# US 11,896,076 B1 · Footwear upper having a unitary knit structure and method of manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,896,076 B1 - Document ID: US11896076B1 - Status: Granted - Kind: B1 - Application number: 18/313,710 - Filed: 2023-05-08 - Granted: 2024-02-13 - Earliest claimed: 2023-05-07 - Assignees: NIKE, Inc. - Applicants: NIKE, Inc. - Inventors: Michael A. Carriero; Evan W. Jones; Sanchari Ashishkumar Mahapatra - Web page: https://patentgrep.com/patent/US11896076B1 ## CPC - A43B 1/04: braided, knotted, knitted or crocheted - A43B 1/0072: {made at least partially of transparent or translucent materials} - A43B 7/085: {in the upper} - A43B 23/0235: {Different layers of different material} - A43B 23/024: {Different layers of the same material} - A43B 23/0245: {characterised by the constructive form} - A43B 23/0265: {having different properties in different directions} - D04B 21/16: incorporating synthetic threads - D04B 21/207: {Wearing apparel or garment blanks} - A43B 23/0215: {Plastics or artificial leather} - D10B 2403/011: Dissimilar front and back faces - D10B 2403/0114: with one or more yarns appearing predominantly on one face, e.g. plated or paralleled yarns (for pile fabrics D03D27/00, D04B1/02, D04B21/02; for intarsia fabrics D04B1/126) - D10B 2403/02: Cross-sectional features (for three-dimensional features D10B2403/033) - D10B 2501/043: Footwear - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - D04B: KNITTING - D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES ## Abstract A footwear upper has a unitary knit structure with a knit outer face layer, a knit inner face layer, and a knit intermediate layer integrally knit to define forefoot, midfoot, and heel regions of the footwear upper. The knit intermediate layer is disposed between the knit outer face layer and the knit inner face layer at a plurality of first zones and absent from or present in a lesser amount or a lesser density in a plurality of second zones, the first zones alternating with the second zones in a longitudinal direction, and the unitary knit structure having a greater modulus of elasticity in the longitudinal direction in the first zones than in the second zones, and a greater breathability in the second zones than in the first zones. A method of manufacturing the footwear upper is disclosed. ## Claims ### Claim 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 the 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, the first zones alternating with the second zones in a longitudinal direction of the footwear upper; 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; 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; wherein the knit outer face layer comprises a mesh pattern including first knitted-in holes of a first size; and 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. ### Claim 2 (depends on 1) The footwear upper of claim 1, wherein the knit outer face layer and the knit inner face layer are connected in the first zones and the second zones. ### Claim 3 (depends on 1) The footwear upper of claim 1, wherein boundaries between adjacent ones of the first zones and the second zones extend substantially linearly in a transverse direction of the footwear upper. ### Claim 4 (depends on 3) The footwear upper of claim 3, wherein: the first zones progressively increase in fore-aft width in a rearward direction at least from the forefoot region to the midfoot region; and the second zones progressively increase in fore-aft width in a forward direction at least from the midfoot region to the forefoot region. ### Claim 5 (depends on 1) The footwear upper of claim 1, wherein an average fore-aft width of the first zones in the midfoot region is less than an average fore-aft width of the first zones in the heel region. ### Claim 6 (depends on 1) The footwear upper of claim 1, wherein the unitary knit structure is more transparent or more translucent at the second zones than at the first zones. ### Claim 7 (depends on 6) The footwear upper of claim 6, wherein the knit outer face layer is more transparent or more translucent than the knit inner face layer and the knit intermediate layer. ### Claim 8 (depends on 1) The footwear upper of claim 1, wherein: the first knitted-in holes of the knit outer face layer each have a first maximum length in the longitudinal direction; the second knitted-in holes of the knit inner face layer each have a second maximum length in the longitudinal direction; and the second maximum length is from about two to about four times the first maximum length. ### Claim 9 (depends on 1) The footwear upper of claim 1, wherein the knit outer face layer comprises one or more monofilament yarns and the knit inner face layer comprises one or more multi-filament yarns. ### Claim 10 (depends on 9) The footwear upper of claim 9, wherein the knit outer face layer consists of the one or more monofilament yarns and the knit inner face layer consists of the one or more multi-filament yarns. ### Claim 11 (depends on 1) The footwear upper of claim 1, wherein the knit inner face layer, the knit outer face layer, and the knit intermediate layer comprise yarns recyclable by melting the yarns and re-extruding melted material of the melted yarns. ### Claim 12 (depends on 1) The footwear upper of claim 1, wherein the unitary knit structure is substantially free of yarn comprising a thermoset material. ### Claim 13 (depends on 1) The footwear upper of claim 1, in combination with a sole structure directly secured to an outer surface of the knit outer face layer. ### Claim 14 A footwear upper comprising: a unitary knit structure having: a knit outer face layer; a knit inner face layer; 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 outer face layer comprises a mesh pattern including first knitted-in holes of a first size; 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 the knit intermediate layer is disposed between the knit outer face layer and the knit inner face layer at a plurality of first zones of the unitary knit structure and absent from or present in a lesser amount or lesser density in a plurality of second zones of the unitary knit structure, the first zones alternating with the second zones in a longitudinal direction of the footwear upper, and the unitary knit structure having a greater modulus of elasticity in the longitudinal direction in the first zones than in the second zones, and having greater breathability in the second zones than in the first zones; 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. ### Claim 15 (depends on 14) The footwear upper of claim 14, wherein the knit outer face layer and the knit inner face layer are connected in the first zones and the second zones. ### Claim 16 (depends on 14) The footwear upper of claim 14, wherein boundaries between adjacent ones of the first zones and the second zones extend substantially linearly in a transverse direction of the footwear upper. ### Claim 17 (depends on 14) The footwear upper of claim 14, wherein: the first zones progressively increase in fore-aft width in a rearward direction at least from the forefoot region to the midfoot region; and the second zones progressively increase in fore-aft width in a forward direction at least from the midfoot region to the forefoot region. ### Claim 18 (depends on 14) The footwear upper of claim 14, wherein an average fore-aft width of the first zones in the midfoot region is less than the average fore-aft width of the first zones in the heel region. ### Claim 19 (depends on 14) The footwear upper of claim 14, wherein: the first knitted-in holes of the knit outer face layer each have a first maximum length in the longitudinal direction; the second knitted-in holes of the knit inner face layer each have a second maximum length in the longitudinal direction; and the second maximum length is from about two to about four times the first maximum length. ### Claim 20 (depends on 19) The footwear upper of claim 19, wherein the knit outer face layer is more transparent or more translucent than the knit inner face layer and the knit intermediate layer. ### Claim 21 (depends on 14) The footwear upper of claim 14, wherein the knit outer face layer is more transparent or more translucent than the knit inner face layer and the knit intermediate layer. ### Claim 22 (depends on 14) The footwear upper of claim 14, wherein the knit outer face layer comprises one or more monofilament yarns and the knit inner face layer comprises one or more multi-filament yarns. ### Claim 23 (depends on 22) The footwear upper of claim 22, wherein the knit outer face layer consists of the one or more monofilament yarns and the knit inner face layer consists of the one or more multi-filament yarns. ### Claim 24 (depends on 14) The footwear upper of claim 14, wherein the knit inner face layer, the knit outer face layer, and the knit intermediate layer comprise yarns recyclable by melting the yarns and re-extruding melted material of the melted yarns. ### Claim 25 (depends on 14) The footwear upper of claim 14, in combination with a sole structure directly secured to an outer surface of the knit outer face layer. ### Claim 26 (depends on 14) The footwear upper of claim 14, wherein the knit inner face layer and the knit outer face layer are coextensive, one-piece layers, each extending to and defining an entire outer perimeter of the unitary knit structure including a medial edge, a lateral edge, a rear edge, and a front edge and characterized by an absence of sewn seams. ### Claim 27 (depends on 1) The footwear upper of claim 1, wherein the knit intermediate layer includes a greater number of yarn ends per unit area in the first zones than in the second zones. ### Claim 28 (depends on 16) The footwear upper of claim 16, wherein the transverse direction is perpendicular to a longitudinal midline of the footwear upper.