Knitted shoe upper with integral eyelets

Abstract

The present invention relates to a shoe upper including a knitted component having a plurality of integrally knitted lines of loops including a set of consecutive lines, wherein each line in the set of consecutive lines includes a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and not interlooped with loops of a line which is not contained in the set, and wherein the set of consecutive lines forms at least a portion of an eyelet which is configured to receive a lace.

Claims

1. A shoe upper, comprising: a knitted component, comprising: a plurality of integrally knitted lines of loops comprising a set of consecutive lines, wherein each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set, wherein the set of consecutive lines forms at least a portion of an eyelet which is configured to receive a lace, wherein a first line in the set of consecutive lines extends from a first end of the eyelet to a second end of the eyelet and comprises a first number of loops, and a second line not contained in the set comprises all loops between a loop adjacent the first end of the eyelet and a loop adjacent the second end of the eyelet and comprises a second number of loops, and wherein the first number is higher than the second number.

2. The shoe upper according to claim 1, wherein the first line in the set of consecutive lines and a first adjacent line not contained in the set form a first aperture in the knitted component, wherein a last line in the set of consecutive lines and a second adjacent line not contained in the set form a second aperture in the knitted component, and wherein the first aperture and the second aperture are configured for the lace to pass through the first and second apertures.

3. The shoe upper according to claim 2, wherein a number of loops of a line located between the first line and the last line in the set of consecutive lines is higher than the number of loops of the first line and the last line.

4. The shoe upper according to claim 1, wherein the knitted component comprises at least one fusible yarn in the area of the set of consecutive lines.

5. The shoe upper according to claim 1, further comprising an inner knitted layer and an outer knitted layer in a unitary knit construction, wherein the inner knitted layer and the outer knitted layer are connected at least in a collar region of the shoe upper, and wherein the outer knitted layer is put over the inner knitted layer or, wherein the inner knitted layer is inserted into the outer knitted layer.

6. The shoe upper according to claim 5, wherein the set of consecutive lines is located on the outer knitted layer.

7. The shoe upper according to claim 5, wherein the inner knitted layer and the outer knitted layer overlap in an area of the set of consecutive lines.

8. The shoe upper according to claim 7, wherein the inner knitted layer and the outer knitted layer are not connected in the area of the set of consecutive lines.

9. The shoe upper according to claim 5, wherein the inner knitted layer and the outer knitted layer overlap in an area of an instep of the shoe upper and are not connected in the area of the instep.

10. The shoe upper according to claim 1, wherein the knitted component comprises at least one elastic yarn in an area of the set of consecutive lines.

11. A method of manufacturing a shoe upper, the method comprising: providing a knitted component; providing the knitted component with a plurality of integrally knitted lines of loops comprising a set of consecutive lines, such that each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set; forming the set of consecutive lines as at least a portion of an eyelet which is configured to receive a lace; forming a first aperture in the knitted component using a first line in the set of consecutive lines and a first adjacent line not contained in the set; forming a second aperture in the knitted component using a last line in the set of consecutive lines and a second adjacent line not contained in the set; and configuring the first aperture and the second aperture, such that the lace is configured to pass through the first and second apertures.

12. The method according to claim 11, further comprising: knitting the set of consecutive lines by means of partial knitting.

13. The method according to claim 11, further comprising arranging at least one fusible yarn in an area of the set of consecutive lines.

14. The method according to claim 11, further comprising the steps: providing an inner knitted layer and an outer knitted layer in a unitary knit construction; connecting the inner knitted layer and the outer knitted layer at least in a collar region of the shoe upper; and putting the outer knitted layer over the inner knitted layer or inserting the inner knitted layer into the outer knitted layer to form the shoe upper.

15. The method according to claim 14, further comprising forming the set of consecutive lines on the outer knitted layer.

16. The method according to claim 11, further comprising the step of providing at least one elastic yarn in an area of the set of consecutive lines.

17. The method according to claim 11, further comprising placing a pin inside the eyelet formed by the set of consecutive lines and maintaining the pin in the eyelet during heat setting the shoe upper.

18. The method according to claim 11, further comprising heat setting the shoe upper.

19. A shoe upper, comprising: a knitted component, comprising: a plurality of integrally knitted lines of loops comprising a set of consecutive lines, wherein each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set, wherein the set of consecutive lines forms at least a portion of an eyelet which is configured to receive a lace, wherein a first line in the set of consecutive lines and a first adjacent line not contained in the set form a first aperture in the knitted component, wherein a last line in the set of consecutive lines and a second adjacent line not contained in the set form a second aperture in the knitted component, wherein the first aperture and the second aperture are configured to receive the lace through the first and second apertures, and wherein a number of loops of a line located between the first line and the last line in the set of consecutive lines is higher than the number of loops of the first line and the last line.

20. A shoe upper, comprising: a knitted component, comprising: a plurality of integrally knitted lines of loops comprising a set of consecutive lines, wherein each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set, and wherein the set of consecutive lines forms at least a portion of an eyelet which is configured to receive a lace, and an inner knitted layer and an outer knitted layer in a unitary knit construction, wherein the inner knitted layer and the outer knitted layer are connected at least in a collar region of the shoe upper, and wherein the outer knitted layer is put over the inner knitted layer or, wherein the inner knitted layer is inserted into the outer knitted layer.

21. A method of manufacturing a shoe upper, the method comprising: providing a knitted component; providing the knitted component with a plurality of integrally knitted lines of loops comprising a set of consecutive lines, such that each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set; forming the set of consecutive lines as at least a portion of an eyelet which is configured to receive a lace; providing an inner knitted layer and an outer knitted layer of the knitted component in a unitary knit construction; connecting the inner knitted layer and the outer knitted layer at least in a collar region of the shoe upper; and putting the outer knitted layer over the inner knitted layer or inserting the inner knitted layer into the outer knitted layer to form the shoe upper.

22. A method of manufacturing a shoe upper, the method comprising: providing a knitted component; providing the knitted component with a plurality of integrally knitted lines of loops comprising a set of consecutive lines, such that each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set; forming the set of consecutive lines as at least a portion of an eyelet which is configured to receive a lace; and placing a pin inside the eyelet formed by the set of consecutive lines of loops and maintaining the pin in the eyelet during heat setting the shoe upper.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The presently preferred embodiments of the invention are described in the following detailed description with reference to the following figures:

(2) FIGS. 1A and 1B show an embodiment of a shoe upper 10 according to the present invention.

(3) FIGS. 2A and 2B show another embodiment of a shoe upper 10 according to the present invention.

(4) FIGS. 3A and 3B show details of the construction of eyelets according to the present invention.

(5) FIG. 4A shows the usage of pins to stabilize the eyelets.

(6) FIG. 4B shows an alternative embodiment to the embodiment of FIG. 4A.

(7) FIG. 4C shows another alternative embodiment to the embodiments of FIGS. 4A and 4B.

(8) FIG. 4D shows the usage of a comb- or spider-like construction to stabilize the eyelets.

(9) FIGS. 5A, 5B and 5C show the construction used in the example of FIG. 4D in more detail.

(10) FIGS. 6A and 6B show the usage of elastic yarn in the eyelets according to the present invention.

(11) FIGS. 7A and 7B show details of eyelets according to the present invention.

(12) FIGS. 8A, 8B, 8C and 8D show an embodiment of a shoe according to the present invention.

(13) FIG. 9 shows an exemplary knitting sequence to create an eyelet according to the present invention.

(14) FIG. 10A shows a side view of a shoe having eyelets according to an embodiment of the present invention.

(15) FIG. 10B shows a front view of the shoe of FIG. 10A having lace loops and a shoe lace according to an embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(16) FIGS. 1A and 1B show an embodiment of a shoe upper 10 according to the present invention. In this embodiment, the shoe upper 10 is made from two sock-like layers 11 and 12 which are connected at a collar region 13 of the respective sock-like layers 11 and 12. In the embodiment of FIGS. 1A and 1B, both layers are made as one piece in a single knitting process on a small circular knitting machine, i.e. as a unitary knit construction. The two socks 11 and 12 are created as a continuous, preferably single jersey, cylinder-shaped knitted fabric. Generally, in the context of the present invention the shoe upper may have a different number of layers, e.g. just a single layer. In case of two layers, the layers may also be made separately and then joined, e.g. by linking, sewing, welding, gluing, etc. Also, instead of a small circular knitting machine, a medium or large circular knitting machine or a flat knitting machine may be used. The machine may have one, two or even more than two needle beds. Generally, in the context of the present invention, weft-knitting or warp-knitting may be used. Suitable knitting yarns may be based on synthetic materials like polyester, but natural yarns, such as cotton, may be used as well.

(17) Coming back to the embodiment of FIGS. 1A and 1B, the layer 11 is the outer layer of the shoe upper 10, whereas the layer 12 is the inner layer of the shoe upper 10. The outer layer 11 is put over the inner layer 12 and both layers are joined at their respective free ends 13 and 14 for example by linking, sewing, welding or gluing. Since the socks 11 and 12 are each made as a cylinder, they comprise openings at their respective free ends 13 and 14 which are also closed by this process. The openings are preferably longitudinal on the bottom of the layers (socks), so that the seam can be completely hidden by the sole. In the final shoe upper 10, the connected free ends will be arranged in a sole area of the shoe upper 10 and, therefore, will not be visible. The inner layer 12 is inserted into the outer layer 11. Alternatively, the outer layer 11 may be put over inner layer 12. Putting over the outer layer 11 over the inner layer 12 may be done on a last.

(18) The outer layer 11 of the embodiment of FIGS. 1A and 1B is a knitted component of the shoe upper 10. In this embodiment, the knitted component makes up a large portion of the shoe upper 10. In other embodiments, the knitted component may be smaller and only make up a portion of the shoe upper 10. Other portions of the shoe upper may then be made from different materials, e.g. leather, artificial leather, woven, non-woven, mesh, etc.

(19) The knitted component, i.e. the outer layer 11 comprises a plurality of integrally knitted lines of loops. Generally, a knitted fabric is obtained by interlooping at least one yarn so that lines of loops are obtained. In the context of the present invention, a line may either be a course or a wale. The knitted component 11 comprises a set of consecutive lines, wherein each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set. Thus, the loops of the lines of this set are connected to only to loops within the same line or to adjacent loops of an adjacent line within the set, but not to loops of lines which are not contained in the set. In this way, the set of consecutive lines forms at least a portion of an eyelet which is configured to receive a lace 16. In the embodiment of FIGS. 1A and 1B, three of those eyelets are denoted by the reference numeral 15. FIG. 1A shows the shoe upper 10 without a lace, wherein in FIG. 1B, a lace 16 has been threaded through the eyelets 15.

(20) In the example of FIGS. 1A and 1B, the set of consecutive lines is obtained by means of partial knitting. In partial knitting, a group of loops is formed by knitting, while other loops are held in a non-knit position. Partial knitting may be performed by a knitting machine programmed accordingly. Partial knitting provides the eyelets of the shoe upper directly during knitting as integrated structures.

(21) FIGS. 2A and 2B show a similar embodiment of a shoe upper 10 as FIGS. 1A and 1B. The shoe upper 10 is a sock-in-sock construction, wherein in the embodiment of FIGS. 2A and 2B the socks have been placed one into the other, in particular by placing the inner sock inside the outer sock. As shown in FIG. 2B, the openings at the respective free ends of the inner and outer sock are closed by a longitudinal seam 21 on the bottom of the socks, i.e. in a sole area.

(22) FIGS. 3A and 3B show details of the construction of the eyelets 15 according to the present invention, wherein FIG. 3A shows the front side of a single-jersey knitted component 11 and FIG. 3B shows the back side of the single-jersey knitted component 11, wherein the two areas of the eyelets 15 on the front side are emphasized by the rectangles 31. As shown in FIG. 3A, the eyelets 15 are formed by lines of loops. Three of those lines are exemplarily denoted by the reference numeral 31. The loops of those lines 31 are interlooped with loops of the respective line, but also with loops of adjacent lines 31 pertaining to the set of consecutive lines. The lines of loops making up an eyelet 15 form a set of consecutive lines. The knitted component 11 also comprises other lines of loops which are not contained in this set. Three of those lines have been exemplarily denoted by the reference numeral 32. The lines 31 in the set of consecutive lines of loops making up an eyelet 15 are not interlooped with the lines 32. In this way, two apertures are created at the sides of the eyelet 15 through which a lace may be threaded.

(23) To provide stability to the eyelets 15, a fusible yarn may be located in the lines of the set of consecutive lines of loops making up an eyelet 15. To activate the fusible yarn, the shoe upper 10 is heat set by placing it for example in a steaming box at a temperature of about 100° C. To stabilize the eyelets during heat setting, pins may be placed inside the eyelets 15 formed by the set of consecutive lines of loops. This is shown in FIG. 4A, where three of those pins are exemplarily denoted by the reference numeral 41. The pins 41 may be made from metal or any other material that is able to resist the heat during heat setting of the upper and especially the fusible yarn. In a preferred embodiment, pins 41 have a length of 52 mm and a diameter of 5 mm.

(24) FIG. 4B depicts an alternative embodiment of the pins shown in FIG. 4A. The pins in the example have different lengths and are provided in corresponding holders 43.

(25) FIG. 4C depicts yet another embodiment of pins 41 which is presently preferred. The pins 41 in this example are made from a soft material. The soft material allows each pin 41 (or finger) to be flexible and bend, to be easily inserted in each eyelet and to adapt to each eyelet. The pins 41 are long enough to be placed through both sets of lace holes (on the lateral and medial sides). In the exemplary embodiment, five pins are connected by a common base 44. Therefore, for example, only two of these constructions are needed for one shoe. Of course, in other embodiments, a different number of pins 41 may be provided on a common base.

(26) In an alternative embodiment depicted in FIG. 4D a comb- or spider-like construction 42 is used to stabilize the eyelets 15 during heat setting. This constructions in depicted in more detail in FIGS. 5A, 5B and 5C, wherein FIG. 5A shows a front view, FIG. 5B shows a side view and FIG. 5C shows an oblique view. The construction 42 comprises a main body 51 from which pins 41 project. The construction allows insertion of multiple pins 41 into corresponding eyelets 15 at the same time and in a single step. The construction 42 may be obtained by a 3D-printing process.

(27) FIGS. 6A and 6B show an embodiment of a shoe upper 10 according to the invention, wherein an elastic yarn has been added to the eyelets 15. In this embodiment, the eyelets 15 do not comprise a fusible yarn. The elastic yarn is sufficient to stabilize eyelets even when heat setting the shoe upper 10 to stabilize the shape of the shoe upper 10. No specific heat setting steps for fusing fusible yarn on the eyelets 15 is needed in this case. Also, it is not required to place pins in the eyelets 15 during heat setting.

(28) FIGS. 7A and 7B show details of the eyelets 15 of shoe uppers according to the present invention. The set of consecutive lines of loops making up an eyelet 15 comprises a first line 71. The loops of this line are interlooped with corresponding loops of an adjacent line of the set, but not interlooped with loops of an adjacent line 72 not contained in the set. In this way, an aperture 73 is created through which a lace may be threaded. The eyelet 15 comprises a similar aperture on the opposite side. The shoe uppers depicted in FIGS. 7A and 7B are based on a sock-in-sock construction as described above. The outer layer 11 covers the inner layer 12. In the exemplary embodiment of FIG. 7A, the outer layer 11 comprises a number of openings through which the inner layer 12 is visible.

(29) FIGS. 8A, 8B, 8C and 8D show an embodiment of a shoe 80 according to the invention. The shoe comprises a shoe upper 10 according to the invention as described herein and a sole structure 81 attached to the shoe upper 10.

(30) The sole structure 81 is attached to the shoe upper 10 by direct injecting PU sole material onto shoe upper 10. Other means of attaching the sole 81 to the upper 10 in the context of the present invention are of course possible.

(31) The shoe upper 10 comprises a knit element comprising a number of eyelets 15 formed by a set of lines of loops comprising a set of consecutive lines, wherein each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and not interlooped with loops of a line which is not contained in the set. As shown in FIG. 8D, the eyelets 15 are configured to receive a lace 16.

(32) FIG. 9 shows an exemplary knitting sequence to obtain eyelets 15 in a knitted component as described herein. The knitting sequence can be provided to a knitting machine as a suitable program and the eyelets 15 can be obtained by partial knitting.

(33) FIGS. 10A and 10B show a shoe upper 20 having a double-layer construction with an inner knitted layer and an outer knitted layer 22. The inner and outer knitted layers may have a unitary knit construction and may be knit together. The inner and outer knitted layers are connected to one another at least at a collar region of the shoe upper as described herein (see, e.g., FIGS. 1A and 1B). The outer knitted layer 22 may be put over the inner knitted layer or the inner knitted layer may be inserted into the outer knitted layer 22 to provide a shoe having a double-layer construction.

(34) In some embodiments, the inner knitted layer and the outer knitted layer may overlap in the area of the set of consecutive lines of loops. The inner knitted layer and the outer knitted layer may not be connected in the area of the set of consecutive lines of loops. In some embodiments, inner knitted layer and the outer knitted layer may overlap in an area of an instep of the shoe upper and may not be connected in the area of the instep.

(35) The outer knitted layer 22 may include one or more eyelets 25. Eyelets 25 may be formed as described above with respect to eyelets 15. Each eyelet 25 may be configured to receive a lace loop 26. The lace loop 26 extends from the inner knitted layer through the eyelet 25 of the outer knitted layer 22 so that the lace loop 26 is exposed on an exterior of the outer knitted layer 22. The lace loop 26 is configured to receive a lace 28. The lace loop 26 defines an aperture 27 configured to receive the lace 28 therethrough. The lace 28 extends through lace loops 26 rather than through the eyelets 25.

(36) The lace loop 26 may be knitted in a similar manner as the eyelet 25 of the outer knitted layer 22. However, the lace loop 26 is knitted in the inner knitted layer. The length of the lace loop 26 may be greater than a length of the eyelet 25 of the outer knitted layer 22 such that the lace loops 26 may extend out from and beyond the eyelet 25. The knitted lace loops 26 form a knitted in double-loop lacing system that provides a uniformly distributed pulling strength that is distributed over the whole shoe upper. The knitted lace loops 26 provide an increase in tensile strength while relieving pressure on the foot. As a result, greater comfort is achieved. The knitted lace loops 26 further provide flexibility in choosing the directions in which the lacing system can be arranged.

(37) Some embodiments described herein relate to a shoe upper comprising a knitted component comprising a plurality of integrally knitted lines of loops comprising a set of consecutive lines, wherein each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set, and wherein the set of consecutive lines forms at least a portion of an eyelet which is configured to receive a lace.

(38) In any of the various embodiments described herein, the set of consecutive lines may be knitted by means of partial knitting.

(39) In any of the various embodiments described herein, the lines of the set of consecutive lines may be wales.

(40) In any of the various embodiments described herein, the eyelet may have a width between 5 mm and 15 mm.

(41) In any of the various embodiments described herein, the set of consecutive lines may comprise 2 to 10 lines.

(42) In any of the various embodiments described herein, the lines in the set of consecutive lines of loops may have a length between 10 mm and 30 mm.

(43) In any of the various embodiments described herein, each line in the set of consecutive lines of loops may comprise 15 to 25 loops.

(44) In any of the various embodiments described herein, the fusible yarn may be located only in the lines of the set of consecutive lines of loops.

(45) In any of the various embodiments described herein, the fusible yarn may be selected from a polyester yarn, a polyamide yarn, and a urethane-based yarn.

(46) In any of the various embodiments described herein, the knitted component may comprise at least one elastic yarn in the area of the set of consecutive lines of loops, and the elastic yarn is located only in the lines of the set of consecutive lines of loops. In some embodiments, the elastic yarn is more elastic than another yarn of the knitted component.

(47) Some embodiments described herein relate to a shoe comprising a shoe upper as described herein, and a sole structure attached to the shoe upper.

(48) Some embodiments described herein relate to a method of manufacturing a shoe upper, the method comprising providing a knitted component, providing the knitted component with a plurality of integrally knitted lines of loops comprising a set of consecutive lines, such that each line in the set of consecutive lines comprises a plurality of consecutive loops which are interlooped with adjacent loops of the respective line and are not interlooped with loops of a line which is not contained in the set, and forming the set of consecutive lines as at least a portion of an eyelet which is configured to receive a lace.

(49) In any of the various embodiments described herein, the plurality of integrally knitted lines of loops may be wales.

(50) In any of the various embodiments described herein, a first line in the set of consecutive lines may extend from a first end of the eyelet to a second end of the eyelet and comprises a first number of loops, and a second line not contained in the set may comprise all loops between a loop adjacent the first end of the eyelet and a loop adjacent the second end of the eyelet and comprises a second number of loops, wherein the first number is higher than the second number.

(51) In any of the various embodiments described herein, the eyelet may have a width between 5 and 15 mm.

(52) In any of the various embodiments described herein, the set of consecutive lines may comprise 2 to 10 lines.

(53) In any of the various embodiments described herein, the lines in the set of consecutive lines of loops may have a length between 10 mm and 30 mm.

(54) In any of the various embodiments described herein, each line in the set of consecutive lines of loops may comprise 15 to 25 loops.

(55) In any of the various embodiments described herein, the number of loops of a line located between the first line and the last line in the set of consecutive lines of loops may be higher than the number of loops of the first and the last line.

(56) In any of the various embodiments described herein, the method may further comprise arranging the fusible yarn only in the lines of the set of consecutive lines of loops.

(57) In any of the various embodiments described herein, the fusible yarn may be selected from a polyester yarn, a polyamide yarn and a urethane-based yarn.

(58) In any of the various embodiments described herein, the method may further include providing an inner knitted layer and an outer knitted layer in a unitary knit construction, connecting the inner knitted layer and the outer knitted layer at least in a collar region of the shoe upper, and putting the outer knitted layer over the inner knitted layer or inserting the inner knitted layer into the outer knitted layer to form the shoe upper. In some embodiments, the inner knitted layer and the outer knitted layer may overlap in the area of the set of consecutive lines of loops. In some embodiments, the inner knitted layer and the outer knitted layer may not be connected in the area of the set of consecutive lines of loops. In some embodiments, the inner knitted layer and the outer knitted layer may overlap in the area of the instep of the upper and may not be connected in the area of the instep.

(59) In any of the various embodiments described herein, the method may further comprise the steps of providing at least one elastic yarn in the area of the set of consecutive lines of loops, and arranging the elastic yarn only in the lines of the set of consecutive lines of loops. In some embodiments, the elastic yarn is more elastic than another yarn of the knitted component.

(60) In any of the various embodiments described herein, the method may further comprise using a small circular knitting machine for providing the knit component.

(61) Some embodiments described herein relate to a shoe upper obtained by a method as described herein.