US 12,302,979 B2
Footwear upper having a unitary knit structure and method of manufacturing
Michael A. Carriero, Portland, OR (US); Evan W. Jones, Portland, OR (US); and Sanchari Ashishkumar Mahapatra, Portland, OR (US)
Assigned to NIKE, Inc., Beaverton, OR (US)
Filed by NIKE, Inc., Beaverton, OR (US)
Filed on Jan. 2, 2024, as Appl. No. 18/401,914.
Application 18/401,914 is a continuation of application No. 18/313,710, filed on May 8, 2023, granted, now 11,896,076.
Claims priority of provisional application 63/500,608, filed on May 7, 2023.
Prior Publication US 2024/0365915 A1, Nov. 7, 2024
Int. Cl. A43B 1/04 (2022.01); A43B 23/02 (2006.01)
CPC A43B 1/04 (2013.01) [A43B 23/0215 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A footwear upper comprising:
a unitary knit structure having:
a knit outer face layer disposed at an outer side of the unitary knit structure when assembled in an article of footwear;
a knit inner face layer disposed at an inner side of the unitary knit structure and facing a foot-receiving cavity when assembled in the article of footwear; and
a knit intermediate layer;
wherein the knit outer face layer, knit inner face layer, and knit intermediate layer are integrally knit with one another to define a forefoot region, a midfoot region, and a heel region of the footwear upper;
wherein the knit intermediate layer is disposed between the knit outer face layer and the knit inner face layer and is different at a plurality of first zones of the unitary knit structure than at a plurality of second zones of the unitary knit structure;
wherein the first zones alternate with the second zones in a longitudinal direction of the footwear upper;
wherein the knit outer face layer includes a first plurality of yarns, the knit inner face layer includes a second plurality of yarns separate and distinct from the first plurality of yarns, the first plurality of yarns are not included in the knit inner face layer and the second plurality of yarns are not included in the knit outer face layer;
wherein the knit outer face layer comprises a mesh pattern including first knitted-in holes of a first size;
wherein perimeters of the first knitted-in holes are defined by the first plurality of yarns and not by the second plurality of yarns;
wherein the knit inner face layer comprises a mesh pattern including second knitted-in holes of a second size larger than the first size and overlapping with the first knitted-in holes;
wherein perimeters of the second knitted-in holes are defined by the second plurality of yarns and not by the first plurality of yarns;
wherein the knit outer face layer does not include the second knitted-in holes and the knit inner face layer does not include the first knitted-in holes;
wherein an average fore-aft width of the first zones in the heel region is greater than an average fore-aft width of the first zones in the forefoot region; and
wherein an average fore-aft width of the second zones in the forefoot region is greater than an average fore-aft width of the second zones in the heel region.