemes having different ratios between the number of tuck stitches and the number of miss stitches of the third yarn 310.

[0073] In some embodiments, for example as illustrated in FIG. 3A, there are two miss stitches 312 between two successive tuck stitches 311 of the third yarn 310, wherein the ratio between the number of tuck stitches 311 and the number of miss stitches 312 is 1:2. FIG. 3B shows a knitting scheme, with three miss stitches 312 between two successive tuck stitches 311 of the third yarn 310, wherein the ratio between the number of tuck stitches 311 and the number of miss stitches 312 is 1:3.

[0074] In some embodiments, the support (with respect to stiffness or stretch properties) of a double layer knitted element can be engineered by the tuck-miss ratio. More tucks close to one another provide a higher amount of the third yarn 310. Thus, a tuck-miss ratio of 1:1 provides a higher support than 1:2, wherein 1:2 provides a higher support compared to 1:3 and so on.

[0075] In some embodiments, a distance between two successive tuck stitches may be less than 2.54 cm (one inch). In particular, 2.54 cm of the needle bed of a knitting machine corresponds to 14 needles on a gauge 14 machine or 7 needles on a gauge 7 machine, wherein the gauge of a knitting machine corresponds to the number of needles in 2.54 cm which corresponds to 1 inch. For safety reasons, floats are usually kept shorter than 2.54 cm. If the floats are longer, there is the risk that the needles are not catching the yarn.

[0076] In some embodiments, for example as shown in FIGS. 3A and 3B, the first layer 100 is attached to the second layer 200 by loop stitches. In some embodiments, for example as shown in FIGS. 3A and 3B, the third yarn 310 is only attached to the second layer 200 by immediately successive tuck stitches 311 to the second layer 200, i.e. there are no tuck stitches of the third yarn 310 in the first layer 100.

[0077] In some embodiments, the third yarn is attached to at least one of the first and the second layer by tuck stitches. For example, the third yarn 310 may be tucked to the first layer 100 and the second layer 200. In some embodiments, the third yarn may be tucked to only the first layer by immediately successive tuck stitches.

[0078] In some embodiments, as shown for example in FIG. 4, the third yarn 310 is knitted at least twice in between two knitting rows. In this embodiment, there are at least two courses of the third yarn 310 knitted in between two knitting rows. In particular, the third yarn 310 is knitted in a first knitting sequence 301 (for example tuck-miss going to right) and in a second knitting sequence 302 (miss-tuck going to the left), which increases the support of the third yarn 310 on the double layer knitted element.

[0079] In some embodiments, knitting the third yarn 310 several times in between two knitting rows can be used for example to increase the stiffness of a fabric.

[0080] In some embodiments, the amount of support can also be engineered by using finer or thicker yarns (150 den to 900 den). In some embodiments, a melt yarn can have a thickness of 2,000 den and for sock knit even more is possible. In particular, higher denier means thicker yarns.

[0081] In some embodiments, as shown for example in FIG. 4, the first layer 100 is attached to the second layer 200 by loop stitches.

[0082] In some embodiments, as shown for example in FIG. 4, the third yarn 310 is only attached to the second layer 200 by immediately successive tuck stitches 311 to the second layer 200 and not to the first layer.

[0083] In some embodiments, not explicitly shown here, the third yarn 310 may be tucked only to the first layer 100, or tucked to the first layer 100 and the second layer 200 by using tuck stitches.

[0084] In some embodiments, the third yarn is independent of and can be combined with all double knit structures. That means that the structure can stay the same, but with function (e.g., stretch, stiffness, and conductive yarn) being applied in various places of the upper.

[0085] In some embodiments, the third yarn can be inserted in repetitive structures as shown for example in FIGS. 1-4 or in jacquard structures, as shown in FIG. 5.

[0086] In some embodiments, the tucked-in third yarn may be combined with knitting techniques such as partial knitting, intarsia (zone knitting), plating, inverted plating, devore, inlay, etc.

[0087] In some embodiments, as shown for example in FIGS. 6A-C, knitting structures using a functional third yarn 310 illustrates an interlock structure with a third yarn.

[0088] In some embodiments, the third yarn can also be inserted in spacer-based structures, as shown, for example, in FIG. 7. In FIG. 7, a spacer layer 400 and the third yarn 310 are alternately knitted in between two knitting rows of the first layer 100 and the second 200 layer.

[0089] FIG. 8 illustrates an embodiment of the present disclosure, wherein the ratio between the number of tuck stitches and the number of miss stitches is variable within a course or a row. In particular, the amount of support in different portions (510, 520) within the same row of the knitting element, can be engineered by the tuck-miss ratio. In some embodiments, as shown for example in FIG. 8, a first portion (510) includes a tuck-miss ratio of 1:3 and a second portion (520) includes a tuck-miss ratio of 1:1. More tucks close to one another will add more yarn in that specific portion.

[0090] A variation of the tuck-miss ratio of the third yarn in different areas can provide different stretch or stiffness properties in the respective areas. In contrast to that, an inlay strand has the same property along its width.

[0091] In some embodiments, the ratio between the number of tuck stitches and the number of miss stitches can be at least one of 1:1, 1:2, or 1:3.

[0092] In some embodiments, as shown for example in FIG. 9, the third yarn 310 is partially knitted in a certain portion of a knitting row. In FIG. 9, the third yarn 310 is provided once in a first portion 530, wherein the third yarn is provided multiple (e.g. three) times in another portion 540.

[0093] In some embodiments, partial knitting of the third yarn, as shown for example in FIG. 9, can provide different support by keeping the same tuck-miss ratio but knitting different amounts of the third yarn 310 in a certain portion of the knitting row or area of the double layer element.

[0094] Further, partially knitting the third yarn is technically easier compared to an inlay strand. The reason is that the third yarn is connected by tuck to the fabric and it will not jump out when the knitting direction is changed.

[0095] FIGS. 10A-B illustrate an embodiment with an efficient placement of a third yarn 310 in a double-knitted element by using Intarsia knitting. In some embodiments, special zones can be engineered on the knitted element to have special properties through intarsia. In some embodiments, as shown for example in FIG. 10A, the third yarn 310 is knitted, in a double-jersey knit, multiple times in immediately successive courses in a portion of the knitted element between the front 100 and back layers 200. In addition, the third yarn 310 is attached to the first 100 and the second 200 layer by alternating tuck-miss stitches.

[0096] In some embodiments, a third yarn 310 with an elastomer material may be used to generate reinforced areas after the application of heat. Besides elastomer, other polymer based yarns can also be used that provide a reinforcing effect on application of heat, pressure or other treatments.

[0097] Further, due to the knitting method, no pre-twisting of materials is needed and manual labor is reduced and high-performance upper materials can be created.

[0098] FIG. 10B shows a section of a double-knitted element by using Intarsia knitting, in a double-jersey knit, wherein the third yarn 310 is attached to the first 100 and the second 200 layer by alternating tuck-miss stitches. By using tuck-stiches of the third yarn 310 to both layers, the third yarn 310 is visible in both layers (e.g. first layer 100 of FIG. 10B).

[0099] In some embodiments, as shown, for example, in FIG. 12, an upper 15 for a shoe 10, in particular a sports shoe, may be provided, which comprises a double layer knitted element 20 according to the present disclosure.

[0100] In some embodiments, a shoe 10, in particular a sports shoe, may comprise an upper 15, which comprises a double layer knitted element 20 of the present disclosure and a sole 25, which is attached to the upper 15.

[0101] FIG. 11 shows a flow diagram illustrating a method of manufacturing a double layer knitted element according to the present disclosure and as described in more detail above. In step 1110, a first layer comprising a first yarn is provided. In step 1120, a second layer comprising a second yarn is provided. In step 1130, a third yarn is at least in part arranged between the first and second layer, wherein the third yarn is attached to at least one of the first and second layer by a plurality of tuck stitches, wherein there is at least one miss stitch between two successive tuck stitches of the third yarn.