Search

EP-4740775-A1 - KNITTED UPPER WITH INTEGRALLY KNITTED ELEMENT

EP4740775A1EP 4740775 A1EP4740775 A1EP 4740775A1EP-4740775-A1

Abstract

The present invention relates to an upper (1) for a shoe, comprising a knitted main part (2), wherein the main part (2) is adapted to form at least a part of a void for receiving a foot of a wearer of the shoe; a knitted flap (3); and a knitted transition part (4) connecting the flap (3) to the main part (2), wherein the main part (2), the flap (3) and the transition part (4) form a unitary knit construction, and wherein the transition part (4) comprises a different knit structure and/or a different yarn and/or yarn combination and/or yarn placement compared to the main part (2) and/or to the flap (3).

Inventors

  • FILIPESCU, FLORIN
  • POPESCU, Claudiu-Ionut
  • Tamm, Stefan
  • Klaas, Annika

Assignees

  • adidas AG

Dates

Publication Date
20260513
Application Date
20251106

Claims (15)

  1. Upper (1) for a shoe, comprising: a. a knitted main part (2), wherein the main part (2) is adapted to form at least a part of a void for receiving a foot of a wearer of the shoe; b. a knitted flap (3); and c. a knitted transition part (4) connecting the flap (3) to the main part (2), d. wherein the main part (2), the flap (3) and the transition part (4) form a unitary knit construction, and e. wherein the transition part (4) comprises a different knit structure and/or a different yarn and/or yarn combination and/or yarn placement compared to the main part (2) and/or to the flap (3).
  2. Upper (1) according to claim 1, wherein: the knit structure of the transition part (4) comprises a first layer and a second layer overlapping the first layer and, wherein the first layer comprises a different number of rows compared to the second layer; and/or the transition part (4) comprises at least one row comprising a plurality of loops the majority of which are frontside loops and at least one another row comprising a plurality of loops the majority of which are backside loops; and/or the knit structure of the transition part (4) is a single layer structure.
  3. Upper (1) according to claim 1 or 2, wherein the transition part (4) comprises a first yarn, wherein the first yarn is different from a second yarn of the main part (2) and/or the flap (3); preferably wherein: the first yarn is more elastic than the second yarn; and/or the first yarn comprises a different color than the second yarn.
  4. Upper (1) according to one of claims 1-3, wherein the transition part (4) comprises a frontside layer and a backside layer and, wherein the frontside layer comprises a more elastic yarn than the backside layer, or the backside layer comprises a more elastic yarn than the frontside layer.
  5. Upper (1) according to one of claims 1-4, wherein: the flap (3) is arranged at a tongue portion of the upper (1) such that it is adapted to cover at least a portion of the tongue or, wherein the flap (3) is arranged at a heel portion of the upper (1); or the flap (3) is arranged in a lace area of the upper (1) such that it is adapted to reinforce the lace area.
  6. Upper (1) according to one of claims 1-5, wherein the flap (3) is folded such that the flap (3) and a portion of the main part (2) of the upper (1) form a void; preferably wherein a padding and/or reinforcement is arranged in the void.
  7. Upper (1) according to one of claims 1-6, wherein: the flap (3) comprises a Jacquard knit structure; and/or the flap (3) comprises a stretch yarn; and/or the transition part (4) comprises at least one yarn that is also present in the main part (2), wherein the number of plies of this yarn in the transition part (4) is lower than the number of plies in the main part (2); and/or the main part (2), the transition part (4) and the flap (3) have been knitted in a single knitting process forming a one-piece construction; and/or the flap (3) has been formed by partial knitting.
  8. Shoe comprising: a. an upper (1) according to one of claims 1-7; and b. a sole structure attached to the upper (1).
  9. Method (100) for manufacturing an upper for a shoe comprising the steps: a. knitting (110) a main part, wherein the main part is adapted to form at least a part of a void for receiving a foot of a wearer of the shoe; b. knitting (120) a flap; c. knitting (130) a transition part connecting the flap to the main part, wherein steps a., b. and c. are performed in a single knitting process, and wherein the transition part comprises a different knit structure and/or a different yarn and/or yarn combination and/or yarn placement compared to the main part and/or to the flap.
  10. Method (100) according to claim 9, wherein: the knit structure of the transition part comprises a first layer and a second layer overlapping the first layer and, wherein step c. (130) comprises knitting the transition part such that the first layer comprises a different number of rows compared to the second layer; and/or step c. (130) comprises knitting the transition part such that at least one row comprises a plurality of loops the majority of which are frontside loops and at least one another row comprises a plurality of loopy the majority of which are backside loops; and/or step c. (130) comprises knitting the transition part as a single layer structure.
  11. Method (100) according to claim 9 or 10, wherein the transition part comprises a first yarn, wherein the first yarn is different from a second yarn of the main part and/or the flap; preferably wherein the first yarn is more elastic than the second yarn.
  12. Method (100) according to claim 11, wherein the first yarn comprises a different color than the second yarn.
  13. Method (100) according to one of claims 9-12, wherein: the flap is arranged at a heel portion or at a tongue portion of the upper such that it is adapted to cover at least a portion of the tongue; or the flap is arranged in a lace area of the upper such that it is adapted to reinforce the lace area.
  14. Method (100) according to one of claims 9-13, further comprising the step of folding the flap such that the flap and a portion of the main part of the upper form a void; preferably further comprising the step of arranging a padding and/or reinforcement in the void; most preferably further comprising the step of securing a free end of the flap to the main part after arranging the padding and or/ reinforcement in the void.
  15. Method (100) according to one of claims 9-14, wherein: step b. (120) comprises knitting the flap as a Jacquard knit structure; and/or the flap comprises a stretch yarn; and/or step b. (120) comprises knitting the flap using partial knitting; and/or in step b. (120) a tighter stitch tension is used than in steps a. (110) and/or c. (130).

Description

Field of the invention The present invention relates to a knitted upper for a shoe comprising an integrally knitted element and a corresponding manufacturing method. Technical background At present, footwear uppers are often equipped with additional functions such as cushioning, reinforcement or support by applying additional components to the upper like foams, reinforcement sheets, toe caps, heel counters, eyestay reinforcements etc. Thus, additional manufacturing steps like cutting, stitching, cementing or other labor-intensive work are necessary. US 2,623,374 A relates to a sock comprising a sole portion, a toe portion and a heel portion having substantially the same height as the heel portions of the shoes with which the socks are to be worn and a heel tab which projects upwardly from the back of the heel portion of the sock with a fold line provided between the tab and the heel portion for folding the tab down over the outside of the heel portion of the shoe. US 2,721,463 A relates to a knit sock which is adapted to be worn with low shoes such as golf shoes and is concealed thereby when in use with the exception of a heel supporting flap. Therefore, the object of the present invention is to provide an upper for a shoe having additional functions, in particular cushioning and reinforcement, which is cost effective in its manufacturing. Summary of the invention This object is met at least in part by an upper as defined in claim 1 and a method for manufacturing such upper as defined in claim 19. Thus, the upper for a shoe according to the invention comprises: a knitted main part, wherein the main part is adapted to form at least a part of a void for receiving a foot of a wearer of the shoe; a knitted flap; a knitted transition part connecting the flap to the main part, wherein the main part, the flap and the transition part form a unitary knit construction and, wherein the transition part comprises a different knit structure and/or a different yarn and/or yarn combination and/or yarn placement compared to the main part and/or to the flap. The invention allows to knit the main part, the transition part and the flap in a single knitting process as a unitary knit construction which saves time and reduces manufacturing costs because additional steps of securing the flap to the rest of the upper can be avoided. The flap is an additional functional element of the upper. For example, as will be described in more detail below, the flap can function as a reinforcement or cushioning element. If needed, those functions can be achieved in cooperation with additional elements such as paddings or reinforcement sheets. In the context of the present invention, a flap is understood as a piece of knitted material connected along one edge to the main part through the transition part. The flap may comprise a straight edge or a curved edge. As the transition part comprises a different knit structure and/or a different yarn and/or yarn combination and/or yarn placement compared to the main part and to the flap, it can function as a natural fold line, i.e. the transition part can be configured such that the flap naturally folds at the transition part which again might save time and costs. In contrast, a traditional stitch and turn line is not adjustable in regard of stretch and other properties and may be detrimental to the visual appearance. The knitted transition part in contrast offers the freedom to be adjusted in terms of stretch and strength. The transition part as formed according to the present invention also provides a better fit and a better comfort for the wearer, since the flap tends to stay in the designated place. For example, it does not tend to unfold. Other advantages of the present invention include saving yarn and textile material because the different parts of the upper are knitted together in a unitary knit construction directly on the knitting machine in the right shape. The process of manufacturing the upper according to the invention can be highly automated involving less human intervention and associated costs. As more parts are knitted together directly on the knitting machine manual labor can be reduced. Generally, the present invention results in less cutting, preparation and stitching work to be done. The product creation process is accelerated because of predefined knitted components. Although most parts are produced together on a knitting machine, there is still a high design freedom because the main knitting techniques that are used for creating visual and functional effects can be used independently on the flap and on the main part. Other common post process treatments can be used in addition, in order to improve the appearance or the functionality of the upper, and in particular of the main part and of the flap, such as screen printing, high frequency welding, gluing etc. Moreover, the yarns can be selected and engineered on the main part and on the flap to meet the specific needs. For instance