Article of footwear having an upper and an integrated sole structure

Abstract

Aspects herein relate to an article of footwear having an upper, an upper for an article of footwear, and a method of manufacturing an upper for an article of footwear. The upper includes yarns and a knit structure that, upon processing, at least partially forms a translucent or transparent thermoplastic polymer layer that facilitates visibility of a first sole structure, such as a midsole, that is removably positioned within a foot-receiving void of the upper. The translucent or transparent thermoplastic polymer layer can also directly secure a second sole structure to a foot-under portion of the upper.

Description

Background Technology

[0001] Traditional footwear products (including those with uppers) may include sole structures that are attached to the upper by applied adhesives or other applied bonding agents. Applying adhesives during the manufacturing process and using these adhesives or bonding agents to attach the sole structures to the upper can increase the number of manufacturing steps and the production time associated with the footwear product. Additionally, the use of adhesives or other types of bonding methods may increase the carbon footprint associated with the manufacturing process and may potentially limit the recyclability of footwear products.

[0002] In some cases, for traditional footwear, the sole structure (such as the midsole) is positioned within the foot-receiving opening of the upper. Typically, due to the materials incorporated into the upper that provide the structure and stability required for wear and reuse, the midsole, or any other component positioned within or adjacent to the foot-receiving opening of the upper, is usually invisible or unobservable from an external viewpoint. This can limit the visual impact of the midsole and / or any visual indicators associated with it or other components / structures positioned within the foot-receiving opening of the upper. Attached Figure Description

[0003] Examples of various aspects of this article are described in detail below with reference to the accompanying drawings, in which:

[0004] Figure 1A and Figure 1B The illustrations show an inner and outer view of a footwear article with an upper having a translucent thermoplastic polymer layer, according to various aspects of this article.

[0005] Figure 2A and Figure 2B The illustrations show an inner and outer view of an alternative example of a footwear article having an upper with a translucent thermoplastic polymer layer, according to various aspects of this article.

[0006] Figure 3 The diagram illustrates the various aspects based on this article. Figure 2A and Figure 2B A top view of the footwear products;

[0007] Figure 4A The diagram illustrates a knitting pattern that depicts various aspects of the process described in this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The first knitted layer in the first knitted section of the upper of footwear products;

[0008] Figure 4BThe diagram illustrates a knitting pattern that depicts various aspects of the process described in this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The first and second knitted layers in the first knitted section of the upper of footwear products;

[0009] Figure 5 The illustration shows yarns with a core of a high-melting-point material and a sheath of a low-melting-point thermoplastic material, according to various aspects of this article.

[0010] Figure 6A The illustration shows the process of applying heat and / or pressure to the first knitted section according to various aspects of this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The cross-section of the first knitted section of the upper of footwear products;

[0011] Figure 6B The illustration shows the process after applying heat and / or pressure to the first knitted section, according to various aspects of this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The cross-section of the first knitted section of the upper of footwear products;

[0012] Figure 6C The illustration shows the process of applying heat and / or pressure to the first knitted section according to various aspects of this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The cross-section of the first alternative structure of the first knitted section of the upper of footwear products;

[0013] Figure 6D The illustration shows the process after applying heat and / or pressure to the first knitted section, according to various aspects of this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The cross-section of the first alternative structure of the first knitted section of the upper of footwear products;

[0014] Figure 6E The illustration shows the process of applying heat and / or pressure to the first knitted section according to various aspects of this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The cross-section of the second alternative structure of the first knitted section of the upper of footwear products;

[0015] Figure 6F The illustration shows the process after applying heat and / or pressure to the first knitted section, according to various aspects of this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B The cross-section of the second alternative structure of the first knitted section of the upper of footwear products;

[0016] Figure 7 The illustration shows a knitted textile prior to the formation of the upper of the footwear articles shown in Figures 1 and 2, according to various aspects of this article;

[0017] Figure 8 The diagram illustrates the crossing based on various aspects of this article. Figure 7 The cross-section of a knitted textile;

[0018] Figure 9A The diagram illustrates the various aspects used to form according to this article. Figure 1A and Figure 1B The manufacturing process of footwear products;

[0019] Figure 9B The diagram illustrates the various aspects used to form according to this article. Figure 2A and Figure 2B The manufacturing process of footwear products;

[0020] Figure 10A The illustration shows a bottom view of the underfoot portion of the upper of a footwear product according to Figures 1 and 2, as described in various aspects of this article;

[0021] Figure 10B The diagram illustrates the various aspects based on this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B In the forefoot area of ​​the upper of footwear products Figure 10A The cross-section taken at the cutting line 10B-10B;

[0022] Figure 10C The diagram illustrates the various aspects based on this article. Figure 1A and Figure 1B or Figure 2A and Figure 2B In the heel area of ​​the upper of footwear products Figure 10A The cross-section taken at the cutting line 10C-10C;

[0023] Figure 11 The diagram illustrates the various aspects based on this article. Figure 2A and Figure 2B A portion of the upper in the second knitted section of footwear;

[0024] Figure 12 The diagram illustrates the crossing based on various aspects of this article. Figure 2A and Figure 2B The cross-section of the second knitted section of the footwear;

[0025] Figure 13 The diagram illustrates the various aspects based on this article. Figure 2A and Figure 2B A bottom-view perspective view of the toe area of ​​the upper of a footwear product;

[0026] Figure 14 The diagram illustrates the various aspects based on this article. Figure 2A and Figure 2B A perspective bottom view of the heel end of the upper of footwear; and

[0027] Figure 15 The illustration shows a heel stabilizer based on various aspects of this paper. Figure 2A and Figure 2B Rear view of footwear products. Detailed Implementation

[0028] This document relates in various aspects to a footwear article having an upper, an upper for a footwear article, and a method of manufacturing an upper for a footwear article. In one example, the upper includes yarns and knitted structures that, after processing, at least partially form a translucent or transparent thermoplastic polymer layer, which can be formed by thermoforming the upper. This thermoplastic polymer layer facilitates the visibility of a first sole structure (such as a midsole) removably positioned within a foot-receiving opening of the upper. In another example, the upper may include yarns and knitted structures and a translucent or transparent thermoplastic polymer film that, after processing, forms a translucent or transparent thermoplastic polymer layer, which facilitates the visibility of the first sole structure. Using this translucent or transparent thermoplastic polymer layer to provide visibility of the first sole structure enhances the visual appeal of the footwear article. The translucent or transparent thermoplastic polymer layer can also act as a visual indicator of the functional characteristics of a specific midsole, which is removably positioned within the foot-receiving opening of the upper. For example, a wearer may have multiple different midsoles, each with different functional features, such as increased arch support, increased heel support, etc. The functional features associated with a particular midsole can be visually indicated, for example, by the color of the midsole (e.g., a red midsole could indicate increased arch support). When a wearer intends to wear the footwear, they can easily observe the midsole positioned within the foot-receiving opening through the translucent or transparent polymer layer and determine whether the midsole meets the specific needs of the activity the wearer intends to perform.

[0029] In an additional example, the polymer layer can also anchor a second sole structure to the foot portion of the upper. For instance, when heat and / or pressure are applied to the upper, a portion of the material forming the yarn of the upper can melt and flow. Upon cooling, the molten material hardens and forms a thermoformed layer that acts as a thermoplastic polymer layer. Alternatively, when using a translucent or transparent thermoplastic polymer film, the film can melt and flow to form a thermoplastic polymer layer when heat and / or pressure are applied to the upper. While the material is molten, the second sole structure can be directly anchored to the molten material, positioning it on the outward-facing surface of the foot portion of the upper. Anchoring the second sole structure in this manner eliminates and / or reduces the need for applied adhesives or bonding agents. In this example, this can reduce the number of processing steps associated with manufacturing footwear, reduce the carbon footprint associated with footwear manufacturing, and potentially enhance the recyclability of footwear. In some aspects, adhesives and / or bonding agents are used, but molten polymer from the upper can help strengthen the bond between the upper and sole structures. In one embodiment, the upper can be thermoformed and molded to form one or more three-dimensional shapes complementary to one or more three-dimensional shapes of the second sole structure. The molded upper can then be attached to the second sole structure via, for example, an adhesive.

[0030] In some instances, during the upper manufacturing process, a last can be positioned within a foot-receiving opening of the upper, wherein the last includes a foot portion having a plurality of last supports or ridges and a plurality of last recesses disposed between adjacent last supports. After heat and / or pressure is applied to at least the foot portion of the upper and subsequently cooled, the resulting thermoplastic polymer layer in the foot portion is molded to include a plurality of supports and a plurality of recesses having shapes corresponding to the plurality of last supports and the plurality of last recesses. The upper can have a knitted structure that allows the supports of the upper to be molded into more precise shapes as described herein. In some instances, each of the plurality of supports can terminate at a support surface, which, in example, can be non-planar (i.e., not smooth or uneven).

[0031] In this example, the second sole structure (which may be in the form of a fluid-filled bladder) includes one or more spherical portions that are fixed to the support surfaces of one or more of the supports of the foot portion of the upper. In this example, the spherical portions of the second sole structure may also include non-planar surfaces. The non-planar surfaces having support surfaces for the supports of the foot portion of the upper, and the non-planar surfaces having spherical portions for the second sole structure, can increase the surface area of ​​each of the supports and the spherical portions. Having a larger surface area at the fixation point between the second sole structure and the foot portion of the upper can improve or enhance the fixation between these structures.

[0032] After the second sole structure is attached to the upper via a polymer layer, the upper is spaced apart from the second sole structure at multiple recesses. This configuration creates a shock-absorbing system in which the spherical portions of the second sole structure absorb forces transmitted through the foot support of the upper. Additionally, the space between the recesses of the upper and the second sole structure helps to direct forces transmitted through the foot support of the upper only to the spherical portions of the second sole structure, increasing the number of flex points in the second sole structure. This further improves wearer comfort and reduces foot fatigue. Similarly, the space between the recesses of the upper and the second sole structure can compress reboundably under load, further enhancing the cushioning characteristics of the footwear.

[0033] In one example, the upper may include a first knitted section comprising a translucent or transparent thermoplastic polymer layer after processing. In some examples, the first knitted section includes a first knitted layer having a knitted mesh structure having a first set of yarns. In one example, the first set of yarns may include core / sheath yarns comprising a core of a high-melting-point material surrounded by a sheath of a thermoplastic material having a relatively low melting point (i.e., a melting point lower than that of the high-melting-point core). In a second example, the first set of yarns may include one or more of a single-component high-melting-point material (such as polyamide (e.g., nylon) monofilament) and / or a bicomponent monofilament yarn (e.g., a co-extruded yarn having a first high-melting-point material and a second high-melting-point material). In one example, the first set of yarns is opaque.

[0034] In some aspects, the knitted structure of the first knitted section is a single-layer structure comprising a first knitted layer. Furthermore, a film comprising a thermoplastic polymer material may be applied over at least a portion of the surface of the first knitted layer. The melting temperature of the thermoplastic polymer material of this film is lower than the melting temperature of the sheath of the first set of yarns (when core / sheath yarns are used). Additionally, in some instances, the film comprises two layers of two different thermoplastic polymer materials, wherein at least one of the thermoplastic polymer materials of the film has a lower melting temperature than the sheath of the first set of yarns. Therefore, heat sufficient to melt the lower melting point thermoplastic material of the film but insufficient to melt the thermoplastic material forming the sheath of the first set of yarns can be applied, but this heat may be sufficient to soften the thermoplastic material of the first set of yarns. The molten thermoplastic material of the polymer film flows by, for example, applying pressure, such that it at least partially envelops the first set of yarns. In examples, the molten thermoplastic polymer film does not completely envelop the first set of yarns, such that it can envelop a portion of the first set of yarns located on the outward-facing surface when the first knitted layer is formed as a shoe upper, but not the portion of the yarn forming the inward-facing surface. In other words, the first knitted layer can be partially embedded within a molten thermoplastic polymer film, such that the film extends through the outward-facing surface of the first knitted layer, but not to the inward-facing surface of the first knitted layer.

[0035] Once cooled, the molten thermoplastic film forms a transparent and / or translucent polymer layer over at least a portion of the first knitted layer. Because this polymer layer is at least translucent, objects positioned within the foot-receiving openings of the upper (such as the midsole) are at least partially visible through the knitted mesh structure of the first knitted layer. This document refers to translucent or transparent polymer layers, and it should be understood that, unless otherwise specified, some embodiments of the examples described herein include translucent polymer layers, and other embodiments include transparent polymer layers. As previously stated, when the thermoplastic material is in a molten state, this polymer layer can be used to directly attach the second sole structure to the foot portion of the upper.

[0036] In other instances, the translucent or transparent polymer layer may be formed from a thermoplastic material melted from the yarn of the knitted structure. Specifically, alternative aspects herein include a first knitted section comprising a double-knitted construction and a second knitted layer comprising a second set of yarns. The second set of yarns may comprise core / sheath yarns comprising a core of a high-melting-point material surrounded by a sheath of a thermoplastic material having a melting point lower than that of the sheath of the first set of yarns (when core / sheath yarns are used). In instances, the sheath of the second set of yarns may be transparent and / or translucent. In instances, the core of the second set of yarns is opaque. In some instances, the second knitted layer is knitted integrally with the first knitted material and may be formed in the same knitting event.

[0037] After being formed into a knitted textile and / or shoe upper, heat and / or pressure are applied to a first knitted section comprising a first knitted layer and a second knitted layer. In these instances, the heat is sufficient to melt the thermoplastic material of the sheath forming the second set of yarns (i.e., the temperature of the heat is greater than the melting point of the thermoplastic material of the sheath forming the second set of yarns), but in some examples, the heat is insufficient to melt the thermoplastic material of the sheath forming the first set of yarns (i.e., the temperature of the heat is less than the melting point of the thermoplastic material of the sheath forming the first set of yarns), but the heat may be sufficient to soften the thermoplastic material of the first set of yarns. The molten thermoplastic material flows by, for example, applying pressure, such that it at least partially encapsulates the first set of yarns and the core of the second set of yarns. Once cooled, the molten thermoplastic material forms a transparent and / or translucent polymer layer similar to the polymer layer described above. In other words, because the polymer layer is at least translucent, objects positioned within the foot receiving gap of the upper (such as the midsole) can be at least partially visible through the knitted mesh structure of the first knitted layer, and / or when the thermoplastic material is in a molten state, the polymer layer can be used to directly attach the second sole structure to the foot portion of the upper.

[0038] In yet another example, the first knitted section may include a first knitted layer, a second knitted layer, and a thermoplastic polymer film applied to the first knitted layer, wherein the second knitted layer may include a second set of yarns of a thermoplastic material having a lower melting point or a material having a higher melting point. In this example, the polymer of the film may be melted in the same manner as described above to produce a transparent and / or translucent polymer layer.

[0039] In some aspects, the first knitted section is attached to one or more additional textiles (including additional knitted textiles) to form the upper. In another example, the upper may also include a second knitted section knitted integrally with the first knitted section. The second knitted section may include a single-knit plain weave structure having multiple rib structures extending longitudinally from the toe of the footwear to the heel. The multiple rib structures may include knit rows extending longitudinally from the toe of the footwear towards the heel. In an example, the second knitted section may be located at least in the tongue area. In this example, the longitudinal orientation of these rib structures facilitates medial-to-lateral stretching of the second knitted section. This may be advantageous in the tongue area to accommodate the insertion of the wearer's foot into the footwear.

[0040] Footwear products described herein may include running shoes, baseball shoes, basketball shoes, skateboarding shoes, cycling shoes, American football shoes, tennis shoes, soccer shoes, training shoes, walking shoes, hiking shoes, etc. The concepts described herein may also be applied to other types of footwear considered non-sports, such as dress shoes, loafers, sandals, and work boots. As used herein, footwear products can be divided into different general areas. The forefoot area typically includes the portion of the footwear product corresponding to the toe and the joints connecting the metatarsals and phalanges, terminating at the tip of the footwear product. The midfoot area typically includes the portions of the footwear product corresponding to the arch and instep areas of the foot. The heel area typically corresponds to the posterior portion of the foot, including the calcaneus, terminating at the heel end of the footwear product. Footwear products described herein may include a lateral and a medial side, the lateral side corresponding to the outer area of ​​the foot (i.e., the surface facing away from the other foot), and the medial side corresponding to the inner area of ​​the foot (i.e., the surface facing the other foot). The different zones and sides mentioned above are intended to represent general areas of footwear to aid the discussion below, and are not intended to delineate precise areas. These different zones and sides can be applied to the overall footwear product, the upper, and the sole construction.

[0041] Footwear articles described herein typically include one or more sole structures. These sole structures may include a midsole (referred to herein as a first sole structure) positioned within the foot-receiving opening of the upper. These sole structures may also include cushioning elements, such as fluid-filled bladders directly attached to the outward-facing surface of the foot portion of the upper. This cushioning element may be referred to herein as a second sole structure. These sole structures may additionally include an outsole structure or a third sole structure attached to the ground-facing surface of the cushioning element. Additional or fewer sole structures are contemplated herein. The different sole structures described herein can provide cushioning, support, force dissipation, etc.

[0042] As used herein, the term "outer-facing surface" refers to the surface of an upper or footwear article that faces the external environment. In some aspects, the outer-facing surface may refer to the outermost surface of an upper or footwear article. As used herein, the term "inner-facing surface" refers to the surface of an upper or footwear article that faces the space intended to accommodate the wearer's foot. In some aspects, the inner-facing surface may refer to the innermost surface of an upper or footwear article. As used herein, the terms "external" and "internal" are relative terms, such that an outer layer is positioned outside one or more inner layers, and an inner layer is positioned inside one or more outer layers.

[0043] As used herein, the term "fluid-filled bladder" refers to, for example, a second sole structure that typically represents a bladder formed by two sealed or bonded polymer material barrier layers. This fluid-filled bladder is pressurized with a fluid such as air and may contain tension members to maintain its shape when it is elastically compressed under applied loads, such as during exercise. Typically, the bladder is designed with a focus on balancing support and cushioning characteristics for the foot, which relate to the bladder's responsiveness when elastically compressed under applied loads.

[0044] As used herein to describe some or all parts of a shoe upper, the term "knitted" refers to a piece of textile formed from at least one yarn that is manipulated (e.g., using a knitting machine) to form multiple interlocking (also referred to as interlacing) loops defining rows and warps. As used herein, the term "row" refers to a main horizontal row of knitted loops produced by adjacent needles during the same knitting cycle (in upright textile knitted on a knitting machine). This row can include one or more stitch types, such as knitted stitch, skip stitch, tuck stitch, hold stitch, transfer stitch, rib stitch, etc., terms known in the knitting field. The term "row direction" refers to the direction parallel to the knitted row of the textile piece. As used herein, the term "warp" is a main vertical row of interlocking or interlacing knitted loops, typically produced by the same needle in consecutive (but not necessarily all) rows or knitting cycles. The term "warp direction" refers to the direction parallel to the knitted warp of the textile piece.

[0045] As used herein, the term "double-knit construction" refers to a knitting construction typically formed on at least two needle beds of a knitting machine (i.e., a multi-needle bed construction). Such multi-needle bed knitting constructions may be characterized by two opposing surfaces or layers of knitted loops and / or tucks, for example, one surface / layer of loops formed on a first needle bed (e.g., a first knitted layer) and a second surface / layer of loops formed on a second needle bed (e.g., a second knitted layer). In an example embodiment, these two surfaces / layers may be connected by yarns (e.g., transfer yarns) that interlock with the yarns in both the first and second surfaces / layers of the double-knit construction. However, aspects herein envision that these two surfaces / layers may not be connected, creating a space or potential space between them. Common double-knit constructions include double plain weave, rib, double rib, quilted knit, other "double-needle bed" knitting structures initially formed on at least two needle beds, and other knitting structures with two opposing surfaces / layers of knitted loops or tucks, including full-needle and non-full-needle variations of these structures. As used herein, the term "single-jersey knit construction" refers to a single-layer knit construction typically formed on a single needle bed (i.e., a single-needle-bed construction). In some instances, a single-jersey knit construction can be formed on a multi-needle-bed knitting machine by knitting multiple rows on the first needle bed of the machine, and then transferring all the loops to the second needle bed of the machine, where multiple rows are knitted. This knitting sequence can be repeated any number of times, as further described below. Common single-jersey knit constructions include single-jersey plain weave.

[0046] The term "knitted mesh structure" used to describe the first knitted layer describes a knitted structure with multiple openings, intentionally created using a combination of tuck stitches (such as similar types of hold stitches) and knitted stitches that can be knitted on every other needle, every three needles, etc., on the needle bed. Thus, the knitted stitches in the knitting rows can be spaced apart from adjacent knitted stitches by one, two, three, etc., to create intentional or engineered openings in the knitted structure. These engineered openings contribute to the mesh structure. This can be contrasted with inherent openings within knitted loops or between adjacent knitted loops, where these inherent openings are typically not spaced apart by one, two, etc., between adjacent knitted loops. In an example, the knitted mesh structure of the first knitted layer has a lower stitch density (i.e., the number of stitches per inch or centimeter) than the knitted structure used to form the second knitted layer.

[0047] As used herein, the term "integrated knitting" can mean that the yarns of one or more knit rows from a first knit layer or section are interlocked with one or more knit rows from another knit layer or section. This interlocking can be achieved through simple knitting stitches, tuck stitches, hold stitches, float stitches, or skip stitches. In this way, the sections knitted together in an integrated manner have a seamless transition, allowing them to extend seamlessly into each other.

[0048] Using knitted constructions to form some or all of the upper can provide several advantages, including, but not limited to, a specific degree of elasticity (e.g., expressed in Young's modulus), breathability, flexibility, strength, moisture absorption, weight, abrasion resistance, and / or combinations thereof. These properties can be achieved by selecting a particular knitted construction, by varying the size and tension of that knitted construction, by using one or more yarns formed from a specific material (e.g., polyester, relatively inelastic materials, or relatively elastic materials such as elastic yarns, thermoplastic materials), by selecting yarns with a specific size (e.g., denier), and / or combinations thereof. Knitted constructions can also provide desired aesthetic properties by incorporating yarns arranged in a specific pattern with different colors, textures, or other visual characteristics. These yarns themselves and / or the knitted constructions formed from one or more of these yarns can vary in different locations, allowing the upper to have the different properties described herein.

[0049] The yarns described in various aspects of this document may include monofilament yarns and multifilament yarns formed from, for example, synthetic materials. In an example aspect, the yarns used for knitting the first and second knitted layers may include high-melting-point polymer yarns (e.g., yarns that melt at about 175 degrees Celsius or higher), including polyethylene terephthalate (PET) yarns (commonly referred to as polyester fibers), recycled PET yarns, polyamide yarns (commonly referred to as nylon), elastic fiber yarns, and other high-melting-point synthetic yarns. In an example aspect, these high-melting-point yarns may form the core of the core / sheath yarn in the first knitted layer (when core / sheath yarns are used) and the core of the core / sheath yarn in the second knitted layer. These high-melting-point synthetic yarns may also be used for knitting the second knitted section.

[0050] In one example, the sheath of the core / sheath yarns in the first knitted layer (when core / sheath yarns are used) and the second knitted layer (in the case of the second knitted layer) may comprise a synthetic polymer material formed of a polymer that melts at a relatively low temperature (e.g., less than about 175 degrees Celsius). In another example, the sheath may comprise a thermoplastic material capable of melting at a temperature greater than or equal to the melting temperature of the thermoplastic material when heat is applied. This thermoplastic material hardens upon cooling and is capable of remelting upon reapplication of heat at a temperature higher than that of the thermoplastic material. In another example, the melting point of the thermoplastic material forming the sheath of the first set of yarns is greater than the melting point of the thermoplastic material forming at least a portion of the additional layer (e.g., a thermoplastic film and / or the sheath of the second set of yarns in the second knitted layer). When heat is applied to the upper at a temperature higher than the melting point of the thermoplastic material forming at least a portion of the additional layer but lower than the melting point of the thermoplastic material forming the sheath of the first set of yarns, the thermoplastic material of the additional layer melts (i.e., the sheath of the second set of yarns melts and / or the film melts), but the thermoplastic material of the first set of yarns does not melt, but it may soften (i.e., the sheath of the first set of yarns softens but does not melt). The melting temperatures of the thermoplastic material forming the sheath of the first set of yarns and the additional material (e.g., the film and / or the sheath of the second set of yarns) can be sufficiently different from the melting temperature of the yarn used to form the core of the first set of yarns (when core / sheath yarns are used). Such melting temperatures can also be sufficiently different from the melting temperature of the yarn used to form the core of the second set of yarns, in which the second knitted layer is present. Therefore, when heat is applied to the first knitted section of the upper during processing, the yarns forming the core of the first set of yarns (and in some respects, the second set of yarns) are not adversely affected (e.g., burned, scorched, or charred).

[0051] The term "thermoplastic polymer layer" refers to a generally integral structure comprising a cured thermoplastic polymer that at least partially encapsulates the yarns of a knitted structure. It may also be referred to herein as a composite layer comprising one or more knitted layers and a thermoplastic polymer material that can form a film. The thermoplastic polymer layer may be a thermoformed layer formed from knitted yarns, as further described herein, or it may be a thermoplastic polymer film bonded to the knitted structure by partially melting and fusing it to the knitted structure or by an adhesive, or it may be a polymer solution sprayed to coat at least a portion of the knitted structure. In examples, the thermoplastic polymer film may comprise a thermoplastic polyurethane film having a thickness in some respects of about 0.3 mm to about 0.8 mm, about 0.45 mm to about 0.7 mm, or about 0.6 mm, and in other respects of about 0.15 mm to about 0.45 mm, about 0.2 mm to about 0.4 mm, or about 0.25 mm.

[0052] The term "thermoformed layer" refers to a generally integral structure formed after heat and / or pressure are applied to the molten thermoplastic material and / or molten thermoplastic polymer film of the second set of yarns to cause it to flow, and after the molten thermoplastic material solidifies upon cooling. Therefore, the thermoformed layer may comprise the same polymer material as the thermoplastic material used to form the sheath and / or polymer film of the second set of yarns.

[0053] As used herein, the term "transparency" refers to the transmission of light, and "transparency" refers to the physical property of an object when light shines on its surface, in which some light passes through or is transmitted through the object and some light is diffused, reflected, and / or absorbed. Generally, the transmission of light is classified as transparent, translucent, or opaque, each corresponding to a different interaction between an object and the light that illuminates its surface. Thus, "transparent" refers to the physical property of an object when light shines on its surface, in which all light passes through or is transmitted through the object and no light is diffused and / or absorbed. "Opaque" refers to the physical property of an object (e.g., yarn) when light shines on its surface, in which no light passes through or is transmitted through the object and all light is diffused and / or absorbed. According to various aspects herein, an object can be determined to be transparent, translucent, or opaque by measuring and / or calculating its transmittance using instruments and / or methods known to those skilled in the art. Therefore, when describing, for example, a thermoplastic polymer layer, the term "translucent" means that the layer has such a physical property that light illuminating a first surface of the thermoplastic polymer layer (e.g., the outward-facing surface) partially passes through the layer, thereby allowing any object positioned adjacent to the opposite surface of the thermoplastic polymer layer (e.g., the inward-facing surface) to be at least partially visible. Various aspects herein also contemplate that the thermoplastic polymer layer may be transparent. Any and all aspects and any variations thereof are contemplated within the scope of these aspects.

[0054] In various aspects, the uppers described herein may comprise or be formed from different types of textiles. For example, alternatively, the upper may comprise or be formed from knitted textiles. In various aspects, alternatively, the upper may comprise or be formed from woven textiles. In various aspects, alternatively, the upper may comprise or be formed from braided textiles. In various aspects, alternatively, the upper may comprise or be formed from nonwoven textiles. In various aspects, alternatively, the upper may be formed substantially entirely from one type of textile (e.g., knitted textiles, woven textiles, nonwoven textiles, etc.). In various aspects, alternatively, the upper may be formed from multiple types of textiles (e.g., knitted and woven textiles combined) and / or may be formed from multiple textile pieces of the same or different types (e.g., assembled together to form a composite structure). Examples of knitted structures or knitted textiles may be frequently mentioned in the aspects described herein; however, it should be understood that these other types of textiles and materials may also be included throughout the aspects described in this disclosure.

[0055] In all respects, the uppers described herein can be formed using knitted, woven, braided, or nonwoven textile forming techniques and methods. The textiles used to form the uppers can be selected based on the desired characteristics of the associated footwear. For example, knitted textiles can be used in uppers when greater stretch, comfort, and / or breathability is required, and woven textiles can be used when greater durability, strength, and / or water resistance is required. These are examples, and other textiles or combinations of textiles with the desired characteristics can be used optionally, additionally, or alternatively.

[0056] In some aspects, the uppers described herein may comprise woven textiles or fabrics, nonwoven textiles or fabrics, or combinations thereof, or be formed from woven textiles or fabrics, nonwoven textiles or fabrics, or combinations thereof. In some aspects, optionally, the uppers described herein may comprise mesh structures and / or translucent and / or transparent materials, such as thermoplastic materials, e.g., thermoplastic polymer layers, overlays, sheets, films, and / or adhesives. These materials may cover and / or enclose and / or wrap the underlying yarns and textile structure. In various aspects, woven constructions may utilize warp-knitted and weft-knitted yarn arrangements to achieve mesh or other patterned configurations to contribute to breathability, flexibility, and / or aesthetic appeal. Nonwoven constructions (e.g., those including felt or bonded materials) may similarly be reinforced with translucent and / or transparent thermoplastic materials (e.g., polymer layers, sheets, overlays, or adhesives covering and / or enclosing and / or wrapping the underlying fibers or strands or other textile structure). In various aspects, the internal components of footwear articles may be at least partially visible through the mesh structure and / or translucent and / or transparent materials of the footwear articles. In various aspects, at least partially visible internal components may include midsoles, outsoles, material layers, inserts within the footwear articles, cushioning pads, cavities, air pockets, or other textile structures included in the footwear articles. These alternative textile constructions are envisioned to provide the desired structural, functional, and visual benefits. The aforementioned materials and techniques may be incorporated into any of the uppers described herein, for example, as a complement to or alternative to knitted structures and associated constructions.

[0057] Unless otherwise specified, all measurements provided herein were performed with the upper and / or footwear under standard ambient temperature and pressure (298.15 K and 100 kPa) and in a static (untensioned) condition. As used herein, the term “about” means within ±10% of the indicated value.

[0058] Figures 1A to 1B The inner and outer views of an example footwear article 100 having an upper 110, a first sole structure 112, and a second sole structure 114 are schematically depicted, respectively. Figure 2A and Figure 2B The inner and outer views of the footwear article 100 are schematically depicted, wherein the upper 110 has different embodiments. Unless otherwise specified, the description of the footwear article 100 and its components herein applies to... Figures 1A to 1B and Figures 2A to 2B Two implementation examples.

[0059] The upper 110 includes an outward-facing surface 111 and an inward-facing surface (not easily seen in these views, but should be understood as being opposite to the outward-facing surface 111). The upper 110 may be formed partially or entirely of knitted textiles. Footwear article 100 is shown in the form of an athletic shoe, but other types of shoes (e.g., sandals, casual shoes, etc.) are also contemplated herein. Footwear article 100 includes: a forefoot area 118 having a toe cap 119, a midfoot area 120, a heel area 122 having a heel end 123, a medial side 124, and a lateral side 126. Footwear article 100 includes an ankle collar 128, a throat area 130, and a tongue 132, the ankle collar 128 defining an opening leading to a gap 129 for receiving the wearer's foot. In an example aspect, the tongue 132 may be integrally formed with the upper 110 as shown, or the tongue 132 may include a separate element, for example, attached to the upper 110 in a post-knitting manufacturing step. Although not shown, various aspects herein envision that footwear article 100 may include additional elements layered on top of upper 110, including, for example, leather materials, synthetic leather materials, knitted or woven textiles, polymer overlays, etc. These additional elements may be positioned at separate locations on upper 110, including, for example, the toe cap 119 (e.g., toe box), the heel end 123 (e.g., heel stabilizer), etc.

[0060] The upper 110 also includes a knitted underfoot portion 134. When the footwear 100 is worn, this underfoot portion 134 extends beneath the wearer's foot and may include multiple supports 136 (in... Figure 9A and Figure 9B (See more clearly in the image) and a plurality of recesses 138 located between adjacent supports 136. Thus, in this example, the foot portion 134 of the upper 110 may have a wavy surface.

[0061] In an example, the first sole structure 112 may include a midsole positioned within the gap 129. The upper edge or border of the first sole structure 112 is marked by line 113. This is an illustrative shape of the first sole structure 112, and other shapes are contemplated herein. As will be described in more detail, the first sole structure 112 may be at least partially visible through a translucent thermoplastic polymer layer positioned outside the first sole structure 112 (indicated by translucent / transparent markings in Figures 1 and 2). In one example, the first sole structure 112 may be removably positioned within the gap 129, such that the first sole structure 112 can be removed by the wearer and replaced, for example, with another midsole structure. In another example, the first sole structure 112 may be permanently fixed within the gap 129 by, for example, a thermoplastic polymer layer or by an additional adhesive. In this example, the lower surface or foot portion of the first sole structure 112 may have supports and recesses whose shapes correspond to the plurality of supports 136 and recesses 138 of the foot portion 134 of the upper 110. Therefore, when the first sole structure 112 is positioned within the gap 129, the supports of the first sole structure 112 are aligned with the plurality of supports 136 of the upper 110, and the recesses of the first sole structure 112 are aligned with the plurality of recesses 138 of the upper 110.

[0062] The second sole structure 114 is attached to the knitted foot portion 134 of the upper 110. In an example, the second sole structure 114 may include a fluid-filled bladder or other type of cushioning or force-absorbing element having a plurality of spherical portions 140 (better seen in FIG. 9). In an example, each of the spherical portions 140 may be attached to one of a plurality of supports 136 of the upper 110. In this respect, the foot portion 134 of the upper 110 is spaced apart from the second sole structure 114 at a plurality of recesses 138 of the upper 110. To describe this differently, a plurality of spaces 141 may be located between the plurality of recesses 138 of the upper 110 and the second sole structure 114. In the described configuration, forces from the wearer's foot can be transmitted to the second sole structure 114 via the plurality of supports 136 of the foot portion 134 of the upper 110 and via the plurality of spherical portions 140 of the second sole structure 114. The second sole structure 114 can compress reboundably in response to these forces. The plurality of spaces 141 help to direct the transmitted forces to discrete areas (e.g., multiple spherical portions 140), which can increase the number of flexion points to improve wearer comfort and reduce foot fatigue. Similarly, the plurality of spaces 141 can also compress reboundably in response to loads, further enhancing the cushioning / force attenuation characteristics of the second sole structure 114.

[0063] The shape of the spherical portion 140 of the second sole structure 114 can be complementary to the shape of the support member 136 of the foot portion 134 of the upper 110, such that each support member 136 can be configured to attach to the corresponding spherical portion 140. In this way, the upper 110 can be molded into a specific shape corresponding to the second sole structure 114. In some instances, the foot portion 134 of the upper 110 has a knitted structure having a thermoplastic polymer layer. The knitted structure within the thermoplastic polymer layer can act as a skeleton, allowing the thermoplastic polymer layer to bend and maintain a specific shape during molding. When compared with other textile structures, such as woven textiles, the knitted loops of the foot portion 134 further enhance the ability of the foot portion 134 to be molded into a desired shape to complement the spherical portion 140 of the second sole structure 114, achieving a robust connection between the upper 110 and the second sole structure 110.

[0064] In an example, footwear article 100 also includes a third sole structure, which may include an outsole structure 116. The outsole structure 116 can be attached to the ground-facing surface of the second sole structure 114. The outsole structure 116 can contact the ground surface and is therefore formed of a material suitable for this function.

[0065] The upper 110 includes a first knitted section 142 and may also include a second textile section. In some instances, the second textile section is also knitted and may be referred to herein as a second knitted section 144. The first knitted section 142 and the second knitted section 144 are schematically depicted and provided to illustrate the approximate location of the knitted sections on the upper 110. Additional macroscopic features of various aspects of the first knitted section 142 and the second knitted section 144 are shown in subsequent figures. In an example, the first knitted section 142 is positioned generally along the medial side 124 and the lateral side 126 of the upper 110 and extends from the forefoot area 118, through the midfoot area 120, and into the heel area 122. The first knitted section 142 may extend through the underfoot portion 134 of the upper 110. As will be described in more detail, in various aspects, the first knitted section 142 comprises a translucent or transparent thermoplastic polymer layer.

[0066] exist Figure 1A and Figure 1B In the example shown, the first knitted section 142 extends partially into the upper foot area and terminates before reaching the throat area 130. Figure 2A and Figure 2BIn the alternative example depicted, the first knitted section 142 may extend upwards to and be adjacent to the ankle collar 128, and may extend upwards to and be adjacent to the throat area 130 and the tongue 132. In this respect, the ankle collar 128, the throat area 130, and the tongue 132 are not included in the first knitted section 142.

[0067] The second knitted section 144 is adjacent to the first knitted section 142. In both examples, the second knitted section 144 is typically higher than the first knitted section 142 and forms at least a portion of the throat area 130. The second knitted section 144 has a different knitted construction than the first knitted section 142 and may comprise different materials (e.g., yarns). In one example, a thermoplastic polymer layer may not be present in the second knitted section 144. Additionally, the first sole structure 112 may not be present in the second knitted section 144. Further examples of the second knitted section can be described further herein.

[0068] For example, the first knitted section 142 and the second knitted section 144 can be formed separately and joined together by sewing. For example, Figure 1A and Figure 1B The boundary line 145 can represent the seam where the first knitted section 142 connects to the second knitted section 144 after knitting. Alternatively, the boundary line 145 between the first knitted section 142 and the second knitted section 144 can represent a seamless transition between the first knitted section 142 and the second knitted section 143. In an example aspect, the upper 110 may include an integral knitted construction and may be formed in a single knitting event. Specifically, the first knitted section 142 and the second knitted section 144 may include an integral knitted construction. Figure 2A and Figure 2B The aspects of the upper 110 depicted may include this seamless construction between the first knitted section 142 and the second knitted section 144. Alternatively, it should be understood that some embodiments of this disclosure may include the first knitted section 142 and the second knitted section 144, which may have Figure 1A and Figure 1B The characteristics depicted (such as position) and have seamless connection, and other instances may include a first knitted section 142 and a second knitted section 144, which may have Figure 2A and Figure 2B The characteristics described in the text (such as position) and non-seamless connections (such as stitching).

[0069] Figure 3 Depicting and Figure 2A and Figure 2BThe example corresponds to a top view of footwear article 100. In this example, the second knitted section 144 forms at least the ankle collar 128, the throat section 130, and the tongue 132 of the upper 110. In this example, the throat section 130 and the tongue 132 can extend from the toe 119 to the ankle collar 128, but the various aspects of this document also envision that the throat section 130 does not fully extend to the toe 119 of the footwear article 100. The various aspects of this document envision that, at least in Figures 2A to 2B and Figure 3 In the example shown, the second knitted section 144 can be knitted to include a plurality of rib structures 146. These rib structures 146 can be positioned within the throat area 130 and the tongue 132, and each rib structure can extend longitudinally from the toe 119 of the upper 110 to the heel end 123 of the upper 110. The orientation of these rib structures 146 facilitates, for example, medial to lateral stretching of the throat area 130 and the tongue 132 of the upper 110, which facilitates the wearing of the footwear 100. Additionally, the rib structures 146 can also extend around the ankle collar 128 to the heel end 123. When the wearer inserts her foot into the gap 129, the longitudinal orientation of the rib structures 146 around the ankle collar 128 can facilitate the expansion of the ankle collar 128. In some respects, a portion of the upper 110 directly adjacent to the ankle collar 128 may include ribs extending in another direction to provide stretch in multiple directions at the ankle collar 128. This other direction may be generally perpendicular to the longitudinal direction of the rib structure 146, such that additional ribs may extend downward from the top of the ankle collar 128.

[0070] Figure 4A and Figure 4B This is a schematic diagram of the knitting of the first knitted section 142 of the shoe upper 110. Figure 4A A single-knit layer structure with a first knit layer 410 is depicted, and Figure 4B A double-knitted layer construction having the first knitted layer 410 and the second knitted layer 412 is depicted. The thermoplastic polymer layer is not depicted to better illustrate the features of the first knitted layer 410 and the second knitted layer 412. The first knitted layer 410 includes a knitted mesh structure having a plurality of engineered openings 414 and having a first stitch density. The first knitted layer 410 is formed of a first set of yarns 411. In an example aspect, the first set of yarns 411 may include core / sheath yarns having a sheath of a first type of material surrounding a core of a second type of material. Figure 5 An example of a core / sheath yarn is shown in the figure. Figure 5A core 510 extending longitudinally along the length of the yarn and a sheath 512 surrounding the core 510 are depicted. It should be understood that references to core / sheath yarn can include yarns formed by coating the core with a sheath polymer or by co-extruding the core and sheath together to form a monofilament core / sheath yarn. Regarding the first set of yarns 411, the sheath can comprise a thermoplastic material with a melting point lower than that of the core. For example, the sheath can comprise a synthetic polymer material formed from a polymer that melts at a relatively low temperature. In example aspects, the sheath can comprise thermoplastic polyurethane (TPU) materials, thermoplastic polyethylene (TPE) materials, and other synthetic polymer materials having low melting points. The core can comprise a high-melting-point polymer yarn, including polyethylene terephthalate (PET) yarn (commonly referred to as polyester fiber), recycled PET yarn, polyamide yarn (commonly referred to as nylon), elastic fiber yarn, and other high-melting-point synthetic yarns. In other example aspects, the first set of yarns 411 can comprise a high-melting-point monofilament yarn, such as, for example, a polyamide monofilament. In some aspects, the first set of yarns 411 may comprise thermoplastic polyurethane monofilaments or polyester monofilaments. Furthermore, in some instances, the first set of yarns 411 may comprise bicomponent monofilament yarns (e.g., co-extruded yarns having a first high-melting-point material and a second high-melting-point material). Any and all aspects and any variations thereof are contemplated as being within the scope of this document. Alternatively, in some aspects, the first set of yarns 411 may be a monofilament or a twisted yarn of filaments having the same composition, which may or may not be thermoplastic. Additionally, in instances, the first set of yarns 411 may be opaque, such that light illuminating the surface of the first knitted layer 410 will pass substantially through the plurality of openings 414 but will not transmit through the first set of yarns 411.

[0071] The first knitted layer 410 includes a knitted mesh structure having a grid or mesh pattern with visible openings between interlocking yarns. These openings are not inherent spacing between any adjacent loops of the yarns; rather, the openings in the mesh structure of the first knitted layer 410 are intentionally formed integrally during knitting by floating across the needles between tuck stitches and / or loop stitches. In this way, the first knitted layer 410 has a relatively low stitch density and is more porous than textiles with a plain knit pattern.

[0072] Figure 4AThe first knitted layer 410 is depicted separately to represent an example of a first knitted section 402 having a single-layer knitted structure. Using a single-layer knitted structure for the first knitted section 142 reduces the time required to knit the first knitted section 142 and also reduces the overall weight of the resulting footwear article 100. In this example, in the footwear article 100, the first knitted layer 410 is positioned inside the thermoformed polymer layer, and the first sole structure 112 is positioned inside the first knitted layer 410.

[0073] Figure 4B A first knitted layer 410 and a second knitted layer 412 are described. When bonded to the upper 110, the first knitted layer 410 can be positioned outside the second knitted layer 412. The second knitted layer 412 has a second stitch density, and in some instances, such as... Figure 4B As shown, the second stitch density is greater than the first stitch density of the first knit layer 410. It is also contemplated in various aspects of this document that the first knit layer 410 and the second knit layer 412 may have substantially the same stitch density, or that the second knit layer 412 may have a stitch density less than that of the first knit layer 410. Any and all aspects and any variations thereof are contemplated within the scope of this document. The second knit layer 412 may include inherent openings 416 created by the spacing between yarn portions forming the same loop, the spacing between yarn portions forming loops in adjacent rows, and the spacing between yarn portions forming loops in adjacent warps. As described above, in the footwear article 100, the second knit layer 412 is positioned inside the first knit layer 410 (which may be inside a thermoformed polymer layer), and the first sole structure 112 is positioned inside the second knit layer 412.

[0074] The second knitted layer 412 is formed of a second set of yarns 413. Prior to processing the upper 110, the second set of yarns 413 may include a core / sheath yarn having a core of a high-melting-point material (e.g., PET yarn, recycled PET yarn, polyamide yarn, elastic fiber yarn, and other high-melting-point synthetic yarns) and a sheath of a low-melting-point material (TPU material, TPE material, and other synthetic polymer materials with low melting points). After processing, and as shown in FIG. 4, the second set of yarns 413 consists only of a core, without a formed sheath. In an example, the core of the second set of yarns 413 is opaque, although it is contemplated in various aspects herein that the core of the second set of yarns 413 may be translucent and / or transparent. When the core of the second set of yarns 413 is opaque, light illuminating the surface of the first knitted layer 410 will generally pass through the plurality of openings 414 in the first knitted layer 410 and the inherent openings 416 in the second knitted layer 412, but will not transmit through the first set of yarns 411 or the second set of yarns 413. In some respects, at least a portion of the sheath may remain around the core of the second set of yarns 413, but sufficient sheath may melt to completely fill the inherent openings 416 within the second knitted layer 412 to form a thermoplastic polymer layer.

[0075] Figure 6A A schematic cross-section of an example knitted structure is depicted through the first knitted section 142 before the upper 110 is processed to form a thermoplastic polymer layer. In this example, the structure includes, for example... Figure 4A The first knitted layer 410 is shown as a single-layer knitted structure. For illustrative purposes, the first knitted layer 410 is simplified. As previously described, the first knitted layer 410 is formed using a first set of yarns 411, which may include core / sheath yarns having a core of a high-melting-point material and a sheath of a low-melting-point material. It is also contemplated that the first set of yarns 411 may alternatively include a single component of a high-melting-point material (e.g., a high-melting-point polyamide monofilament). The first knitted layer 410 has an outward-facing surface 650 and an opposing inward-facing surface 652. In some instances, the first knitted layer 410 does not include other types of yarns.

[0076] like Figure 6AFurther depicted, the first knitted section 142 includes a translucent or transparent thermoplastic polymer film 654 positioned adjacent to the outward-facing surface 650 of the first knitted layer 410. References to the thermoplastic polymer film 654 herein generally describe it as transparent; however, it should be understood that other instances of the thermoplastic polymer film 654 may be transparent unless otherwise specified. In an example, the thermoplastic polymer film 654 may comprise thermoplastic polyurethane, but other known thermoplastic polymers are contemplated herein. In examples, the thickness of the thermoplastic polymer film 654 may be from about 0.3 mm to about 0.8 mm, from about 0.45 mm to about 0.7 mm, or about 0.6 mm.

[0077] Figure 6B Depicting in accordance with Figure 6A The illustrated example shows the upper 110 after it has been processed and incorporated into the footwear article 100, passing through a schematic cross-section of the first knitted section 142. During processing, heat is applied to at least the first knitted section 142, and pressure is applied in some respects. The applied heat is set such that, in the example aspect, the degree of heat applied is equal to or greater than the melting point of the translucent (or transparent) thermoplastic polymer film 654, and less than the melting point of the thermoplastic material of the first yarn set 411 (the sheath of the first yarn set 411 when the first yarn set 411 uses core / sheath yarn, or any other thermoplastic filament in the first yarn set 411 with other configurations). The applied heat melts the thermoplastic polymer film 654, and the applied pressure can cause the molten material to flow or at least increase or guide the flow. In the example aspect, the applied heat may be sufficient to cause the thermoplastic material of the first yarn set 411 to soften but not melt. Therefore, after processing, the first yarn set 411 can still include a core / sheath configuration.

[0078] After cooling the upper 110, a translucent thermoplastic polymer layer 612 is formed. In one example, this translucent thermoplastic polymer layer 612 may at least partially cover and / or enclose and / or wrap the first set of yarns 411. As further shown, the translucent thermoplastic polymer layer 612 may completely wrap the portion of the first set of yarns 411 on the outward-facing surface 650 of the first knitted layer, but may not wrap the portion of the first set of yarns 411 on the inward-facing surface 652 of the first knitted layer 410. To state this differently, in one example, the translucent thermoplastic polymer layer 612 does not extend completely through the first knitted layer 410 to the inward-facing surface 652, such that the first knitted layer 410 may be partially embedded within the translucent thermoplastic polymer layer 612. Thus, the thermoplastic polymer material may be present on the outward-facing surface 651 and within the first knitted layer 410, but may not be present on the inward-facing surface 652 of the first knitted layer 410. In various respects, thermoplastic polymer materials can be applied to textile layers (e.g., knitted and / or woven and / or nonwoven layers) in the form of a surface layer, film, sheet, or applied adhesive, such that a layer of thermoplastic polymer material is formed, for example, similar to, as an example Figure 6B Layer 612 is shown.

[0079] The translucent thermoplastic polymer layer 612 includes a first surface 614 and an opposing second surface 616, the first surface 614 at least partially forming the outermost surface of the upper 110. In this respect, the texture of the first surface 614 is generally smooth, so that the texture of the outermost surface of the upper 110 in the first knit section 142 is generally smooth. Because the thermoplastic polymer layer 612 does not extend to the inward surface 652 of the first knit layer 410 in this respect, the inward surface 652 of the first knit layer 410 retains a knitted structure including loops and generally includes a rougher texture relative to the outward surface 650 of the first knit layer 410.

[0080] like Figure 6B As depicted, the second sole structure 114 is positioned outside the first knitted layer 410 and is directly fixed to the upper 110 via a thermoplastic polymer layer 612. This second sole structure 114... Figure 6B For simplification, relative positioning is shown. To describe this differently, the second sole structure 114 is directly attached to the first surface 614 of the thermoplastic polymer layer 612, which can be relatively smooth as previously described. In some respects, adhesives can also be used to help enhance the bond between the second sole structure 114 and the thermoplastic polymer layer 612 of the upper 110. The first sole structure 112 (which is located on...) Figure 6A(The same simplified representation is used here) It is positioned inside the inward-facing surface 652 of the first knitted layer 410. In some aspects, the first sole structure 112 is not typically attached to the first knitted layer 410, such as... Figure 6C The space between the inward-facing surface 652 of the first knitted layer 410 and the first sole structure 112 is indicated. In this way, the first sole structure 112 can be a removable midsole. It is also envisioned in various aspects of this document that, alternatively, the first sole structure 112 can be directly attached to the thermoplastic polymer layer 612 at the second surface 616 of the thermoplastic polymer layer 612.

[0081] The thermoplastic polymer layer 612 provides a waterproof barrier to prevent moisture from penetrating the interior of the upper 110, which protects not only the wearer's foot but also the first sole structure 112. The thermoplastic polymer layer 612 also provides increased abrasion resistance within the first knitted section 142.

[0082] Due to the translucent and / or transparent properties of the thermoplastic polymer layer 612, light illuminating the first surface 614 of the thermoplastic polymer layer 612 passes through at least the opening 414 in the first knitted layer 410 before illuminating the first sole structure 112, making the first sole structure 112 at least partially visible when the first surface 614 of the thermoplastic polymer layer 612 is observed. As described, this can enhance the aesthetic appeal of the footwear article 100. It can also serve as a visual indicator of a specific function associated with the first sole structure 112. By way of illustrative examples, a red-colored first sole structure can visually indicate to the wearer a function that increases arch support. A blue-colored first sole structure can visually indicate to the wearer a function that increases or enhances heel support. By observing the outward-facing surface 111 of the footwear article 100, the wearer can make a decision about whether the first sole structure 112, removably positioned within the footwear article 100, is suitable for the desired activity. In some aspects, the first sole structure 112 can be a different color than the yarn of the first knitted section 142.

[0083] Figure 6C and Figure 6D Schematic cross-sections of a first alternative example of a first knitted section 142 are depicted before and after the upper 110 is processed to form a thermoplastic polymer layer. Figure 6C and Figure 6D It can usually have the characteristics of targeting Figure 6A and Figure 6B The same characteristics are described, except that thermoplastic polymer film 654 is in Figure 6A and Figure 6DThe film comprises two layers. A first layer 654A of the thermoplastic polymer film 654 can be arranged to cover a second layer 654B. The second layer 654B can be positioned adjacent to the outward-facing surface 650 of the first knitted layer 450, and the first layer 654A of the thermoplastic polymer film 654 can be separated from the first knitted layer 450 prior to processing.

[0084] The first layer 654A and the second layer 654B of the thermoplastic polymer film 654 can have different material compositions and different melting temperatures. In this example, the second layer 654B has a lower melting temperature than the first layer 654A. In this way, sufficient heat to melt the second layer 654B can be applied without melting the first layer 654A or without at least completely melting the first layer 654A.

[0085] Figure 6D Depicting in accordance with Figure 6C The upper 110 of the example has been processed and incorporated into the footwear article 100 through a schematic cross-section of the first knitted section 142. During processing, heat is applied to at least the first knitted section 142, and pressure is applied in some respects. The applied heat is set such that, in the example, the degree of heat applied is equal to or greater than the melting point of the second layer 654B of the polymer film 654, and less than the melting point of the thermoplastic material of the first set of yarns 411 (the sheath of the first set of yarns 411 when the first set of yarns 411 uses core / sheath yarns, or any other thermoplastic filament in the first set of yarns 411 with other configurations). Additionally, the applied heat may be less than the melting point of the thermoplastic material of the first layer 654A of the polymer film 654. The applied heat melts the second layer 654A of the thermoplastic polymer film 654, and the applied pressure can cause the molten material to flow or at least increase or guide the flow. In the example, the applied heat may be sufficient to cause the thermoplastic material of the first layer 654A of the polymer film 654 to soften but not melt.

[0086] Regardless of whether the first layer 654A softens, partially melts, or remains unmodified by heat, the first layer 654A and the second layer 654B can typically form a composite structure with the first set of yarns 411, making the two layers 654A and 654B inseparable and considered as jointly forming a translucent thermoplastic polymer layer 612. In this example, the thermoplastic polymer layer 612 may have a first sublayer 612A and a second sublayer 654B, the first sublayer 612A corresponding to the first layer 654A. In some aspects, the applied heat can also be sufficient to cause the thermoplastic material of the first set of yarns 411 and / or the thermoplastic material of the first layer 654A of the polymer film 654 to soften but not melt. Therefore, after processing, the first set of yarns 411 can still include a core / sheath configuration. Similarly,

[0087] Figure 6E and Figure 6F Schematic cross-sections of a second alternative example of a first knitted section 142 are depicted before and after the upper 110 is processed to form a thermoplastic polymer layer. In this example, the first knitted section 142 has a double-knitted layer construction, which includes... Figure 4B The first knitted layer 410 and the second knitted layer 412. For illustrative purposes, the structure of the first knitted layer 410 and the second knitted layer 412 has been simplified, but it should be understood that the first knitted layer 410 and the second knitted layer 412 may have different knitting patterns and knitting densities as described above.

[0088] The first knitted layer 410 is formed using a first set of yarns 411. As described, the first set of yarns 411 may include core / sheath yarns having a core of a high-melting-point material and a sheath of a low-melting-point material; however, aspects herein also contemplate that the first set of yarns 411 may include a single component of a high-melting-point material (e.g., a high-melting-point polyamide monofilament). The second knitted layer 412 is formed using a second set of yarns 413. Because the upper 110 is not yet processed, the second set of yarns 413 includes a core of a high-melting-point material and a sheath of a low-melting-point material. In an example aspect, the sheath of the second set of yarns 413 includes a first thermoplastic material having a first melting point, and the sheath of the first set of yarns 411 includes a second thermoplastic material having a second melting point greater than the first melting point. In an example aspect, the first thermoplastic material may be transparent and / or translucent. In an example, both the first thermoplastic material and the second thermoplastic material have melting points lower than the melting point of the first yarn 411 (when using core / sheath yarn) and the high-melting-point core of the second yarn 413.

[0089] Before processing and as Figure 6E As shown, in each portion of the first knitting section 142, the first knitted layer 410 is not attached to the second knitted layer 412, such that space 610, or potential space, exists between the first knitted layer 410 and the second knitted layer 412. "Potential space" refers to a location where the first knitted layer 410 and the second knitted layer 412 may contact but not be fixed within the area, allowing them to be pulled apart to create space. As further described herein, the first knitted layer 410 and the second knitted layer 412 can be joined in a post-knitting process, such that keeping the first knitted layer 410 and the second knitted layer 412 unfixed during knitting can reduce the amount of yarn required and reduce knitting time. Other aspects of this document envision that the first knitted layer 410 and the second knitted layer 412 can be attached to each other by one or more transfer yarns extending between the two layers.

[0090] Figure 6FThe image depicts the process of wearing shoes after the upper 110 has been processed and incorporated into the footwear 100. Figure 6E A schematic cross-section of the first knitted section 142. During processing, heat and pressure are applied to at least the first knitted section 142. The applied heat is adjusted such that, in an example, the heat is equal to or greater than the first melting point of the first thermoplastic material of the sheath of the second yarn 413, and less than the second melting point of the second thermoplastic material of the sheath of the first yarn 411 (when the first yarn 411 uses a core / sheath yarn). The applied heat melts the first thermoplastic material of the second yarn 413, and the applied pressure causes the molten material to flow. In an example, the applied heat may be sufficient to cause the second thermoplastic material of the first yarn 411 to soften but not melt. Thus, after processing, the first yarn 411 still comprises a core / sheath configuration, while the second yarn 413 comprises only a core and not a sheath.

[0091] After cooling the upper 110, a translucent thermoplastic polymer layer 612 is formed. While the thermoplastic polymer layer 612 is further described herein as translucent, it should be understood that this description may also apply to a transparent thermoplastic polymer layer 612 unless otherwise specified. In an example, the translucent thermoplastic polymer layer 612 may at least partially wrap around and may completely wrap around both the first set of yarns 411 and the second set of yarns 413, thereby helping to secure the first knitted layer 410 and the second knitted layer 412 together. The translucent thermoplastic polymer layer 612 includes a first surface 614 and an opposing second surface 616, the first surface 614 at least partially forming the outermost surface of the upper 110, and the opposing second surface 616 at least partially forming the innermost surface of the upper 110. In some aspects, the second surface 616 forms the innermost surface, and another component (such as a lining) may be attached to the upper 110 to form this innermost surface.

[0092] like Figure 6F As depicted, the second sole structure 114 is positioned outside the first knitted layer 410 and is directly fixed to the upper 110 via a thermoplastic polymer layer 612. This second sole structure 114... Figure 6F The relative positioning is simplified to indicate this. To illustrate this differently, the second sole structure 114 is directly attached to the first surface 614 of the thermoplastic polymer layer 612. Figure 6F The simplified first sole structure 112 is positioned inside the second knitted layer 412. When the first sole structure 112 includes, for example, a removable midsole, the first sole structure 112 is not fixed to the thermoplastic polymer layer 612, such as... Figure 6BThe space between the second surface 616 of the thermoplastic polymer layer 612 and the first sole structure 112 is indicated by this. It is also envisioned that the first sole structure 112 can be directly attached to the thermoplastic polymer layer 612 at the second surface 616. The thermoplastic polymer layer 612 can provide... Figure 6B The same functional benefits described herein (e.g., waterproof barrier, abrasion resistance and / or providing visibility of the first sole structure 112 (a visual indicator for aesthetic appeal and / or the function of the first sole structure 112)).

[0093] This document also envisions that the thermoplastic polymer layer 612 could be a solution sprayed and dried onto the first knitted layer 410. Different methods of forming the thermoplastic polymer layer 612 can be used, as per [reference to...] Figure 6E and Figure 6F The first knitted layer 410 and the second knitted layer 412 are secured together, and / or the upper 110 is secured to the second sole structure 114 (and in some cases, to the first sole structure 112). These example thermoplastic polymer materials can also create a moisture barrier and / or increase abrasion resistance.

[0094] Figure 7 An example of a knitted textile 700 having a double-knitted layer structure for forming the shoe upper 110 is depicted. This knitted textile 700 may have, as described above... Figure 4B and Figure 6E The characteristics described. The different zones / areas and knitted sections of the resulting upper 110. Figure 7 The text indicates that the knitted sections in the knitted textile 700 can be... Figure 2A and Figure 2BThe knitted sections shown in the example footwear 100 are consistent. The knitted textile 700 is depicted prior to any type of processing (e.g., prior to any application of heat and / or pressure) and therefore does not include the thermoplastic polymer layer 612. As indicated by the knitting direction arrow 711, example aspects of the knitted textile 700 are knitted in a medial-to-lateral direction (e.g., from medial 124 to lateral 126) or a medial-to-lateral direction (e.g., from lateral 126 to medial 124). This is opposite to the toe-to-heel direction or the heel-to-toe direction. Based on the knitting direction 711, the knitted rows forming the knitted textile 700 and the resulting upper 110 extend in a direction from toe-to-toe 119 to heel-to-toe 123. In the example where the first knitted section 142 includes a first knitted layer 410 and a second knitted layer 412, regions 710 and 712 indicate the location where the first knitted layer 410 and the second knitted layer 412 are connected by one or more transfer yarns (e.g., yarns extending between the first knitted layer 410 and the second knitted layer 412 and interlocked with one or more knitted loops in the first knitted layer 410 and the second knitted layer 412). Between regions 710 and 712 and the throat region 130, the tongue 132, and the ankle collar 128, the first knitted layer 410 and the second knitted layer 412 may not be fixed to each other, such that a tunnel-like structure is located between region 710 and the throat region 130, the tongue 132, and the ankle collar 128, and between region 712 and the throat region 130, the tongue 132, and the ankle collar 128.

[0095] Figure 8 Depicting in Figure 7The cross-section is taken at the cutting line 8-8. At the transfer area 710 on the inner side 124 of the knitted textile 700, the first knitted layer 410 and the second knitted layer 412 are secured to each other by one or more transfer yarns (e.g., yarns extending between the first knitted layer 410 and the second knitted layer 412 and interlocked with one or more knitted loops in the first knitted layer 410 and the second knitted layer 412). At the throat area 130 (and the tongue 132 and the ankle collar 128), the first knitted layer 410 and the second knitted layer 412 transition to a single-layer knitted construction (e.g., a single-knit plain weave). In an example, the first knitted layer 410 and the second knitted layer 412 may be secured to each other by one or more transfer yarns before transitioning to the single-layer knitted construction at the throat area 130, the tongue 132, and the ankle collar 128. Between the transfer area 710 and the throat area 130, tongue 132, and ankle collar 128, the first knitted layer 410 is not attached to the second knitted layer 412, such that space 610 lies between these two layers. A similar knitted structure exists between the transfer area 712 on the outer side 126 and the throat area 130, tongue 132, and ankle collar 128. As previously described, after the upper 110 is processed, in the areas between the transfer area 710 on the inner side 124 and the throat area 130, tongue 132, and ankle collar 128, and in the areas between the transfer area 712 on the outer side 126 and the throat area 130, tongue 132, and ankle collar 128, the first knitted layer 410 is fixed or attached to the second knitted layer 412 by a thermoplastic polymer layer 612.

[0096] Knitting the textile 700 from the inside 124 to the outside 126 (or vice versa) helps reduce knitting time compared to knitting the textile 700 from the toe 119 to the heel 123 (or vice versa). For example, all transfer loops connecting the first knit layer 410 to the second knit layer 412 at transfer areas 710 on the inside 124 and 712 on the outside 126 can be completed during one or more strokes of the knitting carriage. In instances where the first knit layer 410 and the second knit layer 412 are connected by transfer yarns before transitioning to the single-layer throat area 130, tongue 132, and ankle collar 128, all these transfer loops can be completed during one or more strokes of the knitting carriage. This contrasts with knitting the textile 700 in a toe-to-heel or heel-to-toe direction. In terms of knitting, each stroke of the knitting bracket will require the completion of transfer stitches in transfer area 710 on the inner side 124, transfer stitches in the throat area 130, tongue 132 and ankle collar 128 and / or the knitting construction to be changed to a single-layer knitting construction, and transfer stitches in transfer area 712 on the outer side 126, which will increase knitting time.

[0097] Figure 9A and Figure 9B An example process flow for forming footwear product 100 is described. Figure 9A and Figure 9B The processes involved have many of the same steps, but involve different types of knitted textiles. For example, Figure 9A The process depicted uses a knitted textile 900, which can be used to produce Figure 1A and Figure 1B Examples of footwear products 100 depicted in the text, and Figure 9B The process described in the text uses materials from... Figure 7 Knitted textile 700, which can be used to produce Figure 2A and Figure 2B Examples of footwear products 100 depicted herein. Unless otherwise stated, it should be understood that... Figure 9A and Figure 9B The markings for similar steps are the same, and may differ only in the textiles used.

[0098] from Figure 9A Beginning at step 905, a thermoplastic polymer film 654 (which may be...) is applied... Figure 9A (Or, as in the example of film 654 in Figure 9C) is laid on the top surface of the knitted textile 900. In an example, the knitted textile 900 includes a first knitted layer 410 and may be a single-layer knitted construction. During step 905, the knitted textile 900 may be secured to a clamp via pins or other fastening structures.

[0099] At step 912, while the knitted textile 900 is laid flat (e.g., flat or two-dimensionally pressed) on a surface, one or more of heat and pressure 914 are applied to the knitted textile 900 and the thermoplastic polymer film 654. In the example where film 654 is a single-layer film, the heat is sufficient to melt the thermoplastic polymer film 654 without melting the first set of yarns 411, and in the example where film 654 is a double-layer film, the heat is sufficient to melt one layer (e.g., the layer in direct contact with the knitted textile 900) without melting the first set of yarns 411 or the second layer of film 654. Furthermore, for either instance, the heat may be sufficient to soften at least a portion of the first set of yarns 411 (e.g., the sheath when using core / sheath yarns) without melting it.

[0100] Heat and / or pressure cause the molten thermoplastic polymer material to reflow, such that the molten thermoplastic polymer material at least partially encapsulates the first set of yarns 411. The molten thermoplastic polymer material can be melted and reflowed to a extent sufficient to partially embed in the first knitted layer 410, but not fully extend to the inward-facing surface 652 of the first knitted layer 410. After the heat and pressure 914 are removed, the thermoplastic polymer material can be cooled and solidified to form a thermoplastic polymer layer 612, which can be considered a thermoformed layer.

[0101] After heat and / or pressure 914 is applied, the knitted textile 900 includes a translucent thermoplastic polymer layer 612. In an example, this thermoplastic polymer layer 612 provides structural stability (i.e., stiffness) to the knitted textile 900, allowing it to be easily positioned for cutting and / or application of additional elements, such as overlays, to the knitted textile 700. Step 918 depicts a portion of the upper 110 after cutting from the knitted textile 900 but before being formed into a three-dimensional shape suitable for footwear article 100. This portion of the upper 110 cut in step 918 may be the bottom or foot portion of the upper 110. In other respects, the knitted textile 900 may be at least partially knitted into the desired shape, thereby eliminating or reducing the need for cutting steps.

[0102] Step 920 depicts the upper 110 in a three-dimensional shape suitable for footwear article 100. In this example of step 920, the upper 100 is formed after the knitted textile 900 is attached to one or more additional upper components 902 (such as additional textile (e.g., knitted, woven, or nonwoven) pieces). In this configuration, the knitted textile 900 may be folded to primarily comprise the foot portion 134, wherein the knitted textile 900 extends upwards partially to the inner 124 and outer 126 of the footwear article 100 (e.g., similar to folding a taco shell). In this example, the foot portion 134 will not include a seam along the bottom. The process of attaching the knitted textile 900 forming the foot portion 134 to other textile pieces forming the upper foot portion can be accomplished by sewing, adhesives, and / or heat bonding, etc.

[0103] At step 922, the upper 110 undergoes a three-dimensional pressing process. Specifically, a last 924 is positioned within the upper 110. In an example embodiment, the last 924 may be hinged at one or more sections to facilitate insertion and removal from the upper 110. The last 924 includes a foot portion having a plurality of last supports 926 and a plurality of last recesses 928 disposed between adjacent last supports 926. Once the last 924 is positioned within the upper 110, the combination of the last 924 and the upper 110 can be positioned within a bottom mold 923, which may have a geometry opposite to the bottom of the last 924, such that the last support 926 (covered by the upper 110) can be located within recesses of the bottom mold 923, while these last recesses 928 can receive protrusions in the bottom mold 923. While positioned on the bottom mold 923, heat and / or pressure are applied to the last 924 within the upper 110, wherein the heat and / or pressure is sufficient to remelt the thermoplastic polymer layer 612, and mold the thermoplastic polymer layer 612 and the knitted textile 900 into a three-dimensional shape corresponding to the foot portion of the last 924. In some respects, the heat is insufficient to melt the first set of yarns 411 (or, when using core / sheath yarns, at least the sheath of the first set of yarns 411) or to alter the physical properties of the other yarns forming the upper 110.

[0104] It has been found that, compared with other types of textiles, knitted textiles 900 (and Figure 9B The knitted textile 700 is particularly advantageous for forming this three-dimensional shape on the bottom of the upper 110. Specifically, it has been found that the knitted loop structure within the foot portion of the upper 110 enables the upper 110 to be molded into the desired shape more precisely than other textile constructions, such as woven constructions.

[0105] As depicted in step 925, after the upper 110 has cooled at least partially, the second sole structure 114 is secured to the foot portion 134 of the upper 110. In some aspects, this can be done while the thermoplastic polymer layer 612 is in a molten or partially molten state, such that the second sole structure 114 is directly secured to the foot portion 134 of the upper 110 via the thermoplastic polymer layer 612 without the use of adhesives. This securing can occur after the thermoplastic polymer layer 612 has softened by reapplying heat at some point after the last 924 has been removed, and the second sole structure 114 can be secured to the foot portion 134 before the thermoplastic polymer layer 612 hardens again. The thermoplastic polymer composition (which may be thermoplastic polyurethane) within the thermoplastic polymer layer 612 can be compatible with the material of the second sole structure 114 to allow for a strong attachment between both the upper 110 and the second sole structure 114. In other respects, adhesives may be used as an alternative or additional method to secure the foot portion 134 to the second sole structure 114.

[0106] Additionally, after the three-dimensional processing in step 922, the foot portion 134 of the upper 110 includes a plurality of supports 136 and a plurality of recesses 138, wherein the plurality of supports 136 and the plurality of recesses 138 have shapes corresponding to the plurality of last supports 926 and the plurality of last recesses 928. In step 925, the shape of the supports 136 molded into the upper 110 may be complementary to the shape of the spherical portions 140 on the second sole structure 114, which are fixed to one or more of the plurality of supports 136 of the foot portion 134 of the upper 110.

[0107] At step 929, the outsole structure 116 is secured to the ground-facing surface of the second sole structure 114. In some instances, an adhesive may be used to secure the outsole structure 116 to the second sole structure 114.

[0108] At step 930, the first sole structure 112 is inserted into the gap 129 of the upper 110. In one example, the first sole structure 112 is removably positioned within the upper 110. In other examples, the first sole structure 112 is permanently positioned within the upper 110 and can be directly fixed to the upper 110. In some aspects, an adhesive can be used to fix the first sole structure 112 within the upper 110. In other aspects, the first sole structure 112 is fixed to the upper 110 by a thermoplastic polymer layer 612 without an adhesive. In this example, after the last 924 is removed, the thermoplastic polymer layer 612 can be softened by applying heat, and the first sole structure 112 can be placed within the upper 110 before the thermoplastic polymer layer 612 hardens again.

[0109] Go to Figure 9B In step 910, the knitted textile 700 is positioned for processing. In an example embodiment, the knitted textile 700 includes a first knitted layer 410 and a second knitted layer 412, which may not be fixed to each other except at transfer areas 710 and 712. Similarly, the knitted textile 700 includes an ankle collar 128, a throat area 130, and a tongue 132, which may comprise a single-layer knitted construction. Step 910 may include positioning the knitted textile on a clamp via pins or other securing structures.

[0110] At step 912, while the knitted textile 700 is laid flat (e.g., flat or two-dimensionally pressed) on a surface, one or more of heat and pressure 914 are applied to the knitted textile 700. Figure 9B Example step 912 in the example is similar to that about Figure 9A Step 912 is described unless otherwise stated. For example, knitted textile 700 may include a first knitted section 142 and a second knitted section 144, wherein heat and pressure 914 may be selectively applied only to the first knitted section 142 (as described above). Figure 9A Compared to step 912 in the previous step, where heat and / or pressure can be applied to the entire knitted textile 900. However, Figure 9B Other aspects of step 912 envisioned include applying heat and pressure 914 to both the first knitting section 142 and the second knitting section 144. Figure 9B In step 912, the heat is sufficient to melt the transparent / semi-transparent sheath of the second set of yarns 413 and sufficient to soften but not melt at least a portion of the first set of yarns 411 (e.g., the sheath when using core / sheath yarn). In this example, the heat is not high enough to alter the physical properties of the core of the first set of yarns 411 (when using core / sheath yarn) or the core of the second set of yarns 413. When heat and pressure 914 are similarly applied to the second knitting section 144, the heat is not high enough to alter the physical properties of the yarns used to knit the structure in the second knitting section 144.

[0111] When the knitted textile 700 includes a first knitted layer 410 and a second knitted layer 412, heat and / or pressure cause molten thermoplastic polymer material to reflow, such that the molten thermoplastic polymer material at least partially encapsulates the knitted core retained by the first set of yarns 411 and the second set of yarns 413. After the heat and pressure 914 are removed, the thermoplastic polymer material can be cooled and solidified to form a thermoplastic polymer layer 612, which can be considered a thermoformed layer.

[0112] Step 916 depicts the knitted textile 700 after heat and / or pressure 914 has been applied. The knitted textile 700 now includes a translucent thermoplastic polymer layer 612. In an example, this thermoplastic polymer layer 612 provides structural stability (i.e., stiffness) to the knitted textile 700, allowing it to be easily positioned for cutting and / or application of additional elements, such as overlays, to the knitted textile 700. Step 918 depicts the upper 110 after cutting from the knitted textile 700 but before being formed into a three-dimensional shape suitable for footwear article 100. The cutting step may involve trimming the edges so that the upper 110 includes one or more cut edges. In other respects, the knitted textile 700 may be knitted into the shape of the upper 110, thereby eliminating or reducing the cutting step.

[0113] Step 920 depicts the upper 110 after it has been formed into a three-dimensional shape suitable for footwear 100. In this respect, the inner and outer edges can be secured to each other in the foot portion 134 of the upper 110. Alternatively, the knitted textile 700 can be cut to fit the foot. Figure 9A The knitted textile 900 in step 920 is similar in shape and is similarly connected to other textile pieces by stitching, adhesives, bonding and / or similar means to form the upper 110.

[0114] At step 922, the shoe upper 110 undergoes a process of contact with... Figure 9A The process is similar to step 922 in the three-dimensional pressing process. For the sake of brevity, the details will not be repeated here, because... Figure 9A and Figure 9B The instances of step 922 should be considered the same, except that the thermoplastic layer 612 is formed from different components, and Figure 9B There may be additional yarns and a second knitted layer 144. Specifically, in Figure 9B The heat and / or pressure applied in step 922 is sufficient to remelt the thermoplastic polymer layer 612 and mold it into a three-dimensional shape corresponding to the foot portion of the last 924, but insufficient to melt the first set of yarns 411 (e.g., the sheath of the first set of yarns 411 when core / sheath yarns are used), or insufficient to change the physical properties of other yarns forming the upper 110 (such as the core retained by the second set of yarns 412).

[0115] Figure 9B Steps 925, 929, and 930 described in the text can be related to... Figure 9AThe process is the same as those described in the corresponding steps. That is, at step 925, the second sole structure 114 is fixed to the foot portion 134 of the upper 110, at step 929, the outsole structure 116 is fixed to the ground-facing surface of the second sole structure 114, and at step 930, the first sole structure 112 is inserted into the gap 129 of the upper 110. Figure 9B Further details of these steps should be considered in conjunction with Figure 9A The same applies, and for the sake of brevity, it will not be repeated.

[0116] Figure 9A and Figure 9B The order of steps described herein is illustrative, and it is envisioned herein that these steps may be combined or performed in a different order than those shown. For example, the first sole structure 112 may be positioned within the gap 129 of the upper 110 before the second sole structure 114 is fixed to the foot portion 134 of the upper 110.

[0117] Figure 10A The illustration shows a bottom view of the foot portion 134 of the upper 110 of a footwear article 100. As described, when the upper 110 is on a three-dimensional mold, after applying one or more of heat and pressure to at least the foot portion 134 of the upper 110, the foot portion 134 includes a plurality of supports 136 and a plurality of recesses 138. In an example, each of the plurality of supports 136 terminates at a distal end to form a plurality of support surfaces 1010. In an example, these support surfaces 1010 may be non-planar (i.e., having an uneven surface). Having non-planar support surfaces 1010 can increase the surface area of ​​each of the support surfaces 1010, which facilitates a more robust attachment to the spherical portion 140 of the second sole structure 114 compared to a planar support surface. When the attachment surface of the spherical portion 140 is also non-planar or generally rough in texture, the strong attachment between the support surface 1010 and the spherical portion 140 can be further enhanced because this increases the surface area of ​​the attachment surface of the spherical portion 140. Additionally, having a non-planar support surface 1010 can also increase the number of discrete points or areas in contact with the spherical portion 140 of the second sole structure 114. When the footwear 100 is used, this can further enhance the flexibility and overall cushioning effect of the foot portion 134 or the attenuation of ground forces.

[0118] like Figure 10AAs depicted, the multiple supports 136 may have different geometries or shape configurations in different areas of the foot portion 134. For example, in the forefoot region 118 of the foot portion 134, these supports 136 may include one or more continuously extending supports (such as supports 1012 and 1014) that typically extend from the inner side 124 of the foot portion 134 to the outer side 126 of the foot portion 134. In an example, the supports 136 (such as supports 1012 and 1014) in the forefoot region 118 may be generally parallel to each other and separated by generally parallel continuous recesses 138 (such as recesses 1016 and 1018). This shape configuration may facilitate toe-to-heel flexion in the forefoot region 118 of the foot portion 134. This, in turn, corresponds to the natural flexion of the wearer's foot in the forefoot region of the wearer's foot, as reflected by movements that shift the center of gravity from the ball of the foot toward the heel of the wearer's foot (or vice versa).

[0119] In the heel region 122 of the foot portion 134, these supports 136 may include one or more separate supports (such as supports 1020, 1022, and 1024) spaced apart from each other in a medial-to-lateral direction and a toe-to-heel direction. In this respect, recesses 138 in the heel region 122 that space the supports 136 may extend substantially continuously in both the medial-to-lateral and toe-to-heel directions. In addition to medial-to-lateral flexion, this shape configuration may also facilitate toe-to-heel flexion in the heel region 122 of the foot portion 134. This shape configuration may reflect movements in which the wearer shifts their weight from the ball of the foot to the heel (or vice versa), and movements in which the wearer shifts their weight from the medial to the lateral (or vice versa), such as when performing lateral movements. Furthermore, having a smaller but greater number of discrete support members 136 in the heel area 122 can provide more points to increase point loads and thus improve the ability to dampen ground forces (i.e., cushion) in the heel area 122.

[0120] Figure 10B Is it through Figure 10A The figure shows a cross-section taken by cutting lines 10B-10B, and illustrates the non-planar support surface 1010 of the support member 1012. As shown, the support surface 1010 includes one or more convex surfaces (such as convex surface 1050), which are separated by one or more concave surfaces (such as concave surface 1052). The convex surface 1050 and the concave surface 1052 create a non-planar support surface 1010, which can increase the contact surface area with, for example, the spherical portion 140 of the second sole structure 114.

[0121] Figure 10C Is it through Figure 10AThe diagram illustrates a cross-section taken by cutting line 10C-10C, and shows the non-planar support surface 1010 of, for example, supports 1020, 1022, and 1024. As illustrated, supports 110 (such as supports 1020, 1022, and 1024) may have non-uniform curvature. For example, the sidewalls of support 136 may be convex, and the distal ends of the support surfaces 1010 forming supports 1020, 1022, and 1024 include concave surfaces such as concave surface 1054. This is an illustrative example, and various aspects herein contemplate that each of supports 1020, 1022, and 1024 may include more than one concave surface or one or more relatively flat regions. These concave surfaces create a non-planar support surface 1010, which in turn can increase the contact surface area with, for example, the spherical portion 140 of the second sole structure 114. Furthermore, the change in curvature of the support member 110 can provide a larger surface area to more firmly attach to the spherical portion 140 of the second sole structure 114 and enhance the cushioning effect provided by the first sole structure 112 within the upper 110.

[0122] Figure 11 A portion of the upper 110 from the second knit section 144 is depicted, as relative to... Figure 2A and Figure 2B The description describes various aspects. In the second knitted section 144, the upper 110 includes a single-sided plain knit construction with knitted rows (such as knitted rows 1110) extending in a direction from the toe 119 of the upper 110 to the heel 123 of the upper 110. The orientation of these knitted rows is based on the above description regarding... Figure 7 The described upper 110 has a knitting direction 711. The yarn used to form the second knitted section 144 may include one or more of PET yarn, recycled PET yarn, polyamide yarn, and elastic yarn. A plurality of rib structures 146 are depicted extending longitudinally in a direction from the toe 119 of the upper 110 to the heel 123 of the upper 110. Figure 12 Depicting in Figure 11 The cross-section is taken at the cutting line 12-12, and further depicts multiple rib structures 146. The upper 110 in the second knitted section 144 includes a wavy surface with height variation in at least one of the positive and negative z directions.

[0123] In an example, the knitting sequence used to form at least one or more portions of the second knitted section 144 may include a repeating pattern that uses a set of yarn to knit a first number of knitted rows on a first needle bed of a knitting machine, transfers loops of the set of yarn held on the first needle bed to a second needle bed of the knitting machine, uses the same set of yarn to knit a second number of knitted rows on the second needle bed, and transfers the loops of the same set of yarn back to the first needle bed to repeat the pattern. Since the yarn is knitted only on one needle bed at a time, a single-knit plain weave structure is obtained. In an example, the first number of knitted rows knitted on the first needle bed differs from the second number of knitted rows knitted on the second needle bed. In one instance, the first number of knitted rows is 2 knitted rows, and the second number of knitted rows is 4 knitted rows. This is an illustrative example, and other combinations of knitted rows are contemplated herein. The uneven distribution of knitted rows on the first and second needle beds, along with the inherent tendency of the single-knit plain weave construction to curl, produces a rib structure 146.

[0124] The longitudinal orientation of multiple rib structures 146 promotes the inner-to-outer stretching of the second knit section 144, such as... Figure 11 As indicated by arrow 1112. The inner to outer stretch of the ankle collar 128, throat area 130, and tongue 132 facilitates the wearer's putting on footwear 100.

[0125] Figure 13 and Figure 14 The feet are depicted separately in 134. Figure 2A and Figure 2B A partial view of the toe 119 and heel 123 of the upper 110. That is, Figure 13 and Figure 14 The shoe upper 110 depicted may have a seamless construction between the underfoot portion 134 and the upper foot portion 135. However, as... Figure 13 and Figure 14 As depicted, one or more seams can connect knitted textiles (which may be from...) Figure 7 The edge of the knitted textile 700 is used to form the upper 110. Specifically, the lower foot portion 134 includes a toe cap seam 1302 that extends at the toe cap 119 of the upper 110 along a portion of the boundary between the lower foot portion 134 and the upper foot portion 135. The toe cap seam 1302 connects the lower foot portion 134 and the upper foot portion 135 on the medial side 124 and the lateral side 126 in the forefoot area 118. The toe cap seam 1302 may terminate at or before the midfoot area 120.

[0126] The foot portion 134 also includes a longitudinal seam 1304 extending from the toe 119 to the heel 123. This longitudinal seam 1304 may extend continuously through the forefoot region 118, midfoot region 120, and heel region 122, thereby connecting the lateral and medial sides 126. In this example, the longitudinal seam 1304 is approximately centered along the central midline of the foot portion 134 between the lateral and medial sides 124; however, in other examples, the longitudinal seam 1304 may be off-center and / or extend diagonally.

[0127] Go to Figure 14 The upper 110 includes a first heel end seam 1306 that extends at the heel end 123 of the upper 110 along a portion of the boundary between the lower foot portion 134 and the upper foot portion 135. The first heel end seam 1306 connects the lower foot portion 134 and the upper foot portion 135 on the medial side 124 and the lateral side 126 in the heel area 122. The first heel end seam 1306 may terminate at or before the midfoot area 120. In an example, the first heel end seam 1306 has a shorter length than the toe cap seam 1302. Both the first heel end seam 1306 and the toe cap seam 1302 can be connected to a longitudinal seam 1304. Although the first heel seam 1306 can be fully positioned on the bottom-facing surface of the upper 110 when the upper 110 exists alone, when the upper 110 is incorporated into the footwear 100, at least a portion of the first heel seam 1306 may be exposed above the external sole structure, as per [reference to...]. Figure 15 Further described.

[0128] The upper 110 may also include a second heel seam 1308 that extends upward to the suprafoot portion 135 of the heel end 123. The second heel seam 1308 may extend from the first heel seam 1306 to the ankle collar 128. The second heel seam 1308 may connect the medial side 124 and the lateral side 126 of the suprafoot portion 135 in the heel area 122. In some instances, the second heel seam 1308 is substantially centered at the heel end 123 along a central midline of the suprafoot portion 134 located between the lateral side 126 and the medial side 124; however, in other instances, the second heel seam 1308 may be off-center and / or extend diagonally.

[0129] Figure 15 Depicting from Figure 13 and Figure 14 When combined with other features, it is constructed into footwear products (similar to...) Figure 2A and Figure 2BThe upper 110 of the footwear 100. Specifically, a first sole structure (such as a first sole structure 112) may be placed within the gaps of the upper 110. Additionally, a second sole structure 114 may be attached to the underfoot portion 134 of the upper 110. The upper 110 may include additional components, such as a heel stabilizer 1310. The heel stabilizer 1310 may include thermoplastic polymer or leather components that provide additional rigidity and abrasion resistance to the upper 110.

[0130] The heel stabilizer 1310 may also extend over at least a portion of the first heel end seam 1306 (shown in dashed lines). When the first sole structure (e.g., first sole structure 112) is positioned within the gap of the upper 110, the underfoot portion 134 of the upper 110 may be shaped such that at least a portion of it appears along the side of the upper 110, making at least a portion of the first heel end seam 1306 visible above an outer sole structure (such as a second sole structure 114). A first portion 1307 of the first heel end seam 1306 on the inner side 124 may extend diagonally upward, while a second portion 1309 of the first heel end seam 1306 on the outer side 126 may extend diagonally upward to intersect with the first portion 1307 of the first heel end seam 1306. Therefore, the heel stabilizer 1310 may have a first bottom portion 1311 that extends diagonally upward and intersects with a second bottom portion 1313 that extends diagonally upward. The first bottom portion 1311 of the heel stabilizer 1310 may cover a first portion 1307 of the first heel end seam 1308, and the second bottom portion 1313 of the heel stabilizer 1310 may cover a second portion 1309 of the first heel end seam 1308. From the point where the first bottom portion 13011 and the second bottom portion 1313 intersect, the heel stabilizer 1310 may extend at least partially upward in the heel region 122 to the upper foot portion 135. Furthermore, the heel stabilizer 1310 may cover at least a portion of the second heel end seam 1308. In the example shown, the top of the heel stabilizer 1310 may extend further outward from the second heel end seam 1308 (shown in dashed lines), but in other examples, the heel stabilizer 1310 may have other shapes. Furthermore, the heel stabilizer 1310 may extend continuously from the upper 110 onto a portion of the second sole structure 114.

[0131] Additionally, the upper 110 may include a heel pull tab 1312. The heel pull tab 1312 may include a textile strip with a loop at the top, extending to the ankle opening 128 and providing a structure that the wearer can grip when pulling the upper 110 up to their heel. The heel pull tab 1312 may be positioned above and cover the second heel end seam 1308. Furthermore, the heel pull tab 1312 may extend from the heel stabilizer 1310.

[0132] Various aspects of this disclosure have been described in an illustrative and not restrictive manner. Alternative aspects will become apparent to those skilled in the art without departing from its scope. Those skilled in the art can develop alternative means to achieve the above improvements without departing from the scope of this disclosure.

[0133] It should be understood that certain features and sub-combinations are useful and can be used without reference to other features and sub-combinations, and are contemplated to be within the scope of the claims. Not all steps listed in the various figures need to be performed in the specific order described.

[0134] Clause 1 A footwear article comprising: an upper having a space for receiving a wearer's foot, the upper comprising: a first knitted layer comprising a knitted mesh structure including a first set of yarns; a translucent or transparent thermoplastic polymer layer at least partially enclosing the first set of yarns; and a first sole structure positioned within the space of the upper, the first sole structure being at least partially visible through the knitted mesh structure of the first knitted layer.

[0135] Clause 2 The footwear article according to Clause 1, wherein the first set of yarns includes a sheath of a first type of material, the sheath surrounding a core of a second type of material different from the first type of material.

[0136] Clause 3 Footwear products according to Clause 1, wherein the first group of yarns includes single-component monofilament yarn, bicomponent monofilament yarn, coated monofilament yarn, or multifilament yarn.

[0137] Clause 4 Footwear articles according to any one of clauses 1 to 3, wherein the first set of yarns is opaque.

[0138] Clause 5Footwear articles according to any one of Clauses 1 to 4, wherein the translucent or transparent thermoplastic polymer layer forms at least partially the outermost surface of the upper.

[0139] Clause 6 Footwear articles according to any one of Clauses 1 to 4, wherein the translucent or transparent thermoplastic polymer layer forms at least partially the innermost surface of the upper.

[0140] Clause 7 Footwear article according to any one of clauses 1 to 6, wherein the first sole structure is located inside the first knitted layer.

[0141] Clause 8 Footwear articles according to any one of clauses 1 to 7, wherein the first sole structure is removably disposed within the upper.

[0142] Clause 9 Footwear article according to any one of clauses 1 to 9, wherein the upper includes a foot portion, the foot portion including the first knitted layer and the translucent or transparent thermoplastic polymer layer.

[0143] Clause 10 The footwear article according to Clause 9 further includes a second sole structure, the second sole structure being fixed to the foot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer fixes the second sole structure to the upper.

[0144] Clause 11 The footwear article according to Clause 10, wherein the second sole structure is positioned outside the first knitted layer.

[0145] Clause 12 The footwear article according to any one of Clauses 9 to 10, wherein the second sole structure includes a fluid-filled bladder.

[0146] Clause 13 A footwear article according to any one of Clauses 9 to 12, wherein the foot portion of the upper includes one or more supports, and wherein a plurality of recesses are provided between adjacent supports in the one or more supports, wherein each of the one or more supports terminates at a distal end to form one or more support surfaces.

[0147] Clause 14 Footwear articles according to Clause 13, wherein at least a portion of the one or more supporting surfaces is non-planar.

[0148] Clause 15The footwear article according to Clause 13 further includes a second sole structure, the second sole structure being fixed to the foot portion of the upper and including one or more spherical portions, each of the one or more spherical portions being fixed to a corresponding support of the foot portion, wherein the foot portion of the upper is spaced apart from the second sole structure at the plurality of recesses.

[0149] Clause 16 Footwear articles according to any one of clauses 1 to 15, wherein the first set of yarns is partially embedded within the translucent or transparent thermoplastic polymer layer.

[0150] Clause 17 Footwear articles according to any one of Clauses 1 to 16, wherein the translucent or transparent thermoplastic polymer layer does not extend completely to the inward-facing surface of the first knitted layer.

[0151] Clause 18 The footwear article according to any one of Clauses 1 to 17, wherein the translucent or transparent thermoplastic polymer layer comprises a first sublayer and a second sublayer, the first sublayer having a first thermoplastic polymer composition, the second sublayer having a second thermoplastic polymer composition, and the second sublayer being positioned between the first knitted layer and the first sublayer.

[0152] Clause 19 Footwear articles according to Clause 18, wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition.

[0153] Clause 20 Footwear articles according to any one of Clauses 18 to 19, wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.

[0154] Clause 21 Footwear article according to any one of clauses 1 to 20, wherein the upper includes a second knitted layer, the second knitted layer including a second set of yarns and positioned inside the first knitted layer.

[0155] Clause 22 The footwear article according to Clause 21, wherein the translucent or transparent thermoplastic polymer layer at least partially encapsulates the second set of yarns.

[0156] Clause 23 Footwear articles according to Clause 21 or 22, wherein the first sole structure is positioned inside the second knitted layer, wherein the second knitted layer is positioned between the first knitted layer and the first sole structure.

[0157] Clause 24Footwear article according to any one of clauses 21 to 23, wherein the upper includes a foot portion, the foot portion including the first knitted layer, the second knitted layer and the translucent or transparent thermoplastic polymer layer.

[0158] Clause 25 The footwear article according to Clause 24 further includes a second sole structure attached to the foot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer attaches the second sole structure to the upper.

[0159] Clause 26 According to Clause 24 or 25, the footwear article wherein the foot portion of the upper includes one or more supports, and wherein a plurality of recesses are provided between adjacent supports of the one or more supports.

[0160] Clause 27 The footwear article according to Clause 26, wherein the foot portion is fixed to a second sole structure, the second sole structure including one or more spherical portions, each of the one or more spherical portions being fixed to a corresponding support of the foot portion, wherein the foot portion of the upper is spaced apart from the second sole structure at the plurality of recesses.

[0161] Clause 28 Footwear products according to Clause 21, wherein the diameter of the second set of yarns is smaller than the diameter of the first set of yarns.

[0162] Clause 29 A footwear article comprising: an upper having a cavity for receiving a wearer's foot, the upper comprising: a composite layer comprising one or more knitted layers and a thermoplastic polymer material forming a thin film structure, wherein the one or more knitted layers are positioned to form at least a portion of an inward-facing surface of the upper, wherein the thermoplastic polymer material forms at least a portion of an outward-facing surface of the upper and is translucent or transparent, and a first sole structure is positioned within the cavity of the upper, the first sole structure being at least partially visible through the composite layer.

[0163] Clause 30 The footwear article according to Clause 29, wherein the composite layer includes a first surface and a second surface, the first surface being defined by the thermoplastic polymer material, the second surface including at least a portion of the one or more knitted layers, wherein the first surface has a smooth texture and the second surface has a non-smooth texture.

[0164] Clause 31The footwear article according to Clause 30, wherein the first sole structure is directly adjacent to the second surface.

[0165] Clause 32 Footwear articles according to any one of Clauses 29 to 31, wherein the one or more knitted layers comprise a single knitted layer.

[0166] Clause 33 Footwear articles according to any one of Clauses 29 to 31, wherein the one or more knitted layers comprise a first knitted layer and a second knitted layer, the second knitted layer being inside the first knitted layer.

[0167] Clause 34 The footwear article according to Clause 33, wherein the first knitted layer comprises a first set of yarns and the second knitted layer comprises a second set of yarns having a smaller diameter than the first set of yarns.

[0168] Clause 35 Footwear articles according to any one of Clauses 29 to 34, wherein the one or more knitted layers comprise a knitted mesh structure.

[0169] Clause 36 Footwear articles according to any one of clauses 29 to 35, wherein the upper includes a foot portion, and the foot portion includes the composite layer.

[0170] Clause 37 The footwear article according to Clause 36 further includes a second sole structure, the second sole structure being fixed to the foot portion of the upper, wherein the film structure fixes the second sole structure to the upper.

[0171] Clause 38 The footwear article according to Clause 37, wherein the second sole structure includes a fluid-filled bladder.

[0172] Clause 39 A footwear article according to any one of clauses 36 to 38, wherein the foot portion of the upper includes one or more supports, and wherein a plurality of recesses are provided between adjacent supports in the one or more supports, wherein each of the one or more supports terminates at a distal end to form one or more support surfaces.

[0173] Clause 40 Footwear articles according to Clause 39, wherein at least a portion of the one or more supporting surfaces is non-planar.

[0174] Clause 41The footwear article according to any one of clauses 39 to 40 further includes a second sole structure, the second sole structure being fixed to the foot portion of the upper and including one or more spherical portions, each of the one or more spherical portions being fixed to a corresponding support of the foot portion, wherein the foot portion of the upper is spaced apart from the second sole structure at the plurality of recesses.

[0175] Clause 42 Footwear articles according to any one of Clauses 29 to 41, wherein the thermoplastic polymer material of the composite structure comprises a first thermoplastic polymer material and a second thermoplastic polymer material, the first thermoplastic polymer material forming a first sublayer of the film structure, the second thermoplastic polymer material forming a second sublayer of the film structure, the second sublayer being positioned between the one or more knitted layers and the first sublayer.

[0176] Clause 43 The footwear article according to Clause 42, wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition.

[0177] Clause 44 Footwear articles according to any one of clauses 42 to 43, wherein the one or more knitted layers comprise a first set of yarns, and wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.

[0178] Clause 45 A method of manufacturing a footwear article having a toe and a heel, the method comprising: forming a first knitted section of an upper of the footwear article, the forming of the first knitted section comprising: knitting a first knitted layer having a knitted mesh structure on a knitting machine using a first set of yarns; applying a translucent or transparent thermoplastic polymer film to a first surface of the first knitted layer; applying one or more of heat and pressure to at least a portion of the first knitted section, such that the translucent or transparent thermoplastic polymer film melts to form a translucent or transparent thermoplastic polymer layer; forming the upper at least by the first knitted section such that the upper includes a gap for receiving a wearer's foot; and positioning a first sole structure within the gap of the upper and within the first knitted layer, the first sole structure being at least partially visible through the knitted mesh structure of the first knitted layer.

[0179] Clause 46The method of manufacturing footwear according to Clause 45, wherein the first surface of the first knitted layer constitutes the outward-facing surface of the first knitted layer after it has been formed into the upper, and wherein the translucent or transparent thermoplastic polymer layer at least partially encapsulates the first set of yarns forming the outward-facing surface of the first knitted layer.

[0180] Clause 47 A method of manufacturing footwear according to any one of clauses 45 to 46, wherein after the first knitted layer is formed as the upper, the translucent or transparent thermoplastic polymer layer does not partially wrap the first set of yarns at the inward-facing surface of the first knitted layer.

[0181] Clause 48 A method of manufacturing footwear according to any one of clauses 45 to 47, wherein the first knitted layer is at least partially embedded within the translucent or transparent thermoplastic polymer layer.

[0182] Clause 49 A method of manufacturing footwear articles according to any one of clauses 45 to 48, wherein after the first knitted layer is formed as the upper, the translucent or transparent thermoplastic polymer layer does not extend to the inward-facing surface of the first knitted layer.

[0183] Clause 50 A method of manufacturing footwear articles according to any one of clauses 45 to 49, wherein the first set of yarns includes a sheath of a first type of material, the sheath surrounding a core of a second type of material different from the first type of material.

[0184] Clause 51 A method for manufacturing footwear articles according to any one of clauses 45 to 50, wherein the first set of yarns is opaque.

[0185] Clause 52 A method of manufacturing footwear articles according to any one of clauses 45 to 51, wherein the translucent or transparent thermoplastic polymer layer at least partially forms the outward-facing surface of the upper.

[0186] Clause 53 A method of manufacturing footwear articles according to any one of clauses 45 to 52, wherein the upper includes a foot portion, the foot portion including the first knitted layer and the translucent or transparent thermoplastic polymer layer.

[0187] Clause 54 The method of manufacturing footwear according to Clause 53 further includes securing a second sole structure to the foot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer directly secures the second sole structure to the upper.

[0188] Clause 55 The method of manufacturing footwear according to Clause 54, wherein the second sole structure is positioned outside the first knitted layer.

[0189] Clause 56 A method of manufacturing footwear articles according to any one of clauses 54 to 55, wherein the second sole structure includes a fluid-filled bladder.

[0190] Clause 57 A method of manufacturing footwear according to any one of clauses 54 to 55, wherein the foot portion of the upper includes one or more supports, and wherein a plurality of recesses are provided between adjacent supports of the one or more supports.

[0191] Clause 58 The method of manufacturing footwear articles according to Clause 57, wherein each of the one or more supports terminates at a distal end to form one or more support surfaces.

[0192] Clause 59 A method of manufacturing footwear articles according to any one of Clauses 57 to 58, wherein at least a portion of the one or more supporting surfaces is non-planar.

[0193] Clause 60 The method of manufacturing footwear according to Clause 59, wherein the upper includes a foot portion, the foot portion including a first knitted layer, a second knitted layer and the translucent or transparent thermoplastic polymer layer.

[0194] Clause 61 . A method of manufacturing a footwear article having a toe and a heel, the method comprising: fixing an upper having a foot portion around a last, the foot portion comprising a first thermoplastic material having a first melting point, wherein the last includes the foot portion having a plurality of last supports and a plurality of last recesses disposed between adjacent last supports, the foot portion of the upper covering the foot portion of the last when the upper is fixed around the last; applying one or more of heat and pressure to at least the foot portion of the upper while fixing the upper to the last, such that the first thermoplastic material melts; and removing the last from the upper after the upper has cooled, wherein after the last is removed from the upper, the foot portion of the upper includes a plurality of supports and a plurality of recesses having shapes corresponding to the plurality of last supports and the plurality of last recesses.

[0195] Clause 62The method of manufacturing footwear articles according to Clause 61, wherein the upper includes one or more cut edges.

[0196] Clause 63 A method of manufacturing footwear according to any one of claims 61 to 62 further comprises: applying a film over a first knitted layer, the film comprising the first thermoplastic material, prior to fixing the upper around a last; wherein, after applying one or more of heat and pressure, the foot portion of the upper comprises the first knitted layer at least partially embedded within a thermoplastic layer comprising a molten first thermoplastic material.

[0197] Clause 64 The method of manufacturing footwear articles according to Clause 63, wherein the first knitted layer is positioned inside the thermoplastic layer.

[0198] Clause 65 A method of manufacturing footwear articles according to any one of clauses 63 to 64, wherein the first knitted layer comprises a second thermoplastic polymer material having a higher melting temperature than the first thermoplastic polymer material.

[0199] Clause 66 A method of manufacturing footwear articles according to any one of clauses 63 to 65, wherein the first knitted layer comprises a knitted mesh structure and the thermoplastic layer is translucent or transparent, wherein the first knitted layer comprises a knitted mesh structure and the thermoplastic layer is translucent or transparent.

[0200] Clause 67 The method of manufacturing footwear according to Clause 67 further includes inserting a first sole structure into a gap defined by the upper, such that the first sole structure is positioned inside the first knitted layer, the first sole structure being at least partially visible through the knitted mesh structure of the first knitted layer and the thermoplastic layer.

[0201] Clause 68 A method of manufacturing footwear articles according to any one of clauses 61 to 67 includes inserting a first sole structure into a gap defined by the upper.

[0202] Clause 69 The method of manufacturing footwear according to Clause 68 further includes securing a second sole structure to the exterior of the foot portion of the upper, wherein the second sole structure includes one or more spherical portions, each of the one or more spherical portions being secured to a support among the plurality of supports of the foot portion, wherein the foot portion of the upper is spaced apart from the second sole structure at the plurality of recesses of the upper.

[0203] Clause 70 The method of manufacturing footwear according to Clause 69, wherein the outsole structure is fixed to the ground-facing surface of the second sole structure.

[0204] Clause 71 A method of manufacturing footwear articles according to any one of clauses 61 to 70, wherein the foot portion is seamless.

[0205] Clause 72 A method of manufacturing footwear articles according to any one of clauses 61 to 71, wherein, prior to applying one or more of heat and pressure, the foot portion of the upper comprises: a first knitted layer knitted using a first set of yarns, and a second knitted layer knitted using a second set of yarns comprising a first high-melting-point material and the first thermoplastic material.

[0206] Clause 73 The method of manufacturing footwear according to Clause 72, wherein the first knitted layer is knitted integrally with the second knitted layer.

[0207] Clause 74 A method of manufacturing footwear articles according to any one of clauses 72 to 73, wherein the upper includes an unfixed area before applying one or more of heat and pressure, wherein the first knitted layer and the second knitted layer are not fixed to each other in the unfixed area.

[0208] Clause 75 The method of manufacturing footwear according to Clause 74 further includes applying one or more of heat and pressure to at least the foot portion of the upper before fixing the upper around the last, causing the first thermoplastic material to melt and form a thermoformed layer, the thermoformed layer at least partially encapsulating the first high-melting-point material of the first set of yarns and the second set of yarns, wherein applying one or more of heat and pressure to at least the foot portion of the upper while the upper is fixed to the last causes the first thermoplastic material to remelt.

[0209] Clause 76 A method of manufacturing footwear articles according to any one of clauses 72 to 75, wherein the first set of yarns comprises a core of a second high-melting-point material and a sheath of a second thermoplastic material, the second thermoplastic material having a second melting point greater than the first melting point of the first thermoplastic material, and wherein the sheath of the second thermoplastic material surrounds the core of the second high-melting-point material.

[0210] Clause 77The method of manufacturing footwear according to Clause 76, wherein during one or more of heat and pressure applied to at least the foot portion of the upper while it is being fixed to the last, the sheath of the second thermoplastic material of the first set of yarns softens.

[0211] Clause 78 A method of manufacturing footwear articles according to any one of clauses 72 to 77, wherein the first knitted layer comprises a knitted mesh structure.

[0212] Clause 79 A footwear article having an inner side, an outer side, a toe area, and a heel end, the footwear article comprising: an upper having a space for receiving a wearer's foot, the upper comprising: a first knitted section integrally knitted with a second knitted section, the first knitted section comprising: a first knitted layer comprising a knitted mesh structure comprising a first set of yarns; a second knitted layer comprising a second set of yarns positioned inside the first knitted layer; and a translucent or transparent thermoplastic polymer layer at least partially enclosing each of the first set of yarns and the second set of yarns; and a second knitted section wherein the translucent or transparent thermoplastic polymer layer is not present in the second knitted section.

[0213] Clause 80 Footwear articles according to Clause 79, wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.

[0214] Clause 81 Footwear articles according to any one of clauses 79 to 80, wherein the first set of yarns is opaque.

[0215] Clause 82 Footwear article according to any one of clauses 80 to 81, wherein the first sole structure is located in the first knitted section.

[0216] Clause 83 Footwear articles according to any one of clauses 80 to 82, wherein the first sole structure is not present in the second knitted section.

[0217] Clause 84 Footwear articles according to any one of clauses 80 to 83, wherein the first sole structure is positioned inside the second knitted layer.

[0218] Clause 85 Footwear articles according to any one of clauses 80 to 84, wherein the first sole structure is removably disposed within the upper.

[0219] Clause 86 Footwear article according to any one of clauses 79 to 85, wherein the upper includes a foot portion, the foot portion including the first knitted section.

[0220] Clause 87 The footwear article according to Clause 86 further includes a second sole structure, the second sole structure being fixed to the foot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer directly fixes the second sole structure to the upper.

[0221] Clause 88 The footwear article according to Clause 87, wherein the second sole structure is positioned outside the first knitted layer.

[0222] Clause 89 Footwear articles according to any one of Clauses 87 to 88, wherein the second sole structure includes a fluid-filled bladder.

[0223] Clause 90 Footwear article according to any one of clauses 79 to 89, wherein the translucent or transparent thermoplastic polymer layer forms the outermost surface of the upper in the first knitted section.

[0224] Clause 91 Footwear article according to any one of clauses 79 to 89, wherein the translucent or transparent thermoplastic polymer layer forms at least partially the innermost surface of the upper in the first knitted section.

[0225] Clause 92 Footwear articles according to any one of clauses 79 to 91, wherein the second knitted section comprises a single-sided plain knitted structure.

[0226] Clause 93 The footwear article according to Clause 92, wherein the second knitted section includes at least the tongue area of ​​the upper, the tongue area including a plurality of rib structures.

[0227] Clause 94 The footwear article according to Clause 93, wherein the plurality of rib structures have knitted rows that extend longitudinally in a direction from the toe of the footwear article to the heel of the footwear article.

[0228] Clause 95A method of manufacturing a footwear article having a toe and a heel, the method comprising: forming a first knitted section of an upper of the footwear article, the first knitted section comprising: knitting a first knitted layer having a knitted mesh structure on a knitting machine using a first set of yarns; knitting a second knitted layer on the knitting machine using a second set of yarns, the second set of yarns comprising a first high-melting-point material and a first thermoplastic material having a first melting point; forming the upper from at least the first knitted section such that the upper includes a space for receiving a wearer's foot, wherein the second knitted layer is positioned inside the first knitted layer; and applying one or more of heat and pressure to at least a portion of the first knitted section such that the first thermoplastic material melts and a thermoformed layer is formed, the thermoformed layer at least partially enclosing the first high-melting-point material of the first set of yarns and the second set of yarns, wherein the thermoformed layer is translucent or transparent; and positioning a first sole structure within the space of the upper and inside the second knitted layer, the first sole structure being at least partially visible through the knitted mesh structure of the first knitted layer.

[0229] Clause 96 The method of manufacturing footwear according to Clause 95, wherein the first thermoplastic material of the second set of yarns includes a sheath, wherein the first high-melting-point material of the second set of yarns includes a core, and wherein the sheath surrounds the core.

[0230] Clause 97 A method of manufacturing footwear articles according to any one of clauses 95 to 96, wherein the core of the second set of yarns is opaque.

[0231] Clause 98 A method of manufacturing footwear articles according to any one of clauses 95 to 97, wherein the first set of yarns comprises a core of a second high-melting-point material and a sheath of a second thermoplastic material, the second thermoplastic material having a second melting point greater than the first melting point of the first thermoplastic material, and wherein the sheath of the second thermoplastic material surrounds the core of the second high-melting-point material.

[0232] Clause 99 A method of manufacturing footwear articles according to any one of clauses 95 to 98, wherein the heat applied to the at least portion of the first knitted section comprises a temperature equal to or greater than the first melting point of the first thermoplastic material and less than the second melting point of the second thermoplastic material.

[0233] Clause 100 A method for manufacturing footwear articles according to any one of clauses 95 to 99, wherein the first group of yarns comprises monofilament yarn, bifilament yarn, coated monofilament yarn, or multifilament yarn.

[0234] Clause 101 A method for manufacturing footwear articles according to any one of clauses 95 to 100, wherein the first set of yarns is opaque.

[0235] Clause 102 A method of manufacturing footwear articles according to any one of clauses 95 to 101, wherein the thermoformed layer forms the outermost surface of the first knitted section of the upper.

[0236] Clause 103 A method of manufacturing footwear articles according to any one of clauses 95 to 101, wherein when the upper is formed, the thermoformed layer at least partially forms the innermost surface of the first knitted section of the upper.

[0237] Clause 104 A method of manufacturing footwear articles according to any one of clauses 95 to 103, wherein the first sole structure is removably disposed within the upper.

[0238] Clause 105 A method of manufacturing footwear articles according to any one of clauses 95 to 104, wherein the first knitted section forms the foot portion of the upper.

[0239] Clause 106 The method of manufacturing footwear according to Clause 97 further includes securing a second sole structure to the foot portion of the upper, wherein the thermoformed layer directly secures the second sole structure to the upper.

[0240] Clause 107 The method of manufacturing footwear according to Clause 106, wherein the second sole structure is positioned outside the first knitted layer.

[0241] Clause 108 A method of manufacturing footwear articles according to any one of Clauses 106 to 107, wherein the second sole structure includes a fluid-filled bladder.

[0242] Clause 109 The method of manufacturing footwear articles according to Clause 95 further includes: forming a second knitted section of the upper of the footwear article, wherein forming the second knitted section includes: knitting a single-sided plain knitted structure having a plurality of rib structures on the knitting machine.

[0243] Clause 110 The method of manufacturing footwear according to Clause 109, wherein the second knitted section is knitted integrally with the first knitted section.

[0244] Clause 111The method of manufacturing footwear according to Clause 109, wherein the plurality of rib structures comprises knitted rows extending longitudinally in a direction from the toe of the foot to the heel.

[0245] Clause 112. The method of manufacturing footwear according to Clause 111, wherein the second knitted section is at least The tongue area of ​​the shoe upper is partially formed.

[0246] Clause 113 A method for manufacturing footwear articles according to any one of clauses 109 to 112, wherein the thermoformed layer is not present in the second knitted section.

[0247] Clause 114 A method of manufacturing footwear articles according to any one of clauses 109 to 113, wherein the knitting sequence for knitting the plurality of rib structures comprises a repeating pattern, the repeating pattern being knitted with a set of yarns on a first needle bed of a knitting machine to a first number of knitting rows, the loops of the set of yarns held on the first needle bed being transferred to a second needle bed of the knitting machine, the set of yarns being knitted with a second number of knitting rows on the second needle bed, and the loops of the set of yarns being transferred back to the first needle bed to repeat the pattern.

[0248] Clause 115 The method of manufacturing footwear articles according to Clause 114, wherein the first number of knitted rows is different from the second number of knitted rows.

[0249] Clause 116 The method of manufacturing footwear articles according to Clause 115, wherein the first number of knitted rows is two knitted rows, and wherein the second number of knitted rows is four knitted rows.

[0250] Clause 117 Footwear articles according to any one of clauses 1 to 44 and 79 to 94, wherein the upper includes a foot portion having one or more seams.

[0251] Clause 118 The footwear article according to Clause 117, wherein the one or more seams include a longitudinal seam extending from the toe of the upper to the heel.

[0252] Clause 119 The footwear article according to Clause 117 or 118, wherein the one or more seams include a first heel end seam having a first portion and a second portion, the first portion extending at least partially diagonally upward to one side of the first sole structure, and the second portion extending at least partially diagonally upward to said side of the first sole structure and intersecting with the first portion of the first heel end seam.

[0253] Clause 120 The footwear article according to Clause 119 further includes a heel stabilizer, the heel stabilizer being attached to the upper and having a first portion covering the first portion of the first heel end seam and a second portion covering the second portion of the first heel end seam.

[0254] Clause 121 The footwear article according to Clause 120, wherein the upper includes a second heel end seam extending from the first heel end seam to the ankle opening, wherein the heel stabilizer covers a portion of the second heel end seam.

[0255] Clause 122 A footwear article comprising: an upper, the upper comprising: a first knitted layer comprising a knitted mesh structure comprising a first set of yarns; a thermoplastic polymer layer at least partially covering and / or wrapping the first set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and at least one internal component of the footwear article, the at least one internal component being at least partially visible through the thermoplastic polymer layer.

[0256] Clause 123 The footwear article according to Clause 122, wherein the knitted mesh structure of the first knitted layer is at least partially visible through the thermoplastic polymer layer.

[0257] Clause 124 Footwear article according to any one of clauses 122 to 123, wherein the at least one internal component is a midsole or sole structure, the sole structure being at least partially visible through both the thermoplastic polymer layer and the knitted mesh structure of the first knitted layer.

[0258] Clause 125 Footwear articles according to any one of clauses 122 to 124, wherein the thermoplastic polymer layer at least partially forms the outermost surface of the upper.

[0259] Clause 126 Footwear article according to any one of clauses 122 to 125, wherein the upper includes a foot portion, the foot portion including the first knitted layer and the thermoplastic polymer layer.

[0260] Clause 127 Footwear articles according to any one of clauses 122 to 126, wherein the first set of yarns is partially embedded within the thermoplastic polymer layer.

[0261] Clause 128Footwear articles according to any one of clauses 122 to 127, wherein the thermoplastic polymer layer does not extend completely to the inward-facing surface of the first knitted layer.

[0262] Clause 129 The footwear article according to any one of clauses 122 to 128, wherein the thermoplastic polymer layer comprises a first sublayer and a second sublayer, the first sublayer having a first thermoplastic polymer composition, the second sublayer having a second thermoplastic polymer composition, and the second sublayer being positioned between the first knitted layer and the first sublayer.

[0263] Clause 130 The footwear article according to Clause 129, wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition.

[0264] Clause 131 Footwear articles according to any one of clauses 129 to 130, wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.

[0265] Clause 132 Footwear article according to any one of clauses 122 to 131, wherein the upper includes a second knitted layer, the second knitted layer including a second set of yarns and positioned inside the first knitted layer.

[0266] Clause 133 The footwear article according to Clause 132, wherein the upper includes a foot portion, the foot portion including the first knitted layer, the second knitted layer and the thermoplastic polymer layer.

[0267] Clause 134 A footwear article comprising: an upper, the upper including: a composite layer comprising one or more knitted layers and a thermoplastic polymer material forming a surface and / or film structure, wherein the one or more knitted layers are positioned to form at least a portion of an inward-facing surface of the upper, wherein the thermoplastic polymer material forms at least a portion of an outward-facing surface of the upper and is translucent or transparent, and wherein at least one internal component of the footwear article is at least partially visible through the composite layer.

[0268] Clause 135 Footwear articles according to Clause 134, wherein the composite layer comprises a first surface and a second surface, the first surface comprising the thermoplastic polymer material, the second surface comprising at least a portion of the one or more knitted layers, wherein the first surface has a smoother texture than the second surface.

[0269] Clause 136Footwear articles according to Clause 135, wherein the sole structure is directly adjacent to the second surface.

[0270] Clause 137 Footwear articles according to Clause 136, wherein the one or more knitted layers include a first knitted layer and a second knitted layer, the second knitted layer being inside the first knitted layer.

[0271] Clause 138 A footwear product comprising an inner side, an outer side, a toe area, and a heel area, the footwear product comprising: an upper, the upper including a first knitted section, the first knitted section and a second knitted section being knitted integrally, the first knitted section including: a first knitted layer including a knitted mesh structure including a first set of yarns; a second knitted layer including a second set of yarns, the second knitted layer being positioned inside the first knitted layer; and a thermoplastic polymer layer, the thermoplastic polymer layer being translucent or transparent and at least partially covering and / or wrapping the first set of yarns and / or the second set of yarns, wherein the thermoplastic polymer layer is not present in the second knitted section.

[0272] Clause 139 The footwear article according to Clause 138, wherein the polymer layer forms the outermost surface of the upper in the first knitted section.

[0273] Clause 140 Footwear articles according to any one of clauses 138 to 139, wherein the second knitted section comprises a single-sided plain knitted structure.

[0274] Clause 141 Footwear articles according to any one of clauses 138 to 140, wherein the second knitted section includes at least the tongue area of ​​the upper, the tongue area including a plurality of rib structures.

[0275] Clause 142 A footwear article comprising: an upper, the upper comprising: a textile layer comprising a first set of yarns; and a thermoplastic polymer layer at least partially covering and / or wrapping the first set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and a sole structure incorporated into the upper and at least partially visible through the thermoplastic polymer layer.

[0276] Clause 143 Footwear articles as described in Clause 142, wherein the textile layer includes knitted textiles.

[0277] Clause 144Footwear articles as described in Clause 142, wherein the textile layer comprises woven textiles.

[0278] Clause 145 Footwear articles as described in Clause 142, wherein the textile layer includes nonwoven textiles.

[0279] Clause 146 Footwear articles according to Clause 142, wherein the textile layer comprises a mesh structure.

[0280] Clause 147 A footwear article comprising: an upper, the upper comprising: a composite layer comprising one or more textile layers and a thermoplastic polymer material forming a surface and / or film structure, wherein the thermoplastic polymer material forms at least a portion of an outward-facing surface of the upper and is translucent or transparent; and a sole structure incorporated into the upper and at least partially visible through the composite layer.

[0281] Clause 148 Footwear articles as described in Clause 147, wherein at least one textile layer comprises knitted textiles.

[0282] Clause 149 Footwear articles as described in Clause 147, wherein at least one textile layer comprises woven textiles.

[0283] Clause 150 Footwear articles as described in Clause 147, wherein at least one textile layer comprises a nonwoven textile.

[0284] Clause 151 Footwear articles according to Clause 147, wherein at least one textile layer comprises a mesh structure.

[0285] Clause 152 A footwear product comprising: an upper, the upper including: a first textile section integrally formed with a second textile section, the first textile section including: a first textile layer including a first set of yarns; a second textile layer including a second set of yarns, the second textile layer being positioned inside the first textile layer; and a thermoplastic polymer layer, the thermoplastic polymer layer at least partially covering and / or wrapping the first set of yarns and / or the second set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and wherein the thermoplastic polymer layer is not present in the second textile section.

[0286] Clause 153 Footwear articles according to Clause 152, wherein the first textile layer and / or the second textile layer comprises knitted textiles.

[0287] Clause 154 Footwear articles according to Clause 152, wherein the first textile layer and / or the second textile layer comprises woven textiles.

[0288] Clause 155 Footwear articles according to Clause 152, wherein the first textile layer and / or the second textile layer comprises nonwoven textiles.

[0289] Clause 156 Footwear articles according to Clause 152, wherein the first textile layer and / or the second textile layer comprises a mesh structure.

Claims

1. A footwear product, comprising: The upper includes: a first knitted layer comprising a knitted mesh structure comprising a first set of yarns; a thermoplastic polymer layer at least partially covering and / or wrapping the first set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and at least one internal component of the footwear article, the at least one internal component being at least partially visible through the thermoplastic polymer layer.

2. The footwear article of claim 1, wherein the knitted mesh structure is at least partially visible through the thermoplastic polymer layer.

3. The footwear article of claim 1, wherein the at least one internal component comprises a midsole and / or sole structure, the midsole and / or sole structure being at least partially visible through both the thermoplastic polymer layer and the knitted mesh structure.

4. The footwear article of claim 1, wherein the thermoplastic polymer layer at least partially forms the outermost surface of the upper.

5. The footwear article according to claim 1, wherein the upper includes a foot portion, the foot portion including the first knitted layer and the thermoplastic polymer layer.

6. The footwear article of claim 1, wherein the first set of yarns is partially embedded within the thermoplastic polymer layer.

7. The footwear article of claim 6, wherein the thermoplastic polymer layer does not extend completely to the inward-facing surface of the first knitted layer.

8. The footwear article of claim 1, wherein the thermoplastic polymer layer comprises a first sublayer and a second sublayer, the first sublayer having a first thermoplastic polymer composition, the second sublayer having a second thermoplastic polymer composition, and the second sublayer being positioned between the first knitted layer and the first sublayer.

9. The footwear article of claim 8, wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition.

10. The footwear article of claim 9, wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.

11. The footwear article of claim 1, wherein the upper comprises a second knitted layer, the second knitted layer comprising a second set of yarns and positioned inside the first knitted layer.

12. The footwear article of claim 11, wherein the upper includes a foot portion, the foot portion comprising the first knitted layer, the second knitted layer and the thermoplastic polymer layer.

13. A footwear product, comprising: An upper comprising: a composite layer comprising one or more knitted layers and a thermoplastic polymer material forming a surface layer and / or a film, wherein the one or more knitted layers are positioned to form at least a portion of an inward-facing surface of the upper, wherein the thermoplastic polymer material forms at least a portion of an outward-facing surface of the upper and is translucent or transparent, and wherein at least one internal component of the footwear article is at least partially visible through the composite layer.

14. The footwear article of claim 13, wherein the composite layer comprises a first surface and a second surface, the first surface comprising the thermoplastic polymer material, the second surface comprising at least a portion of the one or more knitted layers, wherein the first surface has a smoother texture than the second surface.

15. The footwear article of claim 14, wherein the sole structure is directly adjacent to the second surface.

16. The footwear article of claim 15, wherein the one or more knitted layers comprise a first knitted layer and a second knitted layer, the second knitted layer being inside the first knitted layer.

17. A footwear article comprising an inner side, an outer side, a toe area, and a heel end, said footwear article comprising: The shoe upper includes a first knitted section, which is knitted integrally with a second knitted section. The first knitted section includes: a first knitted layer comprising a knitted mesh structure comprising a first set of yarns; a second knitted layer comprising a second set of yarns, the second knitted layer being positioned inside the first knitted layer; and a thermoplastic polymer layer that is translucent or transparent and at least partially covers and / or wraps the first set of yarns and / or the second set of yarns, wherein the thermoplastic polymer layer is not present in the second knitted section.

18. The footwear article of claim 17, wherein the polymer layer forms the outermost surface of the upper in the first knitted section.

19. The footwear article of claim 17, wherein the second knitted section comprises a single-sided plain knit structure.

20. The footwear article of claim 19, wherein the second knitted section includes at least the tongue area of ​​the upper, the tongue area including a plurality of rib structures.

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