Footwear Upper Incorporating a Knitted Component with Sock and Tongue Portions

This application is a Continuation Application of U.S. patent application Ser. No. 17/737,380, filed May 5, 2022, and entitled “Footwear Upper Incorporating A Knitted Component With Sock And Tongue Portions,” which is a Continuation Application of U.S. patent application Ser. No. 16/792,536, filed Feb. 17, 2020, and entitled “Footwear Upper Incorporating A Knitted Component With Sock And Tongue Portions” (now U.S. Pat. No. 11,363,854 issued on Jun. 21, 2022), which is a Continuation Application of U.S. patent application Ser. No. 15/293,829, filed Oct. 14, 2016, and entitled “Footwear Upper Incorporating A Knitted Component With Sock And Tongue Portions” (now U.S. Pat. No. 10,561,200 issued on Feb. 18, 2020), which in turn is a Continuation Application of U.S. patent application Ser. No. 13/681,766, filed Nov. 20, 2012, and entitled “Footwear Upper Incorporating A Knitted Component With Sock And Tongue Portions” (now U.S. Pat. No. 9,498,023 issued on Nov. 22, 2016). Each application listed in this paragraph is hereby incorporated by reference in its entirety.

Conventional articles of footwear generally include two primary elements, an upper and a sole structure. The upper is secured to the sole structure and forms a void on the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower area of the upper, thereby being positioned between the upper and the ground. In athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole often includes a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. Additionally, the midsole may include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. The outsole is secured to a lower surface of the midsole and provides a ground-engaging portion of the sole structure formed from a durable and wear-resistant material, such as rubber. The sole structure may also include a sockliner positioned within the void and proximal a lower surface of the foot to enhance footwear comfort.

The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing system also permits the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.

A variety of material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing the upper. In athletic footwear, for example, the upper may have multiple layers that each include a variety of joined material elements. As examples, the material elements may be selected to impart stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, and moisture-wicking to different areas of the upper. In order to impart the different properties to different areas of the upper, material elements are often cut to desired shapes and then joined together, usually with stitching or adhesive bonding. Moreover, the material elements are often joined in a layered configuration to impart multiple properties to the same areas. As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, stocking, cutting, and joining the material elements may also increase. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and type of material elements incorporated into the upper increases. Moreover, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from fewer types and numbers of material elements. By decreasing the number of material elements utilized in the upper, therefore, waste may be decreased while increasing the manufacturing efficiency and recyclability of the upper.

The following discussion and accompanying figures disclose a variety of concepts relating to knitted components and the manufacture of knitted components. Although the knitted components are disclosed with reference to articles of footwear having configurations that are suitable for running and basketball, concepts associated with the knitted components may be applied to a wide range of athletic footwear styles, including baseball shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennis shoes, training shoes, and walking shoes, for example. Concepts associated with the knitted components may also be utilized with footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, a variety of footwear styles and configurations may incorporate concepts discussed herein.

An article of footwearis depicted inas including a sole structureand an upper. Whereas sole structureis located under and supports a foot of a wearer, upperprovides a comfortable and secure covering for the foot. As such, the foot may be located within upperto effectively secure the foot within footwearor otherwise unite the foot and footwear. Moreover, sole structureis secured to a lower area of upperand extends between the foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence the motions of the foot, for example.

For reference purposes, footwearmay be divided into three general regions: a forefoot region, a midfoot region, and a heel region. Forefoot regiongenerally includes portions of footwearcorresponding with toes of the foot and the joints connecting the metatarsals with the phalanges. Midfoot regiongenerally includes portions of footwearcorresponding with an arch area of the foot. Heel regiongenerally corresponds with rear portions of the foot, including the calcaneus bone. Footwearalso includes a lateral sideand a medial side, which extend through each of regions-and correspond with opposite sides of footwear. More particularly, lateral sidecorresponds with an outside area of the foot (i.e. the surface that faces away from the other foot), and medial sidecorresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Regions-and sides-are not intended to demarcate precise areas of footwear. Rather, regions-and sides-are intended to represent general areas of footwearto aid in the following discussion. In addition to footwear, regions-and sides-may also be applied to sole structure, upper, and individual elements thereof.

The primary elements of sole structureare a midsoleand an outsole. Midsoleis secured to a lower surface of upperand may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further configurations, midsolemay incorporate plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motions of the foot, or midsolemay be primarily formed from a fluid-filled chamber. Outsoleis secured to a lower surface of midsoleand may be formed from a wear-resistant rubber material that is textured to impart traction. In addition, sole structuremay include a sockliner located within upperand is positioned to extend under a lower surface of the foot to enhance the comfort of footwear. Although this configuration for sole structureprovides an example of a sole structure that may be used in connection with upper, a variety of other conventional or nonconventional configurations for sole structuremay also be utilized. Accordingly, the features of sole structureor any sole structure utilized with uppermay vary considerably.

Upperdefines a voidwithin footwearfor receiving and securing a foot relative to sole structure. Voidis shaped to accommodate the foot. When the foot is located within void, therefore, upperextends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. A collaris located in at least heel regionand forms an ankle openingthat provides the foot with access to void. When the foot is located within void, collarand ankle openingextend around or otherwise encircle the ankle. Upperalso has a lacing system located in a throat areaof upper, which is primarily located in midfoot regionand corresponds with an instep region or upper surface of the foot. The lacing system includes a lacethat extends (a) through various aperturesin upperand (b) repeatedly across throat area. The lacing system assists with tightening upperaround the foot and loosening portions of upperto allow entry and removal of the foot from void. As an alternative to the apertures, the lacing system may include other lace-receiving elements, such as D-rings, hooks, or various looped tensile strands. Further configurations of uppermay also include one or more of (a) a heel counter in heel regionfor enhancing stability, (b) a toe guard in forefoot regionthat is formed of a wear-resistant material, and (c) logos, trademarks, and placards with care instructions and material information. Accordingly, uppermay incorporate various features and elements, in addition to the features and elements discussed herein and shown in the figures.

A majority of upperis formed from a knitted componentand a cover component. Knitted componenthas a knitted structure and is formed of unitary knit construction (i.e., as a one-piece element) through a knitting process. When incorporated into upper, knitted componentextends through each of regions-and between sidesand. Although primarily located within upper, portions of knitted componentare exposed in heel regionand throat area. In addition to forming collarand ankle opening, knitted componentdefines a majority or the entirety of void. As such, a foot located within void(or a sock covering the foot) will contact and lay against knitted component. Cover componentis secured to sole structureand is located exterior of knitted component, thereby covering various areas of knitted component. As incorporated into footwear, cover componentextends through each of regions-, between sidesand, and between knitted componentand sole structure. That is, a portion of cover componentmay extend between throat areaand an area where upperis secured to sole structure. Although the structure of cover componentmay vary significantly, cover componentmay be formed from multiple material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) that are joined through stitching or bonding, for example. Moreover, cover componentmay have a layered structure that includes multiple overlapping material elements.

Knitted componentis separable and may be removed from a remainder of footwear, as depicted in. That is, knitted componentis not secured to other portions of upperand may be repeatedly removed from and inserted within cover component. In order to place footwearupon the foot, the wearer may first place knitted componentupon the foot, and then locate the foot and knitted componentwithin cover component. Alternately, the wearer may first place knitted componentwithin cover component, and then locate the foot within knitted component. Although componentsandare separable, knitted componentmay be secured (e.g., through stitching, adhesive bonding, thermal bonding) to cover componentor other portions of upperin some configurations of footwear.

Upperincludes an exterior surfaceand an opposite interior surface. Exterior surfaceis a portion of an outer surface of footwearand is primarily formed by both of knitted componentand cover component. Knitted componentis exposed in heel regionand throat area, thereby forming portions of exterior surfacein these areas. Similarly, cover componentforms portions of exterior surfacebetween throat areaand sole structure. Whereas exterior surfaceis cooperatively formed by each of knitted componentand cover component, knitted componentform a majority or all of interior surface, which also defines a portion of void. As such, a foot located within knitted componentwill contact portions of interior surface.

Advantages of knitted componentinclude stretch and recovery properties, as well as enhanced fit and comfort. When locating the foot within void, collarmay stretch to permit the foot to enter voidthrough ankle opening. As the foot progresses into upper, portions of knitted componentlocated in throat areamay also stretch to permit the foot to fully enter void. In addition to stretching, knitted component may recover or contract to secure the foot within upper. More particularly, collarmay recover to securely extend around the ankle, and other portions of knitted componentmay recover to draw cover componentagainst the foot, thereby tightening upperaround the foot. Various features of knitted component, including materials and knit structure, may be utilized to impart specific stretch and recovery properties to knitted component. That is, the degree of stretch and recovery may be engineered into knitted component. As a result, knitted componentmay be designed to extend around the ankle and tighten upperaround the foot in a manner that enhances the overall fit of footwear. In addition, knitted componentmay be designed with additional layers or padded portions in throat areato separate and cushion the foot from lace. Moreover, knitted componentlays against the foot and enhances the overall comfort of footwear.

Knitted componentis depicted individually and separate from a remainder of footwearinD. Although a knitting process for manufacturing knitted componentwill be discussed in greater detail below, knitted componentis formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a variety of courses and wales. That is, knitted componenthas the structure of a knit textile. Moreover, knitted componentis formed of unitary knit construction. As utilized herein, a knitted component (e.g., knitted component) is defined as being formed of “unitary knit construction” when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures of knitted componentwithout the need for significant additional manufacturing steps or processes. Although portions of knitted componentmay be joined to each other (e.g., edges of knitted componentbeing joined together) following the knitting process, knitted componentremains formed of unitary knit construction because it is formed as a one-piece knit element. Additionally, knitted componentremains formed of unitary knit construction when other elements (e.g., stabilizers, stretch-limiting elements, straps, aesthetic features, logos, trademarks, and placards are added following the knitting process.

Although the configuration of knitted componentmay vary considerably, knitted componentis depicted as including a sock portionand a tongue portion. Sock portionhas the general configuration of a sock and forms, therefore, a generally cylindrical and hollow structure for receiving a foot. Tongue portionis located within sock portionand has an elongate structure that extends along a majority of a length of sock portion. When incorporated into footwear, sock portionforms collar, defines ankle opening, and extends throughout the length and width of footwear. Tongue portionis located in and extends through throat areaor at least a portion of throat area. Moreover, tongue portionis positioned to extend between the foot and laceto separate and cushion the foot from lace.

Sock portiongenerally includes a collar area, a foot area, and a toe area. Collar areaforms an opening that provides access to the interior of knitted component. As such, collar areaforms collarand defines ankle openingin footwear. Although collar areais depicted as having a two-layer configuration, portions of collar areamay also be formed from a single knit layer. Foot areaforms the majority of sock portionand provides the generally cylindrical and hollow structure of sock portionin which the foot is located. Toe areais located opposite collar areaand forms a closed end of sock portionthat receives the toes of the wearer. Based upon this discussion, and as noted above, sock portionhas the general configuration of a sock and may have the general configuration of a variety of conventional socks. That is, sock portionmay incorporate various features and knit structures that are commonly utilized in socks that are intended to cover a foot. Given the unique use for knitted component, sock portionmay also incorporate various non-conventional structures that differ from those found in conventional socks.

Tongue portionextends longitudinally through foot areaand is secured to opposite sides of foot area. More particularly, a collar endof tongue portionis secured to sock portionadjacent to collar area, and an opposite toe endof tongue portionis secured to sock portionadjacent to toe area. Although the area between endsandmay be secured to sock portion, this area is depicted as being unsecured. As discussed in greater detail below, tongue portionmay be formed of unitary knit construction with sock portion. As such, one or both of endsandmay be formed of unitary knit construction with sock portion. In the example configuration depicted in the figures, however, toe endis joined to sock portionwith stitching, whereas collar endis formed of unitary knit construction with sock portion.

Although tongue portionmay be formed from a single layer of textile material, tongue portionis depicted as including a first knit layerand a second knit layerthat are substantially coextensive and lay against each other. First knit layeralso lays against sock portion. Knit layersandare formed during the knitting process and joined to each other through the knitting process, thereby being formed of unitary knit construction. Although the specific locations in which knit layersandare joined may vary, edges or peripheral areas of knit layersandare depicted as being joined to each other, whereas central areas of knit layersandare depicted as being unjoined to each other. In effect, therefore, knit layersandare separate layers of knitted material, but are joined at their peripheries. An advantage of joining knit layersandrelates to retaining the relative positions of knit layersandfollowing the knitting process and while knitted componentor footwearis being worn. In other configurations of knitted component, however, the peripheral areas of knit layersandmay be unjoined or both the peripheral and central areas may be joined.

Knitted componentis formed of unitary knit construction, but knitted componentmay include stitchingthat joins toe endto sock portion. During the knitting process for knitted component, which is discussed in greater detail below, each of sock portionand tongue portionare formed and joined together. More particularly, the knitting process joins collar endto sock portion. Once the knitting process is complete, toe endis joined to sock portionwith stitching. In further configurations, the knitting process may join toe endto sock portion, and stitchingmay be located at collar end. It may also be possible to join both of endsandduring the knitting process, thereby eliminating the need for stitching.

An advantage of forming tongue portionto include both of knit layersandrelates to providing additional separation and cushioning between the foot and lace. When incorporated into footwear, both of knit layersandare positioned between the foot and lace. Moreover, a portion of sock portionalso extends between the foot and lace. In effect, therefore, three layers of knit material separate the foot from lacein throat area, whereas other portions of knitted component (e.g., sock portion) may have a single layer that separates the foot from other portions of upper. Each of the knit layers imparts a degree of cushioning that protects the foot from lace. In combination, however, the three knit layers provide greater separation and cushioning, thereby enhancing the overall comfort of footwear. In some configurations, tongue portionmay include only one knit layer or may include three or more knit layers. In other configurations, a foam material or other element may be utilized to provide even further separation and cushioning between the foot and lace.

Knitted componentmay be formed from a single type of yarn that imparts common properties to each of sock portionand tongue portion. In order to vary the properties of knitted component, however, different yarns may be utilized in different areas of knitted component. That is, portionsandor different areas of portionsandmay be formed from different yarns to vary the properties between areas of knitted component. Moreover, one area of knitted componentmay be formed from a first type of yarn or combination of yarns that imparts a first set of properties, and another area of knitted componentmay be formed from a second type of yarn or combination of yarns that imparts a second set of properties. Properties may vary throughout knitted component, therefore, by selecting specific yarns for different areas of knitted component. Examples of properties that may be varied through choice of yarn include color, pattern, luster, stretch, recovery, loft, hand, moisture absorption, biodegradability, abrasion-resistance, durability, and thermal conductivity. It should also be noted that two or more yarns may be utilized in combination to take advantage of properties from both yarns, such as when yarns are plated or form different courses in the same area.

The properties that a particular type of yarn will impart to an area of knitted componentpartially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is durable, abrasion-resistant, and has relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. Yarns that incorporate thermoplastic materials may also permit areas of knitted componentto be fused or stabilized through the application of heat. In addition to materials, other aspects of the yarns selected for knitted componentmay affect properties. For example, a yarn forming knitted componentmay be a monofilament yarn or a multifilament yarn. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bi-component yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of knitted component. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of knitted component.

In addition to the type of yarn that is selected for knitted component, the knit structure in knitted componentimparts particular properties. As depicted, a majority of knitted componentis formed to have a common or single knit structure, which is relatively untextured and may be referred to as a tubular or plain knit. In further configurations, however, knitted componentmay have a rib knit structure or mesh knit structure, or knitted componentmay have a hybrid knit structure in which multiple types of knit structures are utilized in one area. In order to vary the properties of knitted component, different knit structures may be utilized in different areas of knitted component. That is, portionsandor different areas ofandmay be formed from different knit structures to vary the properties between areas of knitted component. Moreover, one area of knitted componentmay be formed from a first knit structure or combination of knit structures that imparts a first set of properties, and another area of knitted componentmay be formed from a second knit structure or combination of knit structures that imparts a second set of properties. Properties may vary throughout knitted component, therefore, by selecting specific knit structures for different areas of knitted component. Examples of properties that may be varied through choice of yarn include pattern, luster, stretch, recovery, loft, hand, moisture absorption, abrasion-resistance, durability, and thermal conductivity.

Properties may be further varied by selecting both the type of yarn and the knit structure that is utilized in knitted componentor areas of knitted component. By combining various types of yarn with various knit structures, further combinations of properties may be imparted to knitted component. For example, a first type of yarn and a first knit structure may be utilized in one area of knitted componentto provide a set of properties, and a second type of yarn and a second knit structure may be utilized in a different area of knitted componentto provide a different set of properties. As an example, sock portionmay incorporate types of yarn and knit structures that impart high stretch, and tongue portionmay incorporate types of yarn and knit structures that impart loft and low stretch. Given the two-layer configuration in collar area, the outer layer may incorporate types of yarn and knit structures that impart durability and wear-resistance, and the inner layer may incorporate types of yarn and knit structures that impart stretch and recovery. Additionally, some portions of foot areamay have a rib knit structure with a higher denier yarn, and other portions of foot areamay have a plain knit structure with a lower denier yarn. Portions of sock portionmay also incorporate types of yarn and knit structures wick moisture away from the foot. Accordingly, selecting particular combinations of types of yarn and knit structures for each area of knitted componentpermits each area to have a particular combination of beneficial properties.

An advantage of footwearrelates to the separability of knitted componentfrom a remainder of footwear. Different individuals have different foot shapes and proportions, as well as different preferences regarding various aspects of footwear. Each individual may, therefore select a configuration of knitted componentthat best suits their proportions and preferences. Moreover, an individual may replace one knitted componentwith another knitted componentbased upon the intended activity that footwearis intended to be worn during. The ability to replace knitted componentalso permits footwearto have various aesthetics, depending upon which knitted componentis worn. Accordingly, various aspects of footwearmay vary depending upon the specific configuration of knitted componentthat is used with footwear.

Although separability imparts various advantages, non-separable configurations also have various advantages. For example, knitted componentprovides an essentially seamless surface that rests against the foot, thereby enhancing the comfort of footwear. Moreover, the use of knitted componentincreases the efficiency of manufacturing footwearand decreases the number of separate elements that must be joined in making upper.

Based upon the above discussion, a portion of upperincorporates knitted component, which is formed of unitary knit construction. Knitted componentmay include both sock portionand tongue portion. Sock portionhas a generally cylindrical and hollow structure that forms ankle openingextends between regionsandto define void. Tongue portionhas an elongate configuration (a) extending through at least a portion of a length of throat areaand (b) including two knit layersandthat lay adjacent to each other. One of knit layersandmay also lay against sock portionin throat area. Given this structure, a majority of knitted componentis formed from sock portion, which often is a single knit layer. In throat area, however, upperhas a layered structure that includes the knit layer of sock portionand each of knit layersand. Moreover, each of portionsandand the three knit layers are formed of unitary knit construction.

The configuration of footwearand knitted componentdiscussed above and depicted in the figures provides one example relating to the structure of footwearand knitted component. In further configurations, numerous features of footwearand knitted componentmay vary considerably. Referring to, for example, a plurality of looped strandsform lace-receiving elements and replace apertures. Looped strandsextend upward from a lower area of upperand form loops, through which laceextends. Further information regarding structures similar to looped strandsmay be found in U.S. patent application Ser. No. 13/529,381, which was filed in the U.S. Patent and Trademark Office on 21 Jun. 2012 and is entitled Footwear Incorporating Looped Tensile Strand Elements, such application being entirely incorporated herein by reference. Although knitted componentmay be separable and replaceable,depicts a configuration where stitchingjoins knitted componentto cover component. Although footwearmay have the configuration of a running shoe, another configuration of footwearis depicted inas having the configuration of a basketball shoe.

In addition to variations in other areas of footwear, numerous features of knitted componentmay vary considerably. Referring to, knitted componentincludes a rib knit structure. More particularly, substantially all of an upper surface of foot areahas the rib knit structure. In addition, a portion of the lower surface of foot areathat corresponds with the position of the arch of the foot has the rib knit structure. In comparison with other knit structures, the rib knit structure may be utilized to impart significant stretch to knitted component. In another configuration that is depicted in, side regions of foot areahave a mesh knit structure that forms a plurality of holes or apertures in knitted component. An advantage of the mesh knit structure relates to breathability. Although tongue portionmay be located within sock portion,depicts a configuration where tongue portionis located on the exterior of sock portion.

In some variations, the proportions of knitted componentmay vary. As an example,depicts collar areaas having greater height, which would cover more of the ankle of the wearer. Referring to, tongue portionexhibits a reduced length that would extend through less of throat area.depicts a configurations where tongue portionhas greater width. Similarly, the width of tongue portionis also greater inand extends to side areas of sock portion. As a further variation,depicts second knit layeras having an increased thickness, which may be formed by varying the knit structure or type of yarn.

Numerous other aspects of knitted componentmay also vary. Referring to, toe endis stitched to sock portion, whereas collar endis formed of unitary knit construction with sock portion. In, both of endsandare formed of unitary knit construction with sock portion. In order to provide more cushioning and separation between the foot and lace, the thickness of one of knit layersandmay be increased, as in. As further examples,depicts a foam elementlocated between knit layersand, anddepicts tongue portionas having an additional knit layer. Referring to, tongue portionis formed to have the configuration of a spacer material, in which drop yarns extend between sock portionand tongue portionto provide cushioning. As a final example,depicts a configuration wherein tongue portionis located to extend under the foot and may provide cushioning similar to a sockliner.

A knitting process may be utilized to form knitted componentand many or all of the various features discussed above for knitted component. It should be noted, however, that weaving processes may also be utilized to form a textile element having many or all of the various features discussed above for knitted component. Although a knitting process that forms knitted componentmay be performed by hand, the commercial manufacture of multiple knitted componentswill generally be performed by knitting machines. In general, knitting involves forming courses and wales of intermeshed loops of a yarn or multiple yarns. In production, knitting machines may be programmed to mechanically-manipulate one or more yarns into the configuration of knitted component. That is, knitted componentmay be formed by mechanically-manipulating one or more yarns to form a one-piece textile element that has the shape and features of knitted component. As such, knitted component may be formed of unitary knit construction utilizing a knitting machine.

Although knitted componentmay be formed through a variety of different knitting processes and using a variety of different knitting machines, circular knitting (i.e., the use of a circular knitting machine) has the capability of forming knitted componentto have the various features discussed above. In general, circular knitting involves forming a plurality of courses and wales. As an example, courses are circular rows of loops that extend entirely around sock portionand across the width of tongue portion. Wales are columns of loops that extend perpendicular to the courses and from (a) collar areato toe areaand (b) collar endto toe end. Although general or conventional circular knitting processes may be utilized to form knitted component, specific examples of knitting processes that may be utilized include wide tube circular knitting, narrow tube circular knitting, narrow tube circular knit jacquard, single knit circular knit jacquard, double knit circular knit jacquard, warp knit jacquard, and flat knitting, for example.

The knitting process for forming knitted componentwill now be discussed in greater detail. As noted above, sock portionhas the general configuration of a sock. That is, sock portionmay incorporate various features and knit structures that are commonly utilized in socks that are intended to cover a foot. The portion of the knitting process that forms sock portionis, therefore, well-known in the art of knitting. In contrast with a conventional sock, however, knitted componentincludes tongue portion. In order to knit tongue portionwith sock portion, the general knitting process may proceed as follows: Initially, the knitting machine knits a first circular course that forms a portion of collar areaand transfers the first circular course to a dial that holds the first circular course throughout a remainder of the knitting process. Various other circular courses that form portions of collar areamay also be formed. In knitting tongue portion, the knitting machine may reciprocate to form each of knit layersand. Once the reciprocation is complete and tongue portionis formed, the knitting machine may proceed with forming one or more additional circular courses that form portions of collar area, and one of these additional circular courses may be joined with the first circular course held upon the dial. At this point, portions of collar areaand tongue portionare formed, and the knitting process may proceed in a well-known manner to form a remainder of sock portion. In effect, therefore, the knitting process for knitted componentis similar to the conventional process for forming a sock, but includes additional reciprocation steps to form tongue portion.

Many aspects of the knitting process discussed above may be performed using a conventional circular knitting machine. In order to facilitate some portions of the knitting process, however, the circular knitting machine may be modified to raise and lower the dial, which holds the first course formed in knitted component. Additionally, a blower may be utilized to ensure that knitted componentremains properly located within the circular knitting machine during the knitting process.

Based upon the discussion above, A circular knitting process forms knitted component. Once the knitting process is complete, knitted componentmay be incorporated into upper. More particularly, knitted componentis located within cover componentand to extend from forefoot regionto heel region. Moreover, knitted componentis oriented such that tongue portionis located to extend through at least a portion of a length of throat area. In configurations where knitted component is secured to cover component, either stitching, adhesive bonding, or thermal bonding may be used.

The invention is disclosed above and in the accompanying figures with reference to a variety of configurations. The purpose served by 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. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the configurations described above without departing from the scope of the present invention, as defined by the appended claims.