KNITTED POCKET WITH ELEMENT INSERTED

Description

INCORPORATION BY REFERENCE

This application claims the benefit of German Application No. 10 2024 138 741.6 filed Dec. 18, 2024.

The foregoing application, and all documents cited therein or during their prosecution (“appln cited documents”) and all documents cited or referenced in the appln cited documents, and all documents cited or referenced herein (“herein cited documents”), and all documents cited or referenced in herein cited documents, together with any manufacturer's instructions, descriptions, product specifications, testing standards (e.g., ASTM, ISO, DIN) and product sheets for any products mentioned herein or in any document incorporated by reference herein, are hereby incorporated herein by reference, and may be employed in the practice of the invention. More specifically, all referenced documents are incorporated by reference to the same extent as if each individual document was specifically and individually indicated to be incorporated by reference. Citation or identification of any document in this application is not an admission that such document is available as prior art to the present invention.

FIELD OF THE INVENTION

This invention relates to a method of fabricating a sports article comprising a knitting process, and a sports article.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

The invention relates to the field of fabricating sports articles using knitting processes. Traditional manufacturing methods for sports articles, such as shoes and apparel, often involve multiple steps, including cutting, sewing, and adhesive bonding, to integrate various functional elements like reinforcements and/or cushioning into the fabric. These methods can be labor-intensive, prone to inconsistencies, and may compromise the structural integrity and flexibility of the final product.

U.S. Pat. No. 9,538,803 B2 discloses an article of footwear incorporating a textile upper. The upper comprises a knitted component. The knitted component may be warp knitted. The knitted component has an outer side and an inner side that can have different knit configurations. The knitted component can also incorporate portions of a single layer construction and portions of a double layer construction.

It is disadvantageous here, that the fabric needs to be cut to place inserts into pockets formed in the fabric. Thus, there is a demand for a fabrication process, which does not need a cutting step to place insert elements.

The primary problem addressed by the invention is the need for an efficient, consistent, and seamless method to integrate various functional elements into sports articles during the knitting process itself. Traditional methods of attaching elements such as padding or reinforcements to fabrics often result in weaker joints, added bulk, and potential discomfort for the user. Additionally, these methods can be inefficient and costly due to the multiple steps and manual labor involved. The invention described herein provides a method for seamlessly integrating functional elements into sports articles during the knitting process. By creating voids within the knitted fabric and inserting elements such as reinforcement pads, cushioning, magnets, and/or electronic components while the fabric is still on the knitting machine, the method ensures a secure and precise placement of these elements. The use of shrinkable or melting yarns can further enhance the integration by tightly enclosing the elements within the fabric, eliminating the need for additional cutting or adhesive steps.

In view of the foregoing, there is a need for an improved fabrication process of knitted sports articles. It is thus an object of the present invention to overcome some or all the deficiencies of conventional processes.

SUMMARY

This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

Variations of the embodiments are the subject of the independent and dependent claims, and the skilled person will find clues to other suitable aspects of the present invention in the overall disclosure of the present application.

An aspect of the invention relates to a method of fabricating a sports article comprising a knitting process, the knitting process that includes providing a knitting machine, one or more yarns for knitting, and at least one insert element; knitting a fabric such that the fabric includes at least one open void between at least two layers of the fabric; positioning at least one insert element into the at least one open void while the fabric remains in the knitting machine; and further knitting the fabric such that the at least one void is closed at least partially around the insert element(s) by connecting the at least two layers. In particular, during the knitting the void is accessible through an aperture that is then closed after further knitting that follows insertion of the insert element. The knitted layers may form a pocket that defines a void for an insert element and at least a portion of the void may be substantially closed when the layers are knitted together.

Such a method can for instance be used to create a sports shoe with enhanced support. For example, the insert element could be a cushioned pad or a reinforcement strip. By inserting the insert element, for instance a pad into the void within the knitted layers and then knitting further to secure it, the sports article gains additional structural support and comfort without the need for external stitching or adhesives. This approach ensures a more seamless design, reduces manufacturing steps, and enhances the durability and performance of the sports article.

The method can be further improved when the method does not comprise cutting of the knitted fabric to create the open void.

With such a method the open void is formed directly during the knitting process by manipulating the yarn and machine settings to leave a gap or void between fabric layers. This technique eliminates the need for cutting, which is common in the state of the art, preserving the integrity and strength of the fabric. For example, in the creation of a seamless sports article, this method allows for strategic placement of breathable or reinforced section without weakening the material. This results in a more durable and comfortable product, as the fabric maintains its original strength and flexibility.

In some embodiments, the fabric is continuously held in some manner on the knitting machine while knitting, inserting the insert element, and/or further knitting to at least partially close the void. For example, an aperture of the void may be closed using knitting. In a particular, embodiment an aperture of the void may be partially closed by knitting while an opening in the layers forming the void is left open after knitting is completed.

With such a method, the fabric remains on the knitting machine during the entire process of forming an open void, inserting the element, and knitting to close the void. For example, when manufacturing a sports article like a shoe or a glove, this continuous process ensures precise placement and secure integration of, e.g., padding or support elements. This method enhances production efficiency by reducing handling and potential errors associated with moving the fabric between machines. Additionally, it improves the alignment and consistency of the final product, resulting in higher quality and reduced production time. This means that during knitting, insertion of the insert element, and/or further knitting the knitted fabric is not removed from the knitting machine. For example, the knitted fabric may be held on the needles of the machine, although the specific needles holding the fabric could change over the time during the fabrication process. In a particular embodiment, portions of a knitted fabric may be held substantially in place relative to each other by the knitting machine.

Further improvement is achieved when the inserting of the insert element(s) is performed automatically. For example, an insert element may be provided automatically, preferably by supplying the insert element(s) from a storage area.

With such a method, the insertion of insert elements like cushioning pads or reinforcement strips into the fabric is done automatically using a mechanism that retrieves these elements from a designated storage area. For instance, in the production of a sports article, this automated insertion ensures precise and consistent placement of e.g. protective and/or cushioning elements without manual intervention. The automatic insertion may be accomplished through the use of a robotic arm integrated with and/or provided on the knitting machine. This configuration not only ensures precise positioning of the insert but also facilitates maneuvering the insert within the confined space of the machine, for instance in the area between the needle beds. This automation improves production speed, accuracy, and reduces labor costs, leading to a more efficient manufacturing process and higher quality products with consistently placed insert elements. A storage area could for instance be a magazine to store and supply insert elements.

An alternative improvement is achieved when the inserting of the insert element(s) is performed manually by an operator.

With such a method, the insertion of insert elements, such as padding or reinforcement strips, is performed manually by an operator. For instance, in the creation of custom sports articles, an operator can precisely place and adjust each insert element according to specific design requirements. This manual insertion allows for greater flexibility and customization, ensuring that each product meets exact specifications and accommodates individual needs. This method can be advantageous for limited production runs or specialized items, where precision and customization are prioritized over automation.

In some embodiments, the knitting machine gauge is maximum 14.

In alternate embodiments, the knitting machine gauge is maximum 18. In such embodiments, where the knitting machine gauge has a maximum of 18 the knitting process described herein can produce a relatively fine and detailed fabric. For instance, in the production of sportswear, using a machine with a gauge of 18 allows for the creation of a light and fine fabric. As the gauge increases, the material becomes finer; however, this also reduces the distance between the needle beds, making it more challenging to introduce an insert between them. An 18-gauge configuration offers a balance, being fine enough to produce delicate material while still maintaining sufficient distance between the needle beds to allow for the insertion of elements between them and into the knitted material.

In some embodiments, an aperture in the knit layers through which the void is accessible has a width that is larger than the maximum width of the insert element(s). This allows to fully introduce the insert element in the void without deforming it. This may require designing the knitted fabric and the knitting program in a suitable manner to allow the placement of the insert element(s) during the knitting process.

An embodiment of the method and/or article formed may include an insert element having a maximum thickness that is smaller than the distance between the layers of the fabric delimiting the void while the layers are held in the knitting machine. This allows to fully introduce the insert element in the void without deforming it. Alternatively, a maximum thickness of the insert element(s) could be larger than the distance between the layers of the fabric while held in the knitting machine. For example, if at least some of the yarns forming the layers are formed from an elastic material and/or the insert element(s) is made of an elastically deformable material, the thickness of the insert element may be larger than a distance between the layers. In particular, if an insert element may be compressed it may be easier to be introduce the insert element into the void. In particular, the distance between the layers of the fabric is determined by the distance between the needle beds.

Embodiments of a fabric may include fabrics knitted as multilayer fabrics. In particular, a double, triple, or quadruple layer fabric may be used having at least two layers of the fabric interconnected to each other through the knitting process. An open void may be defined in a selected area of the fabric, where the at least two layers of fabric are detached and overlapping. For instance, the fabric could be a double layer fabric having selected areas in which the two layers of fabric are separated, that is, are not connected between, and overlap to define the void. In a particular embodiment, a section of a knitted fabric may include three or more knitted layers proximate each other and define two or more voids into which insert elements may be placed.

Further improvement is achieved when after knitting the fabric comprises more than two layers and two or more voids defined between them, such that after inserting insert elements, the insert elements and the layers are stacked alternately.

Such a method results in a multi-layered fabric with multiple voids for insert elements. For example, in the production of high-performance sports articles, this technique allows for the insertion of both cushioning and structural supports within the same fabric. By stacking insert elements like structural and cushioning layers alternately with the fabric layers, the sports article can offer enhanced cushioning, breathability, and structural integrity. This layered construction improves the functionality and comfort of the sports article, providing tailored performance benefits for various athletic activities. This method can be implemented on knitting machines comprising two needle beds, utilizing alternate needles in a 1×1 technique. Alternatively, it can be performed on knitting machines with additional needle beds, such as those with four needle beds, which simplifies the process and enables knitting on all needles.

Further improvement is achieved, when the height of the void is larger than the height of the insert element(s) and/or the width of the void is larger than the width of the insert element(s).

Such a method creates voids that are larger than the insert elements to ensure easy insertion and slight movement within the void. This design enhances comfort and adaptability, as the insert elements can adjust within the void to provide optimal support and reduce pressure points. This flexibility can also simplify the manufacturing process by accommodating variations in insert element sizes. This is particularly advantageous when no elastic yarns are used in the knit. When elastic yarns are used, in fact, the dimensions of the void could be smaller than the ones of the insert element, since the elastic yarn, by stretching, allows to compensate for the difference in dimensions.

In some embodiments, insert elements may be secured in a void in a layered fabric using one or more yarns. In particular, a yarn may be positioned proximate an insert element. Further improvement is achieved when at least one insert element is fixed in the void by the yarn extending through the insert element.

With such a method, the insert element is fixed within the void by knitting the yarn through the insert itself. For example, in creating protective sports gear such as knee pads, the padding element can be securely anchored in place by threading the yarn through holes or loops in the pad. This ensures the insert remains firmly in position, providing consistent protection and support during use. This method enhances the durability and stability of the sports article, preventing the insert elements from shifting or becoming dislodged during intense physical activities.

This method can be performed in particular with insert elements that are not made of a rigid material, such as padding elements made of foam materials, reinforcing films or fabrics, simply using the needles to punch through the insert elements. This method can be performed also with insert elements made of a rigid material as long as holes or loops are provided in the insert elements to this aim.

Further improvement is achieved when the insert element has a shape adapted to be inserted between the needle beds of the knitting machine. For instance, when using a flat knitting machine which has flat needle beds, the insert element should have advantageously a flat shape to be easily inserted between the needle beds. In case a different shape is desired, the desired shape could be conferred to the insert element and the latter could be made of an elastically deformable material, to be deformed during insertion of the insert element. Alternatively, a flat shape could be initially conferred to the insert element and the latter could be made of a plastically deformable material to be shaped into the desired shape after the knitting process, for instance, using heat pressing.

Differently, when using a circular knitting machine, which has circular needle cylinder and dial, the insert should have a curved shape adapted to be inserted between the needle cylinder and dial or it should be made of a flexible material that can be conveniently bended to the scope.

Further improvement is achieved when the yarn includes a shrinkable yarn and the method includes a shrinking step, such that the fabric around the void conforms around the contour of the insert element(s), wherein the shrinking is achieved by applying heat.

In such a method the fabric is knitted with shrinkable yarn, and after the insert element(s) are placed, the fabric undergoes a shrinking process. For example, in the manufacture of custom-fit sports article, heat can be applied to the fabric, causing the shrinkable yarn to contract and tightly conform around the padding or support elements. This ensures a snug and precise fit, enhancing the functionality and comfort of the sports article. Heat-shrinking ensures that the inserts stay securely in place, preventing them from moving within the void, and the fabric contours perfectly to the desired shape, providing improved performance. The knit products can include numerous different yarns and a shrinkable yarn might be knitted together with other different yarns or used only in a specific location where it is needed and not in other locations. The heat can be applied for instance by steaming, ironing, autoclaving, using an oven or the like.

In an embodiment, fabric layers comprise different yarns wherein one layer of the fabric comprises an elastic and/or shrinkable yarn and another layer comprises a non-elastic and/or non-shrinkable yarn.

With such a method the fabric incorporates layers made from different types of yarn. For instance, in the creation of a sports compression garment, the inner layer can be made from an elastic and shrinkable yarn to provide a snug, conforming fit, while the outer layer is made from a non-elastic, durable yarn to offer support and protection. This combination allows the garment to stretch and adapt to the wearer's body while maintaining structural integrity and durability. This dual-layer construction can enhance comfort, performance, and longevity of the sports article, providing targeted support and flexibility where needed.

In certain embodiments, the yarn comprises an elastic and/or shrinkable yarn.

With such a method the knitting process uses yarn that is elastic and/or shrinkable. For example, in the manufacturing of sports articles, using elastic yarn ensures the fabric can stretch and conform to the foot's movements, providing a comfortable and flexible fit. Additionally, shrinkable yarn can be used to further enhance the fit and shape retention of the garment after a heat treatment. This use of specialized yarns improves the overall performance, durability, and comfort of the sports article, making it ideal for dynamic and high-intensity activities.

Moreover, when the yarn comprises an elastic/shrinkable yarn, the insert element can fit better inside the void, thanks to the layers of fabric that take the shape of the insert element. An elastic or shrinkable yarn might comprise an elastomer and/or thermoplastic polyurethane (TPU).

An embodiment may include one layer comprising a melting yarn, adapted to form a connection with the insert element(s) when fused.

With such a method the fabric layer includes a melting yarn that at least partially fuses, bonding to the insert element(s) when heat is applied. For example, in the production of sport shoes, a melting yarn can be used in the inner layer of the shoe proximate padding. When heat is applied, this yarn melts and bonds with the insert elements, such as impact-absorbing pads, creating a secure and integrated structure. This method enhances the durability and stability of the padding, ensuring it stays firmly in place during use. The melting process also simplifies the manufacturing steps and eliminates the need for additional adhesives, resulting in a more streamlined and efficient production.

In some embodiments, a method may include a melting yarn that is also a shrinkable yarn.

With such a method the melting yarn used in the fabric layer is also shrinkable. When heat is applied, this yarn will not only at least partially fuse, bonding to the insert elements but also shrink to conform tightly around the insert elements. This dual function ensures a secure bond and a snug fit, enhancing the support and stability of the sports article. The combination of melting and shrinkable properties simplifies the manufacturing process and improves the overall effectiveness and comfort of the sports article. A melting yarn that is also a shrinkable yarn could for instance be a hybrid or twisted yarn.

A method using a yarn that is both a melting and a shrinkable yarn, is particularly advantageous during the manufacturing of footwear when, for instance, the insert elements placed in the knitted material are rigid and require precise placement, such as support rods.

Some embodiments may include a yarn that comprises a non-elastic and/or non-shrinkable yarn that includes polyester.

In some embodiments, a method may include a fabric that incorporates a non-elastic and non-shrinkable polyester yarn. For example, in the production of sports articles like footwear or sports bags, using polyester yarn provides durability and resistance to stretching, ensuring that the footwear or bag maintains its shape and can withstand heavy use. Polyester's inherent strength and resistance to environmental factors like moisture and UV light make it an ideal choice for outdoor sports equipment. The use of polyester yarn improves the longevity, structural integrity, and reliability of the sports article, making it suitable for demanding applications.

In an embodiment, the yarn comprises a shrinkable yarn and the void has one or more opening(s) smaller than the insert element(s), a method used comprises a shrinking step, such that after shrinking the yarn, the insert element(s) partially extends through the opening(s). In particular, the one or more opening(s) could be independent from the aperture through which the insert element(s) are placed in the void or could be created by only partially closing the aperture.

An embodiment of a method may include a fabric that uses shrinkable yarn and features openings smaller than the insert elements. For example, when creating sports articles, after placing the insert element(s) within the fabric, heat is applied to shrink the yarn. This causes the fabric to tighten, and the insert element(s) to partially protrude through the openings. This design ensures the insert element(s) remain securely in place while allowing for a part of an insert element to be accessible by protruding through an opening. This is particularly advantageous when the insert element is an electric component and a part of it needs to be accessible, for instance, to allow electrical charging or transfer of data. The shrinking step ensures a precise and snug fit around the insert elements, improving both the performance and the aesthetic of the sports article. The opening of the void is preferably not the aperture that is giving access to the open void for the inserting of the insert elements, but it is a different opening to give additional functionality to the sports article, for instance, by allowing the insert element to extend through this additional opening.

In another embodiment, the knitted fabric comprises one or more holes. In particular, the knitted fabric may include through-holes connected to the void (e.g., in communication with) and the insert element(s) is partially visible through the holes. This design enhances breathability and ensures the insert element(s) remain securely in place while allowing for additional airflow.

An embodiment may include an insert element(s) that comprise(s) reinforcement means and/or cushioning means.

In such an embodiment, the insert elements provide reinforcement and/or cushioning. For example, in the manufacture of sports shoes, the insert elements could be stiffeners for added support and/or cushioned pads for comfort. Reinforcement elements can enhance the structural integrity and durability of the shoes, making them more resistant to wear and tear. Examples of such reinforcement elements may include: vamp reinforcements and/or reinforcements for the toe box, to reinforce the toe and forefoot areas of the shoes, heel counters, to provide the necessary rigidity to the heel area and more support to the foot of the wearer, or eyestay reinforcements, to reinforce the lacing areas. Other reinforcement elements can be provided to improve the shoe performance. Examples of such reinforcement elements are stiffening elements, such as plates or rods, to be provided, for example, on the sole area of the shoe to increase stiffness of the sole allowing better force transmission from the ankle to the ground. Cushioning elements improve comfort by absorbing impact and reducing pressure on the feet. Examples of cushioning elements are heel or tongue paddings. This combination ensures that the sports article meets the specific performance needs of athletes, providing both strength and comfort. Such a cushioning means can be for instance made of a foam or also of a pellet or particle foam.

Some embodiments may include insert element(s) comprising magnets.

For instance, by integrating magnets directly into the fabric, the garment can for example be used to produce a detachable fastener that can replace a zip or a hook and loop fastener. Such a fastener could for instance be used on a shoe element, a bra, a belt, a waistband, a pocket, or a bag. This method enhances the functionality of the sports article and allows for a clean design.

Embodiments of a fabric as described herein may include insert element(s) such as one or more electronic components, for example, microchips.

With such a method the insert elements can comprise electronic components such as microchips. For example, in the production of smart sportswear, microchips can be integrated into the fabric to monitor and collect data on the wearer's performance, such as heart rate, position, movement, speed, ball kicking force and temperature. These electronic components can for instance connect to a mobile app, providing real-time feedback and analysis to the user. This integration of electronics enhances the functionality of the sports article, transforming it into a high-tech garment that offers both performance monitoring and improved training outcomes.

In one embodiment the insert element(s) comprise(s) a RFID tag, for instance for identification or tracking purposes.

In a further embodiment, the insert elements can also be small devices for generating vibrations, providing heat, such as infrared heating, cooling, and/or mild electrical impulses. These could be used, for instance, to warm up muscles before a competition, to warm parts of the body in cold environments, or for pain relief purposes, for instance for menstrual pain relief.

The insert elements could also be light-generating devices for aesthetic or safety purposes, for example for visibility at night. In this case, the yarn used to create at least part of the pocket could be a transparent or translucent yarn, such as a monofilament yarn. The pocket in the knitted fabric may define a void into which one or more insert elements may be positioned.

In some embodiments, the sports article created by the methods described herein is a shoe.

For instance, the method can be applied to create uppers of shoes with integrated cushioning or reinforcement elements for enhanced comfort or support. Alternatively or additionally, the method can be applied to create insoles, strobel boards, or more generically, sole parts of the shoe. Using a knitting process to form one or more parts of the shoe allows for precise placement of these elements within the fabric, resulting in a seamless design. Additionally, incorporating features like shrinkable yarns and electronic components such as microchips can provide a customized fit and performance tracking. This method enhances the overall quality, functionality, and innovation of the sports shoe, making it ideal for various athletic activities.

In an embodiment, the knitted pocket is located on the sole area of the shoe to accommodate, for instance, a midsole, or part of a midsole. The midsole could be a solid foam or be in the form of pellets and/or foam particles, which may be loose or bonded together. In some instances, materials on the knitted pocket may be fused and/or bonded in a post-process after knitting is completed.

In some embodiments, at least part of the pocket could be knitted using a transparent or translucent yarn, such as a monofilament yarn, for the insert to be visible.

The knitted material could also be used to define an insole or a sock liner. The pocket could be defined to cover only a portion of the sole, for instance to create customized areas of cushioning or support. For example, when creating an insole or sock liner, pockets of different shapes and sizes can be knitted into the arch area to accommodate support materials like foam. This allows for a customized fit and different levels of arch support. The orientation of the pocket opening can be controlled by the knitting direction of the sole element, for instance by knitting it lengthwise or widthwise, and/or partial knitting to facilitate the insertion of the support material.

Additionally, a sports article such as a shoe may comprise further components produced by methods other than the one claimed. For example, a knitted material can form a tubular structure for receiving a midsole element, such as an expanded thermoplastic polyurethane foam. In such a case, the tubular pocket can be knitted, and the midsole element can be inserted in a subsequent post-processing step after the component is removed from the knitting machine. An outsole can then be bonded to the bottom of this knitted structure to complete the sole assembly. This component can be present in a shoe together with other parts that are fabricated according to the method of the invention.

In a particular embodiment, a sports article such as a shoe may include a knitted component having a pocket and foamed materials, such as particles, strands, or portions of a midsole element. For example, a knitted material can form a tubular structure for receiving particles, strands, or portions of a midsole element, such as an expanded foam materials. In such a case, the tubular pocket can be knitted, and the expanded foam materials can be inserted during the formation of the knitted component and/or in a subsequent post-processing step after the knitted component is removed from the knitting machine. In particular embodiment, an outsole may be bonded to the bottom of this knitted structure to complete the sole assembly. This component can be present in a shoe together with other parts that are fabricated according to the methods described herein.

In some embodiments, a midsole element may include a knitted fabric having a pocket formed at least partially from a transparent or translucent yarn, such as a monofilament yarn. Using a transparent or translucent yarn in a knitted fabric pocket may allow insert members of the midsole to be visible during formation and/or during use.

In another embodiment the sports article is an apparel item.

For example, the process can be employed to produce garments with integrated cushioning or support elements for improved performance, comfort or safety. The knitting technique allows for the strategic placement of these elements within the fabric, resulting in a seamless and ergonomic design. Additionally, the use of elastic or shrinkable yarns can provide a snug, adaptive fit, while electronic components like microchips can offer advanced features such as performance monitoring. This method enhances the functionality, comfort, and innovation of sports apparel, making it suitable for a wide range of athletic activities.

Examples of sport apparel items are for instance: an upper torso garment for motorsports where the insert element could be a safety padding or reinforcement, a sock where the insert element is a shin guard to be used for instance for playing football, baseball or hockey, cycling shorts or tights with seat padding, protective compression sport garments including integrated protective pads, lower body garments with moisture-wicking and leak-resistant padding.

Another embodiment of the invention is a sports article obtained by the method outlined above.

For example, the sport article could be a sport accessory such as a knee or elbow protector for instance for playing volleyball or for skating, a ball and the knitted material could be the carcass of the ball while the insert element could be for instance a sensor, a bag or a backpack and the insert element could be a reinforcement or a padding element.

For example, a sports shoe produced with this method might feature integrated cushioning, reinforcement elements, and possibly electronic components for performance tracking. The seamless design ensures durability and comfort, while the use of advanced materials like shrinkable and elastic yarns provides a custom fit. Similarly, sports apparel made with this method could include compression garments with strategically placed support and cushioning, offering enhanced performance and comfort.

BRIEF DESCRIPTION OF THE FIGURES

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

In the following, embodiments of the disclosure are disclosed by reference to the accompanying figures.

FIG. 1: illustrates the insertion of an insert element into an open void in a fabric in a schematic view.

FIG. 2: shows the insert element inside the void between two knit layers in a cross-sectional top view.

FIG. 3A: depicts an insert element and a fabric component having a void into which the insert element will be inserted.

FIG. 3B: depicts an insert element positioned in a fabric component and extending through an opening in the fabric component after shrinking the fabric in a schematic view.

FIG. 4: illustrates the insertion of a trapezoidal insert element into an open void in a fabric and the insert element inside the fabric in a schematic view.

FIG. 5: depicts a concave insert element inside a stretchable fabric in a schematic cross-sectional view.

FIG. 6: shows an insert element that is visible through holes inside the fabric in a schematic view.

FIG. 7: illustrates a fabric with two insert elements inside two voids and a fabric with three insert elements inside three voids in a schematic cross-sectional view.

FIG. 8: depicts a fabric with three insert elements as a component for a shoe in a schematic view.

FIG. 9: shows a fabric with four insert elements as a counter-component to FIG. 8 in a schematic view.

FIG. 10: shows a photograph of a manual insertion of an insert element between the needle beds of a knitting machine proximate a knitted fabric.

FIG. 11: shows a closeup photograph of the insertion of the insert element of FIG. 10 between the needle beds of a knitting machine proximate a knitted fabric.

FIG. 12: shows a sideway photograph of the insertion of the insert element of FIG. 10 into a knitting machine proximate a knitted fabric.

FIG. 13: depicts a back photograph of the fabric with insert elements of FIG. 9.

FIG. 14: shows a front photograph of the fabric with insert elements of FIG. 9.

FIG. 15: shows a front photograph of the fabric with insert elements of FIG. 8.

FIG. 16: shows a close-up photograph of the fabric of FIG. 15.

FIG. 17: depicts a photograph of a fabric with an insert element as a shoe tongue.

FIG. 18: illustrates a close-up photograph the fabric of FIG. 17.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. For purposes of the description hereinafter, it is to be understood that the embodiments described below may assume alternative variations and embodiments. It is also to be understood that the specific articles, compositions, and/or processes described herein are exemplary and should not be considered as limiting. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

The descriptions represent examples only and are not intended to limit the invention's scope. Identical reference numerals across the figures and text denote the same components. The illustrations may not reflect actual size or scale; their dimensions, proportions, and depictions of elements might be enhanced for better understanding and visual convenience.

Although the terms first, second, third, etc. may be used herein to describe various elements, members, components, regions, portions, layers, and/or sections, these elements, components, regions, portions, layers, and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

In the present disclosure the singular forms “a,” “an,” and “the” include the plural reference, and reference to a particular numerical value includes at least that particular value, unless the context clearly indicates otherwise. When values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. As used herein, “about X” (where X is a numerical value) preferably refers to ±10% of the recited value, inclusive. For example, the phrase “about 8” preferably refers to a value of 7.2 to 8.8, inclusive. Where present, all ranges are inclusive and combinable. For example, when a range of “1 to 5” is recited, the recited range should be construed as including ranges “1 to 4”, “1 to 3”, “1-2”, “1-2 & 4-5”, “1-3 & 5”, “2-5”, and the like. In addition, when a list of alternatives is positively provided, such listing can be interpreted to mean that any of the alternatives may be excluded, e.g., by a negative limitation in the claims. For example, when a range of “1 to 5” is recited, the recited range may be construed as including situations whereby any of 1, 2, 3, 4, or 5 are negatively excluded; thus, a recitation of “1 to 5” may be construed as “1 and 3-5, but not 2”, or simply “wherein 2 is not included.” It is intended that any component, element, attribute, or step that is positively recited herein may be explicitly excluded in the claims, whether such components, elements, attributes, or steps are listed as alternatives or whether they are recited in isolation.

FIG. 1 illustrates the insertion of an insert element into an open void in a fabric in a schematic view. The fabric 100 is hanging on the needles 150 of a knitting machine and comprises a first layer 101 and a second layer 102. Between the first and second layer 101, 102 is an open void 110, configured to receive the insert element 1000. The void 110 is in particular accessible through an aperture 103.

The fabric 100 remains on the knitting machine needles 150 throughout the process, ensuring that the first layer 101 and the second layer 102 remain spaced apart held by respective needles and the aperture 103 remains open allowing the precise placement of the insert element 1000. This method enhances the sport article's structural integrity and comfort by securely integrating the insert element, for instance a cushioning pad within the fabric layers 101, 102. This technique results in a seamless, durable sports article.

In some embodiments, an insert element may be positioned proximate a knit in a knitting machine and the knit may be further knit around the insert element. FIG. 2 depicts a top cross-sectional view of a knit with an insert element positioned between layers of the knit fabric. In particular, FIG. 2 shows the insert element inside the void between two layers in a cross-sectional view. The fabric 100 comprises a first layer 101 and a second layer 102, and a void 110 between the knit layers. The insert element 1000 sits in the void and is enclosed by the layers 101, 102.

The first and second layers 101, 102 of the fabric 100 create a void 110 where an insert element 1000 is placed. This cross-sectional view illustrates how the insert element 1000 is securely enclosed within the fabric layers 101, 102, ensuring it stays in place during use. This method provides enhanced protection and comfort, as the insert element in form of, e.g., a reinforcement or a padding can absorb impacts while the fabric layers maintain flexibility and durability.

In some embodiments, the insert element may be further secured in the vertical direction by knitting of layers 101, 102 together proximate edges of void 110 as described herein. Aperture 103 is defined by knit layers 101, 102 to form void 110. Further, some embodiments may include melt yarns and/or shrinkable yarns that may further engage insert element 1000 to hold it in place.

In an embodiment of the method, an insert element may be positioned within a partially knit void. FIG. 3A depicts an embodiment of insert element prior to being inserted in the void. FIG. 3B illustrates an insert element positioned within a fabric and extending through an opening after shrinking the fabric in a schematic view. The insert element 2000 is inserted into the fabric 200, wherein the fabric 200 includes a first and a second layer 201, 202. The layers 201, 202 form between them a void 210 to receive the insert element 2000. The void also includes a small opening 220 on the side, through which the insert element 2000 can extend partially.

After closing the void during the knitting procedure and after shrinking the fabric, the shrunken fabric 200′ snugly encloses the insert element 2000 so that parts of the insert element 2000 extend through the opening 220. In particular, knit layers 201, 202 are knitted together proximate edges of void 210 as described herein. Further, some embodiments, may include melt yarns and/or shrinkable yarns that may further engage insert element to hold it in place.

In a particular embodiment, as shown in FIG. 3A the width of the void 210 is preferably larger than the total width of the insert element 2000 when the insert element 2000 is introduced between the first and second layer 201, 202. After the first and second layer 201, 202 have been knitted together to close the void 210 and the knitted fabric has undergone a shrinking post-process treatment, the width of the void is reduced and the insert element 2000 protrudes through the opening 220.

The first and second fabric layers 201, 202 form a void 210 with a small opening 220. The insert element 2000 is placed into the void. After completing the knitting process and applying for instance heat to shrink the fabric 200, the shrunken fabric 200′ tightens around the insert element 2000, ensuring a secure fit. The shrinking process allows the insert element 2000 to extend partially through the opening.

FIG. 4 illustrates a trapezoidal insert element inside a fabric in a schematic view. The fabric 300 comprises a first and a second layer 301, 302 forming a void 310 to receive the trapezoidal insert element 3000. The trapezoidal insert element 3000 is inserted into the void 310 during the knitting procedure. After knitting, the fabric is shrunken, such that it encloses around the insert element 3000, thus adopting the shape of the insert element.

The first and second fabric layers 301, 302 create a void 310 that holds a trapezoidal insert element 3000, for instance a cushioning pad. During the knitting process, the insert element 3000 is inserted into the void, and then the fabric 300 is subjected to a shrinking step, conforming tightly around the trapezoidal insert element 3000. This snug fit ensures that the insert element 3000 remains securely in place and provides, for instance, protection and support. The trapezoidal shape is an example of a shape not including only parallel sides that can be inserted in a void according to the invention, but other shapes could be used, including also irregular shapes. The use of shrinkable yarns and the addition of a shrinking step, after the knitting process, allow the knitted material to conform to the shape of the insert element, even if irregular, without the need to create complex knitting programs. Trapezoidal or similar shapes of insert element(s) could be used for instance to create padding element(s) on the heel area of an article of footwear, offering optimized coverage and comfort.

FIG. 5 depicts a concave insert element inside a stretchable fabric in a cross-sectional schematic view. The insert element 5000 is seated inside the void 510, wherein the void 510 is formed between the first and second layer 501, 502 of the fabric 500. The stretch yarn 530 which is part of the first layer 501 forces the insert element 5000 to bend into a concave form, thus forming an empty volume between the first layer 501 stretched by the stretch yarn 530 and the concave insert element 5000. More in detail, when the method is performed on a flat knitting machine, the insert element 5000 is made of a deformable material, such as for instance a deformable foam or foil, adapted to bend under the action of the stretch yarn 530.

The fabric layers 501, 502 form a void 510 that holds a concave insert element 5000, for instance to form a padding on the heel area of a shoe. The stretch yarn 530 in the first layer 501 forces the insert element to bend into a concave shape, ensuring it fits snugly against the body while creating a small empty volume 532, e.g. for further comfort. This design could also enhance the support and fit of for instance a sports bra, providing better shape and coverage. The concave shape of the insert improves comfort by reducing pressure points and allowing for better airflow, making the sports article suitable for various activities. For a bra, this method could be implemented when the insert element is a soft padding. Similarly, this solution can be applied to other products, such as a shin guard or the visor of a cap, where the insert element would consist of a more rigid yet elastically deformable material.

FIG. 6 shows an insert element that is visible through holes created on the first or second layer of the fabric in a schematic view. The fabric 600 comprises a void 610 which holds the insert element 6000. The insert element is visible due to through-holes 640 in the fabric 600.

The fabric layers form a void 610 defined by the hatched line shown in FIG. 6 to hold the insert element 6000. Through holes 640 in the fabric allow the insert element 6000 to be visible and partially exposed. This design not only provides aesthetic appeal but also enhances breathability and flexibility. The visibility through the holes can also serve functional purposes, such as indicating the correct positioning of the insert or providing additional grip. This method combines protection, comfort, and design innovation in the sports article.

FIG. 7 illustrates a fabric with two insert elements inside two voids and a fabric with three insert elements inside three voids in a schematic cross-sectional views. The first fabric 710 comprises a first and a second void 711, 712, which hold a first and a second insert element 7001, 7002. This way, a stacked assembly is formed by the layers of the fabric 710 and the insert elements 7001, 7002, thus forming a sandwiched structure. The second fabric 720 comprises a first, a second and a third void 721, 722, 723 which hold a first, a second and a third insert element 7001, 7002, 7003. This way, a stacked assembly is formed by the layers of the fabric 720 and the insert elements 7001, 7002, 7003, thus forming a sandwiched structure.

The first fabric 710 with two voids 711, 712 and insert elements 7001, 7002 can be used, for instance, for a shin guard, where each insert provides targeted protection and cushioning. The second fabric 720 with three voids 721, 722, 723 and insert elements 7001, 7002, 7003 can be used for a more complex sports article, where multiple layers can offer enhanced impact absorption and coverage. The sandwiched structure ensures that each insert element is securely held between the fabric layers, providing a robust, durable, and effective protective solution. This allows for customizable protection levels by varying the number and type of insert elements used. Each insert element can provide a different functionality and to this aim can be made of different materials.

FIG. 8 depicts a fabric with three insert elements as a component for a shoe in a schematic view. The fabric 800 is formed as a part of a shoe upper. The insert element 8003 on the front part of the fabric 800 serves as a toe reinforcement and the insert elements 8001, 8002 serve as eyestay reinforcements.

The fabric 800 for the shoe upper includes three strategically placed insert elements 8001, 8002, 8003. The toe reinforcement 8003 provides additional protection and durability to the front of the shoe. The eyestay reinforcements 8001, 8002 ensure that the lacing areas are stronger and more resistant to wear. This design enhances the overall performance, longevity, and comfort of the shoe, making it suitable for rigorous athletic use. The integration of these insert elements within the fabric ensures a seamless, lightweight, and aesthetically pleasing shoe construction.

FIG. 9 shows in a schematic view a fabric component with four insert elements that may be used in combination with the fabric component shown in FIG. 8. The fabric 900 is formed as a counterpart of the shoe upper component of FIG. 8. The insert elements 9001, 9002 of the fabric can serve as lacing reinforcement. The insert element 9004 on the middle and upper part of the fabric 900 can serve as a heel foam cushioning. The insert element 9005 on the middle and lower part of the fabric 900 can serve as a heel reinforcement.

The fabric 900 for the counterpart to the fabric of FIG. 9 includes four insert elements 9001, 9002, 9004, 9005 strategically placed for enhanced functionality. The lacing reinforcements 9001, 9002 ensure durable and secure lacing areas, improving fit and stability. The heel foam cushioning 9004 adds comfort and shock absorption to the heel area, while the heel reinforcement 9005 provides additional structural support and protection. This enhances the shoe's overall performance, comfort, and durability, making it ideal for intense athletic activities. The integration of these elements within the fabric ensures an integrated, lightweight, and efficient shoe design.

In some embodiments, an insert element may be introduced into a knitting machine proximate a knit fabric. FIG. 10 shows a photograph of a manual insertion of an insert element 10000 into a knitting machine, in particular a flat knitting machine. Yarns 1002, 1004 are introduced into the needle beds to form the knitted fabric on the needle beds. Stitches 1006 forming a portion of fabric 1010 are shown on needles proximate the insert on either side of the insert element 10000. A knitted portion of fabric and a portion of the insert element extend below the needle beds 1012, 1014.

FIG. 11 shows a closeup photograph of the insertion of the insert element 10000 of FIG. 10 into a knitting machine. Stitches 1006 of yarn 1002 are shown on needle bed 1010 on a first side of insert element 10000. Yarns 1002, 1004 are visible at the edge of insert element 10000 where the yarns 1002, 1004 are interknitted to form fabric 1010 using needle beds 1012, 1014 and hold insert element 10000 in the void created by layers formed by yarns 1002, 1004.

FIG. 12 shows a side view photograph of the insertion of the insert element 10000 of FIG. 10 into a knitting machine. As visible, the insert element is placed between the needle beds. Stitches 1006 of fabric 1010 that will encompass insert element 10000 are visible between needle beds 1012, 1014.

In another embodiment, any number of yarns may be used to create the fabric and/or layers of the fabric. Layers of knitted fabric may be used to secure insert elements in the fabric through positioning of stitches. As described herein a number of layers of knitted fabric and/or knitted elements may be varied.

FIG. 13 depicts a back photograph of the fabric 900 with the insert elements 9001, 9002, 9004, 9005 of FIG. 9. The surface shown corresponds to the back side of the footwear element; however, from a technical perspective, it represents the front side of the knitted material as it is produced by the knitting machine.

FIG. 14 shows a front photograph of the fabric 900 depicted in FIG. 13 with the insert elements 9001, 9002, 9004, 9005 of FIG. 9. The shown surface constitutes the inner side of the footwear element; however, it corresponds to the back side of the knitted material as it emerges from the knitting machine.

FIG. 15 shows a front photograph of the fabric 800 with the insert elements 8001, 8002, 8003 of FIG. 8. As shown in FIG. 15, insert elements 8001, 8002, 8003 are seamlessly incorporated into fabric 800 between knit layers of the fabric.

FIG. 16 shows a close-up photograph of the fabric 800 with the insert elements 8001, 8002, 8003 of FIG. 8.

FIG. 17 depicts a photograph of an insert element 17000 positioned within fabric 17002 and where the insert element acts as a tongue reinforcement of a shoe tongue.

FIG. 18 shows a close-up photograph of a tongue element 18000 that includes fabric 18002 with an insert element (not shown) positioned within layers of the fabric.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

The invention is further described by the following numbered paragraphs:

• • 1. A method of fabricating a sports article comprising a knitting process, the knitting process comprising the steps:
    • a.) providing a knitting machine, yarn for knitting, and at least one insert element;
    • b.) knitting a fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) such that the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises at least one open void (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) between at least two layers of the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900);
    • c.) inserting at least one insert element into the at least one open void (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) while the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) remains in the knitting machine; and
    • d.) further knitting the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) such that the at least one void (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is closed at least partially around the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) by connecting the at least two layers.
  • 2. A method according to paragraph 1, wherein the method does not comprise cutting of the knitted fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) to create the open void (110, 210, 310, 510, 610, 711, 712, 721, 722, 723).
  • 3. A method according to paragraph 1 or paragraph 2, wherein the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) is continuously held on the knitting machine during steps b.)-d.).
  • 4. A method according to one of the preceding paragraphs, wherein the inserting of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is performed automatically, preferably by supplying the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) from a storage area.
  • 5. A method according to any one of the preceding paragraphs, wherein the inserting of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) is performed manually by an operator.
  • 6. A method according to one of the preceding paragraphs, wherein the knitting machine gauge is maximum 18.
  • 7. A method according to one of the preceding paragraphs, wherein after step b.) the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises more than two layers and two or more voids defined between them, such that after inserting insert elements, the insert elements and the layers are stacked alternately.
  • 8. A method according to one of the preceding paragraphs, wherein the height of the void (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is larger than the height of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) and/or the width of the void (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) is larger than the width of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000).
  • 9. A method according to one of the preceding paragraphs, wherein at least one insert element is fixed in the void (110, 210, 310, 510, 610, 711, 712, 721, 722, 723) by the yarn extending through the insert element.
  • 10. A method according to one of the preceding paragraphs, wherein the yarn comprises a shrinkable yarn and the method comprises a shrinking step, such that the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) around the void conforms around the contour of the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000), wherein the shrinking is preferably achieved by applying heat.
  • 11. A method according to one of the preceding paragraphs, wherein the layers comprise different yarns and wherein preferably one layer of the fabric (100, 200, 300, 500, 600, 710, 720, 800, 900) comprises an elastic and/or shrink-able yarn and another layer comprises a non-elastic and/or non-shrinkable yarn.
  • 12. A method according to one of the preceding paragraphs, wherein the yarn comprises an elastic and/or shrinkable yarn.
  • 13. A method according to one of the preceding paragraphs, wherein one of the layers comprises a melting yarn, adapted to form a connection with the insert element(s) when fused.
  • 14. A method according to paragraph 13, wherein the melting yarn is also a shrinkable yarn.
  • 15. A method according to one of the preceding paragraphs, wherein the yarn comprises a non-elastic and/or non-shrinkable yarn comprising polyester.
  • 16. A method according to one of the preceding paragraphs, wherein the yarn comprises a shrinkable yarn and the void has one or more opening(s) (220) smaller than the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) and the method comprises a shrinking step, such that after shrinking the yarn, the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) partially extend through the opening(s) (220).
  • 17. A method according to one of the preceding paragraphs, wherein the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprise(s) reinforcement means and/or cushioning means.
  • 18. A method according to one of the preceding paragraphs, wherein the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprise(s) magnets.
  • 19. A method according to one of the preceding paragraphs, wherein the insert element(s) (1000, 2000, 3000, 5000, 6000, 7001, 7002, 7003, 10000) comprise(s) one or more electronic components, preferably microchips.
  • 20. A method according to one of the preceding paragraphs, wherein the sports article is a shoe.
  • 21. A method according to one of the preceding paragraphs, wherein the sports article is apparel.
  • 22. Sports article obtained by a method according to one of the preceding paragraphs.