Upper and article of footwear

Abstract

This paper discloses footwear with integral knitted uppers that feature increased restraint around the wearer's foot, improved strength and durability, and the ability to combine tactile feedback with increased friction coefficient while eliminating weight due to conventional add-ons. The knitted components can be radially knitted such that rows of loops converge toward common areas such as the throat region of the upper. Additionally, fusible yarns can be knitted at least on the outward-facing surface of the restraint area of ​​the knitted components to create additional locking along the restraint line. Furthermore, tensile elements can be incorporated within the restraint area to provide strength and locking along the desired restraint line. Additionally, the fusible yarns can be clamping yarns that create areas with a higher coefficient of friction.

Description

Technical Field

[0001] This article concerns a type of shoe upper and footwear products. Prior Technology

[0002] Conventional footwear typically comprises two main components: the upper and the sole structure. The upper is attached to the sole structure and forms a cavity within the footwear to comfortably and securely accommodate the foot. Uppers can be formed from various materials, including knitted fabrics. When an athlete moves their foot within a knitted upper, a force can be applied to the athlete's foot, partially pushing it away from the sole structure. By keeping the foot restrained to the sole structure during movement, performance and comfort can be improved. Various components can be added to knitted uppers via post-knitting processes to maintain foot restraint. However, such post-knitting additions can increase the weight of the upper, increase production time, and reduce its recyclability. Similarly, to increase the durability and / or water resistance of the upper, additional components (e.g., synthetic leather fabrics, laminated layers) can be added and secured (e.g., glued, stitched) to the fabric, but these components can also increase the weight of the upper, increase production time, and reduce recyclability. These additional components may also reduce the shoe's ability to fit the wearer's foot and provide proprioceptive feedback, which can be particularly useful for athletes during certain sporting activities. Summary of the Invention

[0003] This paper discloses footwear with integral knitted uppers that feature increased restraint around the wearer's foot, improved strength and durability, and the ability to combine tactile feedback with increased friction coefficient while eliminating weight due to conventional add-ons. The knitted components can be radially knitted such that rows of loops converge toward common areas such as the throat region of the upper. Additionally, fusible yarns can be knitted at least on the outward-facing surface of the restraint area of ​​the knitted components to create additional locking along the restraint line. Furthermore, tensile elements can be incorporated within the restraint area to provide strength and locking along the desired restraint line. Additionally, the fusible yarns can be clamping yarns that create areas with a higher coefficient of friction. Simple Explanation of the Diagram

[0004] The footwear products and their manufacturing methods described in this article are discussed in detail with reference to the accompanying diagrams. [Figure 1A] depicts an exterior perspective view of footwear products according to various aspects of this article; [Fig. 1B] depicts an inside view of the footwear product according to various aspects of this document, as shown in Fig. 1A; [Figure 2] depicts the knitted component of the footwear product according to Figure 1A in various aspects of this document; [Figure 3] illustrates a schematic diagram of the radially knitted component according to various aspects of this article; Figures 4A through 4D depict different views of footwear products according to various aspects of this article; [Figure 5] depicts a polymer layer for footwear products according to various aspects of this document; [Figure 6] depicts an outer perspective view of a footwear product having the polymer layer of Figure 5 according to various aspects thereof; [Figure 7] is a block diagram depicting a method for manufacturing an upper for footwear products according to various aspects of this article; [Figure 8] depicts the knitted components on a jig used to manufacture the shoe upper according to the elements of Figure 7, based on various aspects of this text; [Figure 9] depicts a close-up view of a portion of a footwear product with a simulated embedded structure according to various aspects of this article; [Figure 10] depicts an example knitted component for footwear products according to various aspects of this article. Implementation

[0005] This detailed description relates to knitted components for footwear articles that provide restraint and support while maintaining a lighter upper weight, reducing production time, improving recyclability, and providing other benefits. In at least some instances, the upper can be formed with knitted components having radially extending rows of loops that converge toward a common area, such as the throat area of ​​the upper, which can be arranged along a desired restraint line of the upper. Additionally, fusible yarns, such as clamping yarns, can be knitted at least on the outward-facing surface of the radially extending restraint area of ​​the upper to create additional locking or restriction along the restraint line. Additionally, some examples herein also include radially extending tensile elements within the restraint area, such that the tensile elements can provide strength and locking along the desired restraint line, while also combining with the strength generated by the bonded fusible yarns. Compared to the subject matter of this disclosure, conventional footwear may require several post-knitting processes, such as sewing or bonding additional components to the knitted components, so that the footwear can provide a desired amount of restraint around the wearer's foot or have other properties, such as water resistance and durability. These components added after knitting may increase the weight of the shoe upper, increase production time, and reduce the recyclability of the shoe upper.

[0006] Accordingly, examples of this disclosure include an upper with a knitted component having radially extending rows of loops that can be aligned along a desired constraint line. Additionally, a fusible yarn, such as a clamping yarn, can be knitted at least on the outward-facing surface of the radially extending constraint area of ​​the upper. The fusible yarn can be used to create a fused region to produce additional locking along the constraint line, and to increase abrasion resistance, water resistance, and durability. Furthermore, in the case where the fusible yarn is the clamping yarn described herein, the constraint area can have a greater coefficient of friction than the portion of the knitted component without fusible clamping material, which can provide additional benefits to increase the wearer's ability to effectively control a ball, such as a global soccer ball, using the upper.

[0007] Other examples include knitted components with tensile elements, such as embedded tensile elements, which can be fused within a constrained area using fusible yarns such as clamping yarns. The tensile elements can impart tensile strength and locking to the upper, which can be enhanced by the fusible material knitted with the tensile elements. In some aspects, the tensile elements can be incorporated into a radially knitted upper such that the tensile elements extend radially along the upper along the desired constraint line.

[0008] Additional aspects of this disclosure include applying a polymer layer (e.g., a skin layer) to the outward-facing surface of the knitted component. In some aspects, the polymer layer includes pores exposing portions of the outward-facing surface, which include a fusible clamping material to retain tactile properties (e.g., a greater coefficient of friction) generated by the fusible clamping material.

[0009] Another aspect of this disclosure includes incorporating tensile elements through knitting, in a manner analogous to the strength and tensile properties provided by embedding tensile elements but through knitting. For example, the tensile element can be formed with a repeating knitted sequence across a row of loops, wherein the knitted sequence is at least one knitted stitch and a float stitch spanning multiple rows of loops (e.g., needle positions). For example, within a row of loops, the tensile element can have a repeating sequence of one knitted stitch and one float stitch extending for five rows of loops.

[0010] As described herein, certain aspects of this disclosure relate to footwear articles or aspects thereof that are at least partially formed of knitted fabric. In illustrative examples, aspects relate to uppers that are at least partially formed of knitted components. As used herein, the term "upper" refers to a footwear component that extends along the medial and lateral sides of the foot and around the heel region of the foot to form a cavity for receiving the wearer's foot. Illustrative, non-limiting examples of uppers may include uppers incorporated into basketball shoes, cycling shoes, cross-training shoes, global football (English football) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. Furthermore, in other aspects, uppers may also be incorporated into non-athletic footwear such as dress shoes, loafers, and sandals. Therefore, the concepts disclosed herein regarding footwear articles apply to a wide variety of footwear types. Although the illustration may depict footwear intended for use on only one foot of the wearer (e.g., the left foot), those skilled in the art will recognize that the corresponding footwear for the other foot (e.g., the right foot) will be a mirror image of the right footwear.

[0011] Positional terms used in describing footwear or its aspects, such as top, bottom, front, side, back, upper, lower, outer, inner, right, left, inside, outside, facing inward, and facing outward, are relative to footwear or uppers intended for wearing, where the wearer is standing upright with the wearer's foot in a foot-receiving cavity and the wearer's ankle or leg extending through an ankle opening. For example, the "upward-facing surface" and / or "upper surface" of an upper refers to the surface oriented in an "upper" anatomical direction (i.e., towards the wearer's head) when the footwear is worn by the wearer. Similarly, the directional terms "downward" and / or "lower" refer to an anatomically "below" (i.e., towards the ground and away from the wearer's head). "Front" or "forward" means "front" (e.g., towards the toes), and "back" means "back" (e.g., towards the heel). "Inner" means "towards the midline of the body," and "outer" means "away from the midline of the body." "Longitudinal axis" refers to the centerline of the workpiece extending between the heel and forefoot areas. Similarly, "longitudinal length" refers to the length of the workpiece along the longitudinal axis, and "longitudinal direction" refers to the direction along the longitudinal axis. However, it should be understood that, for interpretive purposes, the use of positional terms does not depend on the actual presence of a person.

[0012] The term "knitted part" refers to a piece of fabric formed from at least one yarn, which is manipulated (e.g., using a knitting machine) to form multiple interlocking loops defining a row of loops and a warp. As used herein, the term "row of loops" refers to a main horizontal row of knitted loops produced by adjacent needles during the same knitting cycle (in upright fabric when knitted on a knitting machine). Rows of loops can include one or more stitch types, such as knitted stitches, skip stitches, tuck stitches, transfer stitches, rib stitches, etc., terms known in the knitting industry. As used herein, the term "warp" is a main vertical row of knitted loops that interlock or become tangled, typically produced by the same needle in consecutive (but not necessarily all) rows of loops or knitting cycles.

[0013] As used herein, the term "whole knit" can refer to a knitted section in which yarns from one or more rows of knitted loops in a first region or area are intertwined with one or more rows of knitted loops in another region or area. The intertwining can occur through simple knitting stitches, tuck stitches, hold stitches, float stitches, or skip stitches, etc. In this way, the areas knitted together seamlessly transition.

[0014] In one aspect, a radial knitting process or a sequential knitting process can be performed such that the inner and outer sides of the knitted part can generally be formed sequentially, rather than simultaneously. For example, the entire (or substantially all, e.g., within 5% of the length) inner side can be formed, followed by the entire (or substantially all, e.g., within 5% of the length) outer side, rather than forming the inner and outer sides simultaneously. Alternatively, the outer side can be formed first, followed by the inner side. In some aspects, a portion of a first side (inner or outer) can be formed first, and then the second side (e.g., another side) can be formed before completing the knitted part by knitting the remaining portion of the first side. In some aspects, a reverse sequence can be used. Thus, multiple adjacent loop rows forming at least a portion of the first side (e.g., the inner or outer side) can be knitted before multiple adjacent loop rows forming at least a portion of the second side (e.g., the other of the inner or outer side).

[0015] As used herein, the term "radial extension" refers to the orientation of elongated structures (such as rows of knitted loops and / or segments of embedded yarn) radiating outward from the common portion of a knitted component. Specifically, rows of knitted loops and / or segments of embedded yarn can extend radially if they extend between the outer periphery of the knitted component and the common portion. Thus, rows of knitted loops and / or segments of embedded yarn can radiate inward from the outer periphery toward the common portion and, for example, not extend continuously across the body of the knitted component from the outer edge to the inner edge of the outer periphery. While the structure of a knitted component can extend radially from the common portion when it is laid flat after knitting, it is also conceivable that, after the knitted component has been folded into the shape of an upper or part of an upper, the radial extension of the structure can be determined based on its orientation toward the common portion.

[0016] As used herein, the term "common part" refers to an area of ​​a knitted component toward which multiple similar structures (e.g., multiple rows of loops or multiple segments of insert yarn) extend. Accordingly, rows of loops or segments of insert yarn may extend from the outer periphery to a single common part, rather than, for example, extending from the outer periphery to different parts along a common direction. The common part is spaced apart from the outer periphery and, in various respects, may be relatively centrally located within the knitted component. Thus, the common part may enclose and / or be directly adjacent to the longitudinal axis of the knitted component. In some examples disclosed herein, the common part may include the throat area or a portion thereof.

[0017] As used herein, the term "throat area" refers to the area on the top (upward-facing) side of the upper that extends generally between the ankle opening and the forefoot area. The throat area may include an opening formed between the outer and inner sides of the upper when shaped as a footwear article, and in some aspects, the throat area may include a tongue extending across the opening in the throat area. In some aspects, the throat area has no opening but comprises a continuous, integral knitted area of ​​knitted components extending between the inner and outer sides, for example, a continuous, integral knitted area that may be formed of elastic yarns, materials, and / or other components incorporating a degree of stretchability.

[0018] As used herein, the term "perimeter" refers to the area that forms the boundary of the object referred to. For example, the perimeter of a knitted component is the area extending along the boundary of the structure. "Outer perimeter" can refer to portions of the perimeter of a knitted component that, once formed into a footwear article, are fixed to the sole structure or form a seam between the two ends of the outer perimeter (so that they can extend at least partially under the wearer's foot when the footwear is worn). Conversely, "inner perimeter" can refer to portions of the perimeter of a knitted component that, once formed into a footwear article, define openings, such as openings in the throat area and / or ankle openings. Perimeter (outer perimeter or inner perimeter) can refer to the edge of a knitted component or the perimeter area adjacent to that edge.

[0019] The following diagrams describe different aspects, where identical elements are typically identified by identical element symbols. A better understanding of the relationships and functions of the various elements in each aspect can be achieved by referring to the following detailed descriptions. However, the aspects are not limited to those illustrated in the diagrams or explicitly described below. It should also be understood that the diagrams are not necessarily drawn to scale, and in some cases, details unnecessary for understanding the aspects disclosed herein (such as conventional assemblies) may be omitted. Additionally, various measurements are provided herein. Unless otherwise indicated, the terms “about” or “substantially” with respect to measurement mean within ±10% of the indicated value.

[0020] Figures 1A and 1B depict an outer perspective view and an inner perspective view, respectively, of a footwear article 100 and its components according to various aspects herein. The footwear article 100 includes a sole structure 102 and an upper 104. The upper 104 is coupled to and extends from the sole structure 102, forming a foot receiving cavity between the sole structure 102 and the upper 104. The area of ​​the sole structure 102 of the footwear article 100 where the upper 104 is joined may be referred to as the interlocking line 106. The upper 104 can be joined to the sole structure 102 in a fixed manner using any suitable technique, such as by using adhesives, by stitching, etc. It is conceivable that the upper 104 may extend partially or completely around the wearer's foot, may extend under the wearer's foot, and / or may be integral with the sole. An insole, which may or may not be used, may be referred to as a strobel (midsole fabric). The insole may include various materials, including fabrics, leather, foam, and / or other types of materials.

[0021] Footwear article 100 (and / or its components) may be divided into one or more zones (which may also be referred to as "regions" or "parts"). For example, in a front-to-back direction, footwear article 100 (and / or its components) may be divided into (and / or include) a forefoot zone 108, a midfoot zone 110, and a heel zone 112. The forefoot zone 108 of footwear article 100 may correspond to the front portion of the foot, including the toe and the joints connecting the metatarsals and phalanges of the foot. The midfoot zone 110 of footwear article 100 may correspond to the arch region of the foot. The heel zone 112 of footwear article 100 may correspond to the rear portion of the foot, including the calcaneus. In a medial-to-lateral direction, footwear article 100 (and / or its components) may be divided into a lateral zone 114 and a medial zone 116, both extending through the forefoot zone 108, the midfoot zone 110, and the heel zone 112. More specifically, when footwear 100 is worn, the outer side 114 corresponds to the outer region of the foot (i.e., the side facing away from the other foot), while the inner side 116 corresponds to the inner region of the foot (i.e., the side facing the other foot). The outer side 114 and the inner side 116 are separated by a longitudinal axis 318 (see Figure 3). These regions 108, 110, and 112, as well as the sides 114 and 116, are not intended to define precise areas of footwear 100, but rather to represent general areas of footwear 100 to illustrate the various descriptions provided herein.

[0022] When the footwear article 100 is worn, the sole structure 102 extends generally between the foot and the ground. The sole structure 102 may include multiple components, such as an outsole, midsole, and insole or insole. Various materials can be used to form the sole structure 102, such as rubber, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), thermoplastic elastomers (e.g., polyether block amide), etc. The sole structure 102 may also include various other elements, such as heel stabilizers and toe caps. The sole structure 102 may include various other features to reduce force, enhance stability, and / or provide adhesive friction, such as a tread as understood by those skilled in the art. For example, the sole structure 102 may include anti-slip studs as illustrated in Figures 1A and 1B, as seen in English football (global football) boots. However, it should be understood that this disclosure can be applied to footwear without anti-slip studs.

[0023] The upper 104 defines a cavity within the footwear article 100 to receive and secure the foot relative to the sole structure 102. An entrance to the cavity is provided through an ankle opening 125 located in at least the heel area 112. The upper 104 includes a throat area 126 disposed in a midfoot area 110 between the ankle opening 125 and the forefoot area 108. The throat area 126 can be configured to cover the top side of the wearer's foot and thus form part of the top side (or suprafoot area) between the outer side 114 and the inner side 116 of the upper 104. The footwear article 100 may also include a closure system in the throat area 126 to adjust the foot receiving cavity. Thus, the closure system can be used, for example, to secure the footwear article 100 to and / or release it from the wearer's foot. Example closure systems include laces 132 (as shown in Figures 1A and 1B), straps, bands, cables, cords, ratchet mechanisms, hook-and-loop connections, etc.

[0024] At least a portion of the upper 104 may include at least one knitted component 140, which is formed by a knitting process, such as weft knitting on a flat knitting machine. In some respects, the entire or substantially the entire upper 104 may be formed by the knitted component 140. Figure 2 depicts another view of the knitted component 140 before it is formed into the upper 104 shown in Figures 1A and 1B.

[0025] The knitted part 140 may combine various types of yarns that impart different properties to each individual region of the upper 104 . That is, one region of the knitted member 140 may be formed from a first type of yarn imparting a first set of properties, and another region of the knitted member 140 may be formed from a second type of yarn imparting a second set of properties. Utilizing the configuration, by selecting specific yarns for different areas of the knitted component 140 , the properties can vary throughout the upper 104 . The properties of the area that a particular type of yarn will confer on the knitting component 140 depend in part on the material that forms the various filaments and fibers within the yarn. For example, cotton offers a soft feel, natural beauty and biodegradability. Elastic fibers and stretched polyester each provide significant tensile and recovery, and stretched polyester also provides recyclability. Rayon provides high gloss and moisture absorption. In addition to its insulating properties and biodegradability, wool provides high moisture absorption. Nylon is durable and wear-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to the material, other aspects of the yarn selected for knitting component 140 may also affect the properties of the upper 104 . For example, the yarn forming the knitting component 140 may be a monofilament yarn or a multifilament yarn. Accordingly, unless otherwise specified, the term "yarn" does not require multiple filaments or fibers as used herein. The yarn may also include separate filaments formed from various different materials. In addition, the yarn may include filaments each formed from two or more different materials, such as a two-component yarn having filament, wherein the filament has a leather-core configuration or two halves formed from different materials. Different degrees of addition and curl as well as different deniers may also affect the properties of the upper 104 . Thus, the material forming the yarn and other aspects of the yarn can be selected to impart various properties to a separate region of the upper 104 . Additional properties of the yarns used in various aspects of the present disclosure are described in further detail below.

[0026] The knitted component 140 may be formed as a single integral single piece element during a knitting process (e.g., weft knitting or another suitable knitting process). Add-ons such as instep portions and / or heel elements (including, but not limited to, heel stabilizers or other elements or components) may be formed with the upper 104 in its entirety as a single piece unified structure, such as during a single knitting process performed on a knitting machine. Alternatively, one or more such add-ons may be formed detached from the upper 104 and subsequently attached, fixed or otherwise assembled and / or integrated as required. Forming an upper 104 with a knitted component may provide the upper 104 with favorable characteristics including, but not limited to, a specific degree of elasticity, breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and / or a combination of such properties. Furthermore, the formation of upper 104 from integral knitted components can form various features and structures of upper 104 without significant additional manufacturing steps or processes, thereby increasing production efficiency.

[0027] Referring to Figures 1A and 1B, and Figure 2, the knitted component 140 may include radially extending rows of loops. That is, the knitted component 140 may include rows of knitted loops extending from its outer periphery 124 (e.g., as shown in Figure 2) (which may form or be adjacent to the webbing 106 when the knitted component 140 is formed as an upper 104 and connected to the sole structure 102) to a common portion of the knitted component 140. The common portion may be an area of ​​the knitted component 140 such that all rows of loops extend toward this area when the knitted component 140 is formed into the shape of the upper 104 or otherwise constructed. In some aspects, the common portion is positioned along a longitudinal axis of the upper 104 that separates the outer side 114 and the inner side 116. In some aspects, the common portion is adjacent to the longitudinal axis. For example, the common portion may include a throat area 126 that extends along the longitudinal axis between the inner side 116 and the outer side 114. As further described with respect to Figure 3, radially extending rows of loops within a knitted component (such as knitted component 140) can produce rows of loops aligned with a number of different constraint lines, such that the knitted loop rows can provide constraint around the entire foot of the wearer.

[0028] Figure 3 illustrates a schematic diagram of a knitted component 340 having radially extending rows of loops. The knitted component 340 of Figure 3 is intended to generally depict radially extending rows of loops, and the details disclosed with respect to knitted component 340 can be applied to any of the other knitted components disclosed herein (including knitted components 140, 440, 640, 840, 940, and 1040) unless otherwise indicated. Knitted component 340 has radially extending rows of loops, such as loops 342a to 342e, which may be collectively referred to as "loops 342". Loops 342 are depicted in a simplified form as strands of yarn each having a knitted loop, and it should be understood that the strands of these loops do not necessarily represent the stitch order used. For example, loops 342 may include other types of stitches, such as float stitches, tuck stitches, transfer stitches, etc. Similarly, only a few loop rows are depicted throughout the knitted part 340 as representatives of the various directions in which the loop rows 342 can extend. However, it should be understood that there may be additional loop rows between the loop rows 342 depicted in FIG3, which extend radially from the common portion of the knitted part 340 in a similar manner as described below (as with many other aspects depicted herein).

[0029] The loop rows 342 extend from the outer perimeter 324 to the common portion or area. In the example shown in Figure 3, the common portion is the throat area 326, which may include a tongue component, an opening for the tongue component, and / or an inner perimeter 334 of a knitted component 340, the inner perimeter 334 of which defines a space through which the tongue component can extend. In some aspects, the throat area 326 is continuously knitted from the outer side 314 to the inner side 316, making it possible that no opening or space for the tongue component may exist.

[0030] Each of the forefoot region 308, midfoot region 310, and heel region 312 may include radially extending coil rows extending in different directions, such that at least some of the coil rows are not parallel to each other, for example, at an angle. For example, at least one forefoot coil row in the forefoot region 308 (such as coil row 342c) extends in a direction not parallel to the midfoot coil row in the midfoot region 310 (such as coil row 342b). In other words, at least some of the coil rows (including forefoot coil row 342c and midfoot coil row 342b) may be at an angle relative to each other, wherein the angle is greater than 0 degrees and less than 180 degrees.

[0031] Conversely, once the knitted component 340 is worn in footwear (such as footwear 100 shown in Figures 1A and 1B), the loops 342 can extend in different directions, which can represent different constraint lines or constraint angles. Constraint lines can be represented by loops of knitted components extending toward a common portion of the knitted component, while another loop of knitted components extends toward the common portion from the opposite direction to the first loop, but at the same or substantially the same angle. In a conventionally knitted component, where all or most of the loops extend horizontally across the upper, such constraint lines can be constrained at the same angle. Conversely, in a radially knitted component, different loops of knitted components can effectively extend 360 degrees around the length of the wearer's foot to form additional constraint lines. At least some of the constraint may be due solely to the radial direction of the knitted loops. In some respects, greater constraint is achieved by using yarns with higher tensile strength, higher toughness, and / or higher tensile strength for the loop rows along certain constraint lines, by using certain knitting stitches (such as floats) to reduce stretching in the loop rows along certain constraint lines, or a combination thereof. At least some of the knitted components described herein (such as knitted component 140) are described in at least some respects as including one or more constraint regions. These constraint regions may represent areas within the knitted component that include one or more features, such as a particular yarn type, fusion region, and / or certain knitting stitches, which increase the constraint beyond what is provided solely by the direction and alignment of the radial knitted loop rows.

[0032] In an example, the knitted component 340 includes rows of loops parallel to a first constraint diagonal (shown by a first axis 321) and rows of loops parallel to a second constraint diagonal (shown by a second axis 323), the second constraint diagonal intersecting the first constraint diagonal in a common portion of the knitted component 340. The first axis 321 may extend from a portion of the knitted component 340 configured to cover a wearer's first metatarsal to a heel area 312 on the outer side 314, and the second axis 323 may extend from a portion of the knitted component 340 configured to cover a wearer's fifth metatarsal to a heel area 312 on the inner side 316. These axes 321 and 323 may collectively form an x-shape and may represent constraint lines that can improve the stability of the wearer's foot within the upper for many types of movement, including rotation or change of direction, side-to-side movement, forward movement, and backward movement. Accordingly, the performance of footwear articles (such as footwear article 100) can be enhanced by restricting the wearer’s foot within the upper (such as upper 104) by a row of coils that provide support along these axes 321 and 323 in a way that limits stretching or otherwise provides support.

[0033] A knitted component 340 with radially extending loop rows 342 can be achieved by a radial knitting process, wherein the outer side 314 and the inner side 316 of the knitted component 340 are formed sequentially, rather than simultaneously. As shown in FIG3, the knitted component 340 is formed by a knitting machine 362 (e.g., having a front needle bed 361 and a rear needle bed 361) through the following steps: starting at the heel area 312 on the inner side 316 of the knitted component 340, knitting in a knitting direction 344 from the heel area 312 to the forefoot area 308, and then starting at the forefoot area 308 to knit the outer side 314 of the knitted component and ending at the heel area 312 on the outer side 314, as shown in the knitting direction 344. Thus, the knitted part 340 can be formed by the following steps: knitting the inner side 316 (or at least a plurality of loop rows on the inner side 316), knitting the forefoot area 308 after knitting the loop rows on the inner side 316, and knitting the outer side 314 (or at least a plurality of loop rows on the outer side 314) after knitting the forefoot area 308.

[0034] In other respects, similar but opposite knitting directions can be used to form the knitted part 340. For example, the knitted part 340 can be formed by the following steps: knitting the outer side 314 (or at least a plurality of loop rows on the outer side 314), knitting the forefoot area 308 after knitting the loop rows on the outer side 314, and knitting the inner side 316 (or at least a plurality of loop rows on the inner side 316) after knitting the forefoot area 308.

[0035] The knitting process for creating the knitted part 340 can be performed on a knitting machine 362, which may include an automatic knitting machine. The knitting machine 362 in Figure 3 is intended as a simplified representation. In an example aspect, the knitting machine 362 may be a flat knitting machine, such as a V-bed flat knitting machine with a front needle bed and a back needle bed. The knitted part 340 may be formed by needles from a single needle bed or needles from two needle beds.

[0036] The knitting process that forms the outer side 314 and the inner side 316 in this sequence involves at least some of the needles used to form the outer side 314 also being used to form the inner side 316. Thus, compared to conventional knitting processes that simultaneously form the outer side 314 and the inner side 316 of the heel and / or midfoot portion, the knitting bed of the knitting machine 362 may require fewer needles to produce the knitted part 340. Additionally, the same yarn feeder can be used for both the outer side 314 and the inner side 316, eliminating the need to repeat the yarn feeder for each side. This disclosed knitting process allows more needles and / or yarn feeders on the knitting machine 362 to be used for knitting separate items, such as another knitted part for another shoe upper, while the knitted part 340 is being knitted.

[0037] Furthermore, radially extending loop rows within the knitted component 340 can divide the knitted component 340 into wedge-shaped portions. For example, viewed in the forefoot region 308, the wedge-shaped portion between axes 321 and 318 can have radially extending loop rows, and the wedge-shaped portion between axes 318 and 323 can have additional radially extending loop rows. In some aspects, the loop rows forming the wedge-shaped portion between axes 321 and 318 are knitted before the wedge-shaped portion between axes 318 and 323. The remainder of the knitted component 340 can similarly be divided into various wedge-shaped portions. These wedge-shaped portions can be formed by knitting full-length, radially extending loop rows and partial-length, radially extending loop rows. Full-length loop rows, such as loop row 342a, can extend from one edge of the knitted component 340 (e.g., at the outer periphery 324) to the other edge of the knitted component 340 (e.g., at the inner periphery 334 in the throat region 326). Partial-length knitted loops, such as loop rows 342d and 342e, may not extend between the two edges of the knitted part 340. One or both ends of a partial-length knitted loop may end before the edge of the knitted part 340. However, partial-length knitted loops, such as loop rows 342d and 342e, can still be considered to extend radially because they extend in a direction from the outer perimeter 324 toward the common area (e.g., the throat area 326). Forming partial-length knitted loops distributed between full-length knitted loops can create shape and size in the knitted part 340 while also allowing the loops to extend radially.

[0038] In one aspect, the forefoot region includes a set of wedges configured to form a curved structure with a high curvature (e.g., a small radius of curvature). For example, each of the wedges in the forefoot region may have a smaller surface area than the set of wedges in the midfoot region. Alternatively, the total number of wedges in the forefoot region can be increased. Thus, by combining multiple wedges in the forefoot region, a curved structure of the knitted component of the upper is generated in the forefoot region.

[0039] Thus, the knitted component may include a stack of wedges, such that when knitted in a direction from the inside to the outside, a first set of wedges is configured to form the inner side of the knitted component, a second set of wedges is configured to form the toe area of ​​the knitted component, and a third set of wedges is configured to form the outer side of the knitted component. Additionally, in one aspect, a fourth set of wedges may be included to form the heel area of ​​the knitted component. In a second example (optionally including the first example), among other possibilities, the number of wedges in the second set of wedges is greater than the number of wedges in the first set of wedges or the number of wedges in the third set of wedges.

[0040] As described with respect to Figure 3, the entire side (e.g., the inner side 316) can be knitted before knitting the other side (e.g., the outer side 314). However, in other respects, the areas where the knitting process of the knitted part begins and ends can vary. For example, some example knitted parts can have other shapes and configurations before being formed into the upper, such as where a portion of the inner side of the heel area of ​​the knitted part is knitted integrally with a portion of the outer side of the heel area in a seamless manner. In this way, a seam can be formed on the inner or outer side of the heel area, rather than forming a central seam in the heel area. However, since the outer and inner sides of the knitted part are not knitted simultaneously, the sequential manner described with respect to Figure 3 can be maintained for these configurations. Instead, where the seam of the knitted part will be formed on the inner side, the inner heel portion can be knitted first, then the outer side (e.g., the heel area, midfoot area, and forefoot area on the outer side), followed by the remaining portion of the inner side (e.g., the forefoot area and midfoot area on the inner side). When the seam of the knitted part will be formed on the outside, the outer heel part can be knitted first, then the inner side (e.g., the heel area, midfoot area and forefoot area on the inner side), and then the rest of the outer side (e.g., the forefoot area and midfoot area on the outer side).

[0041] Returning to the example knitted component 140 shown in Figures 1A to 1B and Figure 2, the knitted component 140 includes radially extending rows of knitted loops as described with respect to the knitted component 340 of Figure 3. Additionally, the knitted component 140 includes radially extending tensile elements 150. Similar to the rows of knitted loops of the knitted component 140, the tensile elements 150 extend from the outer periphery 124 to common portions or areas, such as the throat area 126 in Figures 1A and 1B, which may include a tongue, an opening for the tongue, and / or the inner periphery 134 of the knitted component 140.

[0042] Similar to a row of knitted loops, tensile elements 150 can extend along constraint lines. Additionally, due to the material composition and / or integration of tensile elements 150, they can provide additional strength and structure to the underlying knitted structure of the knitted component 140. Thus, tensile elements 150 can be positioned in certain areas of the knitted component 140 corresponding to specific constraint lines desired or suitable for the footwear article 100. In the example knitted component 140, tensile elements 150 are arranged in groups that, when viewed from above, collectively have an X-shaped configuration. For example, Figure 2 shows the knitted component 140 prior to being formed into the upper 104 and more clearly depicts the X-shaped configuration of the groups, which may be referred to herein as constraint regions (or constraint vectors) 152a, 152b, 152c, and 152d. The first restraint region 152a includes a tensile element 150 and a row of knitted loops extending from a portion of the outer periphery 124 of the heel region 112, at least partially on the medial side 116, to a common portion of the midfoot region 110, or the throat region 126, on the medial side 116. The second restraint region 152b includes a tensile element 150 and a row of knitted loops extending from a portion of the outer periphery 124 of the forefoot region 108, at least partially on the medial side 116, to a common portion of the midfoot region 110, or the throat region 126, on the medial side 116. The third restraint region 152c includes a tensile element 150 and a row of knitted loops extending from a portion of the outer periphery 124 of the heel region 112, at least partially on the lateral side 114, to a common portion of the midfoot region 110, or the throat region 126, on the lateral side 114. The fourth constraint region 152d includes tensile elements 150 and rows of knitted loops extending from a portion of the outer periphery 124 in the forefoot region 108, at least partially on the outer side 114, to a common portion in the midfoot region 110 or throat region 126 on the outer side 114. The distance between adjacent tensile elements 150 within a single constraint region (e.g., constraint region 152a) (which can be measured by the number of rows of loops) is less than the distance between tensile elements 150 in different constraint regions.

[0043] The arrangement (including density) and orientation of the tensile elements 150 within the knitted component 140 can vary based on the intended activities of the footwear article 100. Typically, the constraint provided by the tensile elements 150 on one side (e.g., the outer side 114) can be enhanced by a constraint on the other side (e.g., the inner side 116) to act as an anchor. Thus, a first constraint region 152a of the tensile element 150 extending toward the heel area 112 on the inner side 116 can anchor a fourth constraint region 152d of the tensile element 150 extending toward the forefoot area 108 on the outer side 114, while a second constraint region 152b of the tensile element 150 extending toward the forefoot area 108 on the inner side 116 can anchor a third constraint region 152c extending toward the heel area 112 on the outer side 114.

[0044] Tensile elements 150 may each have an arrangement such as multifilament yarn, filament (e.g., monofilament yarn), thread, rope, webbing, cable, or chain. Tensile elements 150 may comprise materials with properties that increase the strength of the knitted portion 140 in the region where the tensile element 150 is located. For example, tensile elements 150 may comprise yarns with high toughness, such as a toughness greater than 5 g / denier. In some embodiments, the toughness of tensile elements 150 may be greater than that of other yarns in the knitted portion 140. In one example, tensile elements 150 are formed from high-toughness polyester yarns, such as Gran produced by Coats Group PLC. In another example, tensile elements 150 are formed from high-toughness nylon yarns. Furthermore, in some instances, the tensile element 150 may exhibit greater tensile strength than the rest of the knitted part 140, and may be formed from a variety of engineered filaments for high tensile strength applications, including glass, aromatic polyamides (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene, and liquid crystal polymers.

[0045] Tension elements 150 can be incorporated into the knitted structure of the knitted part 140 in various ways. For example, tension elements 150 can each be embedded within the structure of the knitted part 140. When the tension elements 150 are embedded, they can each extend in a loopless state along a row of loops formed by knitted loops of one or more other yarns. Embedding the tension element 150 may include loops at each end of the tension element 150 to anchor it to the knitted structure of the knitted part 140, but it can generally extend through the row of loops in other ways without tangling with another yarn strand. For example, within a row of loops, the tension element 150 may alternate between being located behind a loop of another yarn and being located in front of a loop of another yarn, such that the tension element 150 extends through an intertwined structure formed by another yarn of the knitted part. In some aspects, the knitted part 140 includes a double-knitted fabric construction formed by at least both ends of yarns of the knitted part that switch between needles on two needle beds. In this configuration, the tensile element 150 can be embedded such that it extends substantially between the surfaces formed by the loops formed on the two needle beds. In other instances, the knitted component 140 includes a first layer and a second layer that extend together and overlap each other to form a channel extending in the transverse direction of the loops, and the tensile element 150 can each extend through the channel.

[0046] In other instances, the tensile element 150 can be knitted into the knitted structure of the knitted part 140 using a knitting sequence, analogous to the embedded structure described above. For example, as the tensile element 150 extends from the outer periphery 124 to the inner periphery 134 of the knitted part 140, the loop rows of the tensile element 150 can be knitted using a repeating sequence of float stitches and knitted stitches. Further details of this knitting technique, referred to herein as a pseudo-embedding, are discussed with reference to Figure 9.

[0047] As shown in Figures 1A to 1B and Figure 2, at least some of the tensile elements 150 may form loops around the tie holes formed in the knitted part 140, which can reinforce the knitted part 140 to withstand additional tension applied to the knitted part 140 in those areas when the tie 132 is tensioned. In other embodiments, at least some of the tensile elements 150 may extend out of the knitted part 140 and form loops for receiving the tie 132.

[0048] In some instances, the knitted component 140 may be at least partially formed of a fusible yarn. For example, the knitted component 140 may be formed of a first yarn knitted with at least a second yarn, wherein the first yarn has a first melting temperature, and the second yarn has a second temperature greater than the first melting temperature of the first yarn, wherein the second temperature is the lower of the decomposition temperature or melting temperature of the second yarn. Accordingly, when heat is applied, the first yarn, which may be referred to as a fusible yarn, may at least partially melt or soften, while the second yarn may retain its solid structure. Once fully melted, partially melted, or softened, the fusible yarn may fuse with other portions of the fusible yarn and / or the second yarn. Activation of the fusible yarn within the knitted component can result in certain properties of the upper 104. For example, the fused region formed by the fusible yarn may provide increased abrasion resistance and / or water resistance in selected areas, and may limit the stretching of the knitted component 140, thereby imparting tensile strength and restraint in selected areas. The example fusible yarn in the knitted component 140 may have one of the following structures: a multifilament yarn having some filaments formed of a low-melting-point material and some filaments formed of a high-melting-point material; a multifilament yarn made entirely of filaments having a low-melting-point material; a bicomponent yarn having a low-melting-point material and a high-melting-point material (arranged in a core / sheath configuration or in a side-by-side configuration); or a monofilament yarn made entirely of a low-melting-point material.

[0049] As further described below with reference to specific examples, the fusible yarn in the knitted component 140 can be activated by heating to a temperature higher than the melting temperature of the fusible material (such as a thermoplastic polymer) in the fusible yarn, and the molten fusible material can be bonded to one or more other knitted strands or structures within the knitted component 140. For example, the fusible yarn can be a coated yarn (e.g., having a core-skin configuration), wherein the coating is a first material (which may include a thermoplastic polymer) and has a melting temperature lower than that of a second material forming the core (which may exclude the thermoplastic polymer from the first material). This example fusible yarn can be activated by softening, partially melting, or completely melting the coating, while at least the core retains its substantially solid structure. In an example where the fusible yarn is a coated yarn, the coating can be softened such that portions of the coating can be fused with adjacent portions of the coated yarn (and any other yarn or tensile element) within intertwined rows of loops of the coated yarn. In another example where the fusible yarn is a coated yarn, the coating can be partially melted, allowing the molten material of the coating to flow back and solidify between adjacent structures within the knitted component. Thus, the partially melted coating can fuse adjacent portions of the coated yarn together, as well as to other yarns or tensile elements, the coated yarn comprising a core yarn and the remaining (unmelted) portion of the coating. In another example where the fusible yarn is a coated yarn, the coating can be completely melted, flowed back, and solidified, such that the re-cured coating fuses portions of the remaining core together with other yarns or tensile elements. In yet another example, the fusible yarn is a monofilament yarn made entirely of a thermoplastic polymer material that can be heated to partially melt and re-solidify to fuse the unmelted portion of the monofilament yarn to other unmelted portions of the monofilament yarn and / or to other yarns or tensile elements knitted with the fusible yarn, or heated to completely melt and re-solidify to fuse other yarns knitted with the fusible yarn together.

[0050] The knitted component 140 may have an outward-facing surface 142 and an inward-facing surface. Although not visible in the views of the knitted component 140 in Figures 1A, 1B, and 2, the inward-facing surface of the knitted component 140 should be understood as generally facing away from the outward-facing surface 142 and toward the foot receiving opening when the knitted component 140 is formed as the upper 104. In some aspects, the outward-facing surface 142 is formed by a first layer of the knitted component 140, and the inward-facing surface is formed by a second layer knitted integrally with the first layer. For example, the knitted component may have a double-knitted structure (e.g., a double-knitted jacquard structure) such that the outward-facing surface 142 is formed by yarns on a first needle bed (e.g., a front needle bed), and the inward-facing surface is formed by yarns on a second needle bed (e.g., a rear needle bed). Furthermore, as described below, the knitting component 140 may have a jacquard double-knitting structure, such that yarns knitted on the first needle bed to form an outward-facing surface in some areas of the knitting component 140 may be selectively moved to the second needle bed to form an inward-facing surface in other areas of the knitting component 140, and yarns knitted on the second needle bed to form an inward-facing surface in some areas may be selectively moved to the first needle bed to form an outward-facing surface 142 in other areas.

[0051] At least the outer-facing surface 142 of the knitted component 140 is formed with a fusible yarn in the region having tensile elements 150 (e.g., restraint regions 152a to 152d). The fusible yarn can be knitted on the outer-facing surface 142 to form a row of loops including the tensile elements 150. Thus, once the fusible yarn is activated (e.g., by heating), the fusible yarn can at least partially melt to fuse to the tensile elements 150. Additionally, aspects of this disclosure may include: the fusible yarn being knitted on the outer-facing surface 142 to form a row of loops positioned between and separating adjacent tensile elements 150 within the restraint regions (e.g., 152a to 152d) of the tensile elements 150. When fully or partially melted, the fusible material of the fusible yarn can flow to fill the spaces between the remaining knitted structures, as further described below. For example, the fusible yarn may be a yarn having a sheath surrounding a core, wherein the sheath is formed of a material with a lower melting temperature than the material forming the core. In this respect, the sheath of the fusible yarn can be at least partially melted and fill the spaces between the knitted loops formed by the remaining core of the fusible yarn. Additionally or alternatively, the fusible material of the fusible yarn can be at least partially melted to fill the spaces between other yarns or structures, such as the space between the tensile element 150 and / or the second yarn forming the knitted part 140. Using fusible yarn to create a fusion zone along the loop rows within the restraint areas 152a to 152d can help increase the restraint or locking provided by the tensile element 150, and provide other benefits such as increased abrasion resistance and water resistance, while minimizing or even eliminating the need for additional layers and post-knitting processes. Minimizing or eliminating the need for additional layers helps the upper 104 maintain a lighter weight. For example, aspects of the upper 104 can have a weight of about 50 grams or less in some aspects, about 40 grams or less in some aspects, or about 30 grams or less in some aspects.

[0052] In other regions of the knitted part 140, such as the region extending between the constraint regions 152a and 152d of the tensile element 150, the outward-facing surface 142 of the knitted part 140 does not include fusible yarn. Instead, the outward-facing surface 142 in these regions may be formed of a second yarn having a higher melting or decomposition temperature than the fusible yarn. Thus, when heat is applied, a fusion region on the outward-facing surface 142 can be created only in selected portions of the knitted part 140.

[0053] Fusible yarns may include thermoplastic polymer materials. Example materials for fusible yarns may include polyurethanes, such as thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), low-melting-point polyamide (nylon) yarns (such as nylon-6, nylon-11, or nylon-12), low-melting-point polyesters, or combinations thereof. In some respects, the melting temperature of the fusible yarn is less than about 115 degrees Celsius, in some respects less than about 100 degrees Celsius, or in some respects less than about 100 degrees Celsius. Conversely, the melting or decomposition temperature of the second yarn knitted with the fusible yarn and / or the material forming the tensile element 150 is greater than about 150 degrees Celsius, in some respects greater than about 185 degrees Celsius, or in some respects greater than about 100 degrees Celsius.

[0054] In an example, the fusible yarn also includes a "clamping" property that, when knitted into the knitted part 140, creates areas with a higher coefficient of friction compared to areas with no or lower concentrations of clamping yarn. Creating areas with a higher coefficient of friction on the outward-facing surface 142 within the knitted part 140 can help the wearer of footwear 100 control a ball, such as a soccer ball, because the upper 104 with the knitted part 140 can better clamp the ball. Differences in the coefficient of friction in various portions of the knitted part 140 mentioned herein, or other knitted parts of this disclosure, can be determined using the fabric-ball friction coefficient test disclosed herein.

[0055] In examples of this disclosure, a fusible yarn with clamping properties (referred to herein as a clamping yarn) may have a coating of a first polymer composition surrounding a core having a second material composition different from the first polymer composition. The first polymer composition may include a thermoplastic elastomer not present in the second composition. The thermoplastic elastomer may include one or more of the following: thermoplastic copolyester elastomers, thermoplastic polyether block amide elastomers, thermoplastic polyurethane elastomers, polyolefin-based copolymer elastomers, thermoplastic styrene copolymer elastomers, thermoplastic ionomer elastomers, or any combination thereof. In one aspect, the first polymer composition includes a thermoplastic elastomer styrene copolymer. In another aspect, the thermoplastic elastomer styrene copolymer may be a styrene-butadiene-styrene (SBS) block copolymer, styrene-ethylene / butene-styrene (SEBS) resin, styrene-acrylonitrile (SAN) resin, or any combination thereof. In one aspect, the polymer composition includes a thermoplastic elastomer polyester polyurethane, a thermoplastic polyether polyurethane, or any combination thereof. In some aspects, the thermoplastic elastomer polyester polyurethane may be an aromatic polyester, an aliphatic composition, or a combination thereof. It should be understood that other thermoplastic polymer materials not specifically described below may also be conceivable for use in the clamping yarns described herein. In one aspect, the coatings for clamping yarns described herein are produced from fibers or filaments consisting of only a single thermoplastic elastomer. In other aspects, the coatings consist of blends of two or more different thermoplastic elastomers.

[0056] In one aspect, the first polymer composition comprising a thermoplastic elastomer has a melting temperature greater than about 110 degrees Celsius and less than about 170 degrees Celsius. In another aspect, the first polymer composition comprises a thermoplastic elastomer having a melting temperature of about 110 degrees Celsius to about 170 degrees Celsius, about 115 degrees Celsius to about 160 degrees Celsius, about 120 degrees Celsius to about 150 degrees Celsius, about 125 degrees Celsius to about 140 degrees Celsius, about 110 degrees Celsius to about 150 degrees Celsius, or about 110 degrees Celsius to about 125 degrees Celsius.

[0057] Additionally, the second material composition of the core yarn can be a thermoplastic composition or a thermosetting composition. The core yarn can be any material that retains its strength at the temperature at which the first polymer material is extruded during the coating process. The core yarn can be a natural fiber or regenerated fiber or filament, or a synthetic fiber or filament, and can have a structure of staple fiber yarn, multifilament yarn, or monofilament yarn. In one aspect, the core yarn can be composed of cotton, silk, wool, rayon, nylon, elastic fiber, polyester, polyamide, polyurethane, and / or polyolefin. In one aspect, the core yarn is composed of polyethylene terephthalate (PET). The second material composition of the core yarn can have a second melting or deformation temperature that is at least 20 degrees Celsius, at least 50 degrees Celsius, at least 75 degrees Celsius, or at least 100 degrees Celsius greater than the first melting temperature of the first polymer composition. Further details of various examples of clamped yarns are disclosed below.

[0058] In some embodiments, the clamping yarn is heated to partially or completely melt a thermoplastic elastomer to form a coating. Once the coating is partially or completely melted, it can flow into the space between remaining entangled structures (e.g., entangled portions of the remaining coating and core where the coating is only partially melted; entangled portions of the remaining core where the coating is completely melted; and / or entangled portions of another strand, such as tensile element 150). As the knitted part 140 cools, the return coating from the clamping yarn effectively fuses these various structures together, as described more generally above with respect to fusible yarns. The remaining structures may be referred to herein as a fusion network of entangled yarns, since entangled yarns may remain within the fusion region. The return coating, and in some aspects, the remaining (unmelted) coating of the clamping yarn, can help provide a greater coefficient of friction for the fusion region, while also providing increased constraint by fusing the coils together within a coil row and / or adjacent coil rows. In some aspects, the clamping yarn can be heated by steam. In some respects, the clamped yarns can be heated via a thermoforming process, in which heat and pressure are applied to the knitted part 140 in a mold. In these respects, the remaining structure, once cooled, can be referred to herein as a thermoformed network of intertwined yarns.

[0059] In the examples described herein, a knitted part is formed such that it includes clamping yarns in one or more zones. During such a process, one or more of the temperature, pressure, humidity, and duration of the post-treatment applied to the knitted part including the clamping yarns are adjusted based on one or more of a desired coefficient of friction, a desired level of constraint, and a desired level of air permeability. Post-treatment may include treating the knitted part after knitting. In one example, post-treatment of the clamping yarns may include at least partially melting the clamping material of the clamping yarns. Furthermore, post-treatment of the clamping yarns may include at least partially refluxing the clamping material. Additionally, post-treatment of the clamping yarns may include curing the clamping material after melting and refluxing. In one example, the knitted part may be subjected to the same post-treatment conditions entirely. In another example, one or more zones of the knitted part may be selectively post-treated. For example, one or more constrained areas (where clamping yarns are present on the outward-facing surface of the knitted part) can be selectively treated by applying heat and / or pressure to these clamping areas, while heat and / or pressure may not be applied to the remaining areas of the knitted part (where clamping yarns are not present on the outward surface), or different amounts of heat and / or pressure may be applied.

[0060] As a non-limiting example, to process the clamped yarns, such as melting, reflowing, and then at least partially re-solidifying them, the knitted part is placed in a steam chamber. Steam and / or heat are then applied at least at the melting temperature of the clamping material, but below the melting temperature of the remaining yarn forming the knitted part. This allows the clamping material of the yarn to melt and reflow in the desired amount. In one case, the process can be performed at 150 to 153 degrees Celsius, at 1 to 3 bar, for 10 to 15 seconds. Once the heating and steaming process reaches the desired completion level, e.g., the fusible material has at least partially melted, reflowed, and begun to solidify, the knitted part can then be transferred to a cooling chamber and cooled at atmospheric pressure until the knitted part reaches 20 to 25 degrees Celsius.

[0061] In various aspects, fusible yarns can be treated, such as heated, melted, and / or reflowed to varying degrees. In some aspects, certain portions of a knitted part comprising a fusible material (e.g., yarn) may not be treated at all, such as by heating, melting, and / or reflowing. In other aspects, some areas of a knitted part comprising a fusible material (e.g., yarn) may be treated, such as by heating, melting, and / or reflowing, while other areas may remain untreated. In still other aspects, some areas of a knitted part comprising a fusible material (e.g., yarn) may be treated more extensively than other areas comprising a fusible material, for example, by exposure to higher heat, exposure to steam for a longer duration, exposure to heat and / or steam for a longer duration, or otherwise treated to cause different material changes, such as the amount of melting, reflowing, and re-curing of the fusible material, and / or the degree of formation of a thermoformed network of intertwined yarns.

[0062] In some embodiments, clamping yarns are not included on at least the outward-facing surface in the rear portion of the knitted component 140. Accordingly, clamping yarns may not be included on the outward-facing surface 142 within the first constraint region 152a or the third constraint region 152c. Because the front of the footwear 100 is more likely to come into contact with the ball, it may be more advantageous to include clamping yarns on the outward-facing surface 142 in the front portion of the knitted component 140, such as in the second constraint region 152b and the fourth constraint region 152d. Additionally, in some aspects, clamping yarns may be included in the outward-facing surface 142 in the central forefoot region 109 between the second constraint region 152b and the fourth constraint region 152d of the knitted component 140. In some aspects, portions of the outward-facing surface 142 having clamping yarns (such as the second constraint region 152b and the fourth constraint region 152d) include different fusible yarns on the inward-facing surface. In one example, this fusible yarn, in the form of a monofilament, may have a different polymer composition than the clamping yarn and, in at least some aspects, form a knitted area with a lower coefficient of friction than the area formed with the clamping yarn. Furthermore, in some aspects, monofilament yarns with different material compositions are knitted with the fusible yarn on the inward-facing surface. In some aspects, the fusible yarn may be completely or at least partially melted after knitting to form a fused region on the inward-facing surface, which can provide additional abrasion resistance, water resistance, and structural support for the wearer's foot.

[0063] In some aspects, clamping yarns are not included at all in the rear portion of the knitted part 140 (on the outward-facing surface 142 or the opposite inward-facing surface). Instead, in some aspects, high-tenacity yarns having a higher melting or decomposition temperature than clamping yarns can form the outward-facing surface 142 and the inward-facing surface of the knitted part 140 in these rear portions, and the restraint regions 152a and 152c may also include tensile elements 150 knitted with or embedded with high-tenacity yarns.

[0064] In an alternative configuration, the knitted component 140 includes clamping yarns on an outward-facing surface 142 in each of the constraint regions 152a, 152b, 152c, and 152d of the tensile element 150, but the outward-facing surface 142 of the knitted component 140 extending between the constraint regions 152a and 152d excludes clamping yarns. For example, clamping yarns can be excluded from the outward-facing surface 142 in the central forefoot region 109 between the second constraint region 152b and the fourth constraint region 152d, in the midfoot region 110 on the inner side 116 between the first constraint region 152a and the second constraint region 152b, in the midfoot region 110 on the outer side 114 between the third constraint region 152c and the fourth constraint region 152d, in the heel region 112 on the inner side 116 adjacent to the first constraint region 152a, and in the heel region 112 on the outer side 114 adjacent to the third constraint region 152c.

[0065] As previously described, one or more additional yarns may be knitted (entangled) with the clamping yarn, such that the clamping yarn and the one or more additional yarns form the same loop rows within the knitted component 140. In various examples, the clamping yarn may be knitted to form at least a portion of the outward-facing surface 142, while a high-tenacity yarn having a higher melting or decomposition temperature than the clamping yarn may be knitted to form at least a portion of the inward-facing surface. In the loop rows including the tensile element 150, the tensile element 150 may also be knitted to form at least a portion of the outward-facing surface 142 with the clamping yarn, or embedded between the loop rows forming the outward-facing surface 142 and the inward-facing surface. In some aspects, the tensile element 150 is a high-tenacity yarn, which may have a different material composition than the second yarn, which may also be a high-tenacity yarn; however, it is conceivable that the high-tenacity yarn knitted on the inward-facing surface may have the same material composition as the tensile element 150.

[0066] In the portions of the midfoot region 110 on the inner side 116 between the first constraint region 152a and the second constraint region 152b, and on the outer side 114 between the third constraint region 152c and the fourth constraint region 152d, the knitting component 140 may not include clamping yarn. Instead, these portions may be formed of monofilaments knitted on both the first and second needle beds, wherein the monofilaments have a melting or decomposition temperature greater than that of the clamping yarn. The monofilaments knitted on the first and second needle beds may have the same or different material compositions. Additionally, in some aspects, high-tenacity yarns are knitted in these portions of the midfoot region 110 between the first and second needle beds. The high-tenacity yarns can be knitted between the two needle beds by intermittently switching between knitting with a first monofilament on the first needle bed and knitting with a second monofilament on the second needle bed.

[0067] Figures 4A to 4D depict various views of a footwear article 400 and its features according to another embodiment of the present disclosure. The footwear article 400 includes a sole structure 402 coupled to an upper 404. The sole structure 402 may have the same features described with respect to the sole structure 102 of footwear article 100 and may be coupled to the upper 404 in a similar manner. Additionally, the upper 404 may have the same or similar features as the upper 104, unless otherwise indicated below.

[0068] For example, the upper 404 includes a knitted component 440. In various instances, the knitted component 440 forms the entire or substantially the entire upper 404 and can incorporate various types of yarn to impart different properties to individual areas of the upper 404. Any type of yarn described as being incorporated into the knitted component 140 can be incorporated into the knitted component 440, and specific examples will be discussed further below. The knitted component 440 can be formed by any of the processes described for the knitted component 140 and can similarly have a uniform knitted structure, wherein various structures are knitted integrally to provide different properties to the upper 404. Additionally, in some aspects, the knitted component 440 is radially knitted in a manner similar to that described with respect to knitted components 140 and 340, such that the knitted component 440 includes a radial row of knitted loops extending from the outer periphery of the knitted component 440 (which may extend at the bite line 406 or partially under the foot) to common parts (such as the throat area 426, which may be adjacent to the inner periphery 434 of the knitted component 440).

[0069] Furthermore, similar to the example of knitted component 140, knitted component 440 may include radially extending tensile elements 450 extending from the outer periphery 424 to a common portion as described above. Due to the material composition of the tensile elements 450 and / or the manner in which they are integrated into the knitted component 440, these tensile elements 450 can provide additional strength and structure to the underlying knitted structure of the knitted component 440. Such materials and / or methods of integrating the tensile elements 450 can be any of the examples described with respect to tensile element 150 of knitted component 140. Additionally, the tensile elements 450 may be arranged in groups (referred to herein as constrained regions) such that the distance between adjacent tensile elements 450 within a single constrained region is less than the distance between tensile elements 450 in different constrained regions. Examples of knitted component 440 include at least two constrained regions, each including a tensile element. In one example, the knitted component 440 includes four constraint regions: a first constraint region 452a having a tensile element 150 extending from at least partially a portion of the outer periphery 424 in the heel area 412 on the inner side 416 to the common portion or throat area 426 in the midfoot area 410 on the inner side 416; a second constraint region 452b having a tensile element 450 extending from at least partially a portion of the outer periphery 424 in the forefoot area 408 on the inner side 416 to the common portion or throat area 426 in the midfoot area 410 on the inner side 416. The footwear includes a common portion or throat area 426; a third constraint region 452c having a tensile element 450 extending from a portion of the outer periphery 424 of the heel area 412 on the outer side 414 to the common portion or throat area 426 of the midfoot area 410 on the outer side 414; and a fourth constraint region 452d having a tensile element 450 extending from a portion of the outer periphery 424 of the forefoot area 408 on the outer side 414 to the common portion or throat area 426 of the midfoot area 410 on the outer side 414. The first, second, third, and fourth constraint regions 452a to 452d may be generally arranged in an X-shape on the upper 404, as depicted in the top view of the footwear article 400 in FIG4C.

[0070] Additionally, in some aspects, additional tensile elements 450 may be located in the forefoot region 408. These tensile elements 450 may extend from the outer periphery 424 in the forefoot region 408 to the common portion or throat region 426 in the forefoot region 408. The examples depicted in Figures 4A to 4C include three such additional tensile elements 450 extending in the forefoot region 408 between the second restraint region 452b and the fourth restraint region 452d. These tensile elements 450 in the forefoot region 408 may provide additional restraint for the forefoot of the wearer in the toe area, which may be particularly advantageous during activities requiring agility and / or sudden or rapid stops in forward movement. Furthermore, for the knitted component 440 shown in Figures 4A to 4D and any other aspect described herein, additional tensile elements may be included in the forefoot region 408, for example, such tensile elements having a greater density (e.g., smaller spacing), and these additional tensile elements extend radially around the common portion (e.g., throat region 426). Similarly, in addition, multiple tensile elements may be included on the inner side 416 between constraint regions 452a and 452b and / or on the outer side 414 between constraint regions 452c and 452d, wherein these additional tensile elements extend, for example, in a linear or radial manner around the common portion between the outer perimeter 424 and the inner perimeter 434 to provide additional reinforcement and / or constraint in these directions.

[0071] In another example, the knitted component 440 is partially formed with fusible yarn in the same or similar manner as described with respect to the knitted component 140. For example, the fusible yarn may be bonded to the outward-facing surface 442 in selected areas of the knitted component 440, and may not be present on the outward-facing surface 442 in other areas of the knitted component 440. The melting temperature of the fusible yarn may be lower than the temperature of the second yarn, wherein the temperature of the second yarn is the lower of the decomposition temperature or the melting temperature. The second yarn may be knitted with the fusible yarn on the outward-facing surface, or knitted to form the inward-facing surface. The fusible yarn in the knitted component 440 may be thermally activated such that the outward-facing surface 442 of the knitted component 440 includes fused regions (corresponding to areas formed with fusible yarn on the outward-facing surface 442) and unfused regions (corresponding to areas on the outward-facing surface 442 where the fusible yarn is excluded).

[0072] The example materials and structures of the fusible yarn described for knitted part 140 can be similarly used for the fusible yarn in knitted part 440. Additionally, examples of the fusible yarn in knitted part 440 can be clamping yarns as described with respect to knitted part 140, such that the portion of knitted part 440 formed with clamping yarns can have a greater coefficient of friction than the portion of knitted part 440 without clamping yarns or with a lower concentration of clamping yarns.

[0073] Fusible yarns, or clamping yarns in some respects, can be knitted on the outward-facing surfaces 442 within the constrained regions 452a to 452d. The fusible yarns can be knitted to form loops including tensile elements 450 within these constrained regions 452a to 452d. Accordingly, once the fusible yarns are activated (e.g., by heating), the fusible yarns can be fused to the tensile elements 450. For example, the fusible yarns can be clamping yarns with a core having the thermoplastic elastomer coating described herein, and once heated, the core of the clamping yarns is fused to the tensile elements 450 via the melting of the thermoplastic elastomer coating. Additionally, aspects of this disclosure may include: fusible yarns being knitted on the outward-facing surfaces 442 to form loops positioned between adjacent tensile elements 450 within the constrained regions (e.g., 452a to 452d or any of them). When fully or partially melted, the fusible material of the fusible yarns can flow to fill the spaces between the remaining knitted structures. Using fusible yarns to create fusion zones along the coil rows within restraint areas 452a to 452d can help increase the restraint or locking provided by tensile element 450, and provide other benefits such as increased abrasion resistance and water resistance, while minimizing or even eliminating the need for additional layers and post-knitting processes. Minimizing or eliminating the need for additional layers helps the upper 104 maintain a lighter weight. For example, aspects of the upper 104 may have a weight of about 50 grams or less in some aspects, about 40 grams or less in some aspects, and about 30 grams or less in some aspects. Additionally, in aspects where the fusible yarns are the clamping yarns disclosed herein, the areas of the upper 404 with clamping yarns can allow the wearer to better feel and hold a ball, such as a football, to provide the wearer with better ball control.

[0074] Examples of knitted components 440 may include fusible yarns in other portions outside the constraint regions 452a to 452d of the knitted component 440, and in some aspects, include clamping yarns. For example, the knitted component 440 may include clamping yarns in the outward-facing surface 442 in the region adjacent to the bite line 406 between the upper 404 and the sole structure 402 within the midfoot region 410 (e.g., between the first constraint region 452a and the second constraint region 452b on the inner side 416 and between the third constraint region 452c and the fourth constraint region 452d on the outer side 414). Similarly, the knitted component 440 may include clamping yarns to knit in the region adjacent to the bite line 406 in the forefoot region 408 between the second constraint region 452b and the third constraint region 452c to form the outward-facing surface 442. These additional regions of fusible or clamping yarns on the outward-facing surfaces 442 outside the restraint regions 452a to 452d may extend only a portion of the upper 404 upwards. For example, as shown in the dotted figures in Figures 4A to 4C, the fusible or clamping yarns on the outward-facing surfaces 442 outside the restraint regions 452a may extend from the interlocking line 406, but not continuously to the inner periphery 434 at the throat region 426. Thus, although the fusible or clamping yarns may be knitted in the loop rows having additional tensile elements 450 in the forefoot region 408, the fusible or clamping yarns do not extend the length of these additional tensile elements 450 in the same way as the length by which the fusible or clamping yarns extend the tensile elements 450 within the restraint regions 452a to 452d.

[0075] Some examples of the knitted component 440 may also include fusible or clamping yarns knitted along the inner periphery 434 in the throat region 426 on the outward-facing surface 442. Additionally, as shown in FIG4D, the fusible or clamping yarns may be knitted along a central region in the heel region 412. For example, the upper 404 may include a heel seam, wherein the outer side 414 is secured to the inner side 416 in the heel region 412, and fusible or clamping yarns may be knitted along the seam from the interlocking line 406 to the ankle opening 425 of the knitted component 440 on the outward-facing surface 442.

[0076] As previously described, one or more additional yarns can be knitted (entangled) with the clamping yarn, such that the clamping yarn and the one or more additional yarns form the same loop course within the knitting section 440. In various examples, the clamping yarn can be knitted on a first needle bed (e.g., a front needle bed), while a high-tenacity yarn with a higher melting or decomposition temperature than the clamping yarn can be knitted on a second needle bed (e.g., a rear needle bed). In the loop course with tensile element 450, in some aspects, the tensile element 450 can be knitted with the clamping yarn on the first needle bed, or in other aspects, the tensile element 450 can be embedded between the first and second needle beds. In some aspects, the high-tenacity yarn knitted on the second needle bed has a different material composition than the tensile element 450, but it is conceivable that the high-tenacity yarn knitted on the second needle bed can have the same material composition as the tensile element 450. In the portion of the knitting part 440 where there is no yarn clamping on the outward-facing surface 442, the clamping yarn can be knitted on the second needle bed to be included on the inward-facing surface of the knitting part 440, while the high-tenacity yarn can be knitted on the first needle bed to be included on the outward-facing surface 442.

[0077] Some aspects of footwear described herein may include a polymer layer applied to at least a portion of the outward-facing surface of a knitted component after knitting. Figure 5 depicts an example polymer layer 500, and Figure 6 depicts an example footwear article 600 having the polymer layer 500 of Figure 5. Various structures may be used for the polymer layer 500, including, for example, polymer films, polymer webs, polymer powders, and nonwoven fabrics. For any of these structures, various polymer materials may be used for the polymer layer 500, including polyurethane, polyester, polyester polyurethane, and / or nylon. Although the polymer layer 500 may be formed from thermosetting polymer materials, many configurations of the polymer layer 500 are formed from thermoplastic polymer materials (such as thermoplastic polyurethane), such that the polymer layer 500 can melt upon heating and return to a solid state upon cooling. Accordingly, the polymer layer 500 formed from thermoplastic polymer materials can be repeatedly melted, molded, cooled, remelted, remolded, and cooled again. The polymer layer 500 formed from thermoplastic polymer materials may also be welded or thermally bonded to fabrics, such as knitted components described further below.

[0078] Figure 6 depicts a polymer layer 500 applied to a footwear article 600, which includes a sole structure 602 attached to an upper 604. The polymer layer 500 is positioned adjacent to at least a portion of the outward-facing surface 642 of a knitted component 640 and attached to the knitted component 640 to form a portion of the outer surface of the upper 604. The knitted component 640 can be any of the knitted components disclosed herein, including any of knitted components 140, 340, 440, 840, and 1040. The polymer layer 500 can extend continuously from the forefoot region 608, midfoot region 610, and heel region 612 of the footwear article 600, for example, covering any portion or all of each of these regions in different aspects. Furthermore, in different aspects, the polymer layer 500 can extend continuously from the interlocking line 606 between the upper 604 and the sole structure 602 to the throat region 626, or can extend a portion of that distance.

[0079] As depicted in Figures 5 and 6, the polymer layer 500 may include holes 510 extending through the polymer layer 500 to expose the underlying portion of the knitted component 640 when the polymer layer 500 is applied to the upper 604. Thus, when the polymer layer 500 is applied, the holes 510 allow the utilization of certain properties of the knitted component 640. For example, the outward-facing surface 642 of the knitted component 640 may be formed at least partially with the clamping yarns described with respect to knitted components 140 and 440, and the area of ​​the outward-facing surface 642 formed with clamping yarns may have a higher coefficient of friction compared to the area of ​​the outward-facing surface 642 without clamping yarns. The holes 510 in the polymer layer 500 may be positioned to expose those areas with a higher coefficient of friction due to the clamping yarns, allowing the wearer of the footwear 600 to better grip the ball and have improved ball control by utilizing the clamping yarns in the knitted component 640. The holes 510 in the polymer layer 500 may also increase the breathability and flexibility of the upper 604.

[0080] In addition, the polymer layer (e.g., similar to 500) may cover different percentages of the knitted component forming part of the upper, such as at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the surface of the knitted component, for example, across the entire knitted component, or across each zone (e.g., forefoot, heel, medial, and / or lateral). Furthermore, although holes 510 are depicted on the polymer layer 500 shown in FIG. 5, in any aspect of this document including the polymer layer, holes may be present, but may also be partially or completely omitted, such that the clamping yarns are instead exposed in the area surrounding the polymer layer. Additionally, in various aspects, the polymer layer may overlap with the edges of the areas formed with, for example, heat-treated clamping yarns.

[0081] Referring again to Figure 5, the regions of the polymer layer 500 may have a varying distribution of pores 510. For example, as shown in Figures 5 and 6, pores 510 may be distributed only in the anterior aspects of the forefoot region 608 and the midfoot region 610, while pores may not be present in the posterior aspects of the heel region 612 and the midfoot region 610. In other words, a first region of the knitted component 640 that may be located in the forefoot region 608 may have a first surface area covered by the polymer layer 500, while a second region of the knitted component 640 that may be located in the midfoot region 610 and / or the heel region 612 may have a surface area covered by the polymer layer 500 that is larger than the first surface area.

[0082] Concentrating the holes 510 at the front portion of the upper 604 allows for access to the area of ​​the clamping yarn most likely to come into contact with the ball, while maintaining increased abrasion resistance, water resistance, and stability in other areas. Further aspects of the polymer layer 500 may include graphic designs, and omitting the holes in areas of the polymer layer 500 that do not particularly benefit from exposure to the fusible clamping material allows for greater flexibility in graphic designs on the polymer layer 500.

[0083] Furthermore, the holes 510 in the polymer layer 500 can have different sizes (e.g., different diameters). For example, the polymer layer 500 includes larger holes (e.g., hole 510a) located closer to the front end 618 of the upper 604 and smaller holes (e.g., hole 510b) located closer to the midfoot area 610 and / or the throat area 626. Thus, a larger surface area of ​​the knitted part 640 can be exposed through the holes 510 of the polymer layer 500 in the forefoot area 608 and / or near the front end 618 of the upper 604, exposing the outward-facing surface 642 knitted with clamping yarns. In addition to varying the size of the holes 510, or as an alternative, the density of the holes 510 in the polymer layer 500 can be varied in different areas to expose more fusible clamping material in some areas of the knitted part 640 compared to other areas.

[0084] Similarly, the shape of the polymer layer 500 (e.g., the shape of the periphery of the polymer layer 500) can also be based on a location where it is advantageous to expose areas knitted with clamping yarns that provide tactile properties such as a higher coefficient of friction. For example, some aspects of the polymer layer 500 may not extend continuously from the bite line 606 to the throat region 626 in one or more areas of the upper 604. In Figure 6, the polymer layer 500 extends from the bite line 606 in the forefoot region 608, but does not extend completely to the front end 628 of the throat region 626. Instead, the portion of the polymer layer 500 in front of or in front of the throat region 626 extends only a portion of the upper 604 upward from the bite line 606. In some aspects, the polymer layer 500 may terminate at approximately one-third of the distance from the bite line 606 to the front end 628 of the throat region 626, approximately half the distance from the bite line 606 to the front end 628, or approximately two-thirds of the distance from the bite line 606 to the front end 628. In all aspects of the polymer layer 500, which extends upward from the bite line 606 in the forefoot area 608 to a portion of the upper 604, the additional surface area of ​​the knitted component 640 is exposed, and thus the area knitted with clamping yarns can be exposed to maintain its tactile properties.

[0085] Aspects of this disclosure may include methods for manufacturing shoe uppers having polymer layers (such as shoe upper 604 of FIG. 6). This may include knitting a knitted component 640, which may include knitting clamping yarns on at least one needle bed to form the knitted component 640, wherein the clamping yarns form at least a portion of the outer-facing surface 642 of the knitted component 640. After the knitted component 640 is knitted, the clamping yarns on at least the outer-facing surface 642 may be activated by heat and / or pressure, such that the clamping yarns at least partially melt and fuse with the infusible portions of the clamping yarns, second yarns, and / or tensile elements, as described with respect to knitted components 140 and 440. In one example, a heat source applied during a steam process may heat the knitted component 640 to a temperature greater than the melting temperature of the clamping yarns and less than the melting or decomposition temperature of the second yarns in the knitted component 640. After the clamping yarns have at least partially melted, the knitted component 640 may be cooled, such that the molten fusible material of the clamping yarns may solidify. Additionally, the knitted part 640 can be held on a clamp, which may include applying tension to the knitted part 640 during heating and cooling, for example, from spaced pins extending through holes in the knitted part 640.

[0086] After the clamping yarns in the knitted part 640 are activated, the polymer layer 500 can be fixed to the knitted part 640. This process can be performed by stacking the polymer layer 500 on the knitted part 640 between the various parts of a hot press, which compresses and heats the knitted part 640 and the polymer layer 500 to bond them together. In the example of footwear 600, the polymer layer 500 may have a polymer composition (formed from one or more polymer materials) with a melting temperature lower than that of the fusible material in the clamping yarns of the knitted part 640. Additionally, the polymer layer 500 stacked on the knitted part 640 can be heated to a temperature higher than that of the polymer layer 500 but lower than that of the clamping yarns. In this way, when the polymer layer 500 is bonded to the knitted part 640, the fusible polymer composition from the clamping yarns in the knitted part 640 will not be reactivated (e.g., remelted). After the polymer layer 500 is bonded to the knitted component 640, the polymer layer 500 and the knitted component 640 can be formed into the shape of the upper 604 and fixed to the sole structure 602.

[0087] Additional aspects of this disclosure include processes for manufacturing uppers and / or knitted components for uppers. In particular, some aspects include steps for reducing fan-shaped notches on the edges of knitted components during manufacturing to produce straight edges without adding additional components. For example, Figure 7 illustrates a flowchart depicting an example method 700 for manufacturing an upper for footwear articles, which may include upper 104, upper 404, or upper 604. The steps provided in method 700 are illustrative only, and method 700 may include additional steps not illustrated. Figure 8 depicts an example knitted component 840 during method 700, and the steps of method 700 can be illustrated with reference to Figure 8.

[0088] At step 710, the knitted part is knitted on a knitting machine. Step 710 can be performed by an automatic knitting machine, and accordingly, it can be performed and / or controlled using a control unit having a processor or computer communicatively coupled to or integrated into the knitting machine. In an example aspect, the knitting machine used for knitting the part is a V-bed flat knitting machine with two needle beds—a front needle bed and a rear needle bed—angled relative to each other to form a V-shape. The front and rear needle beds may each include a plurality of independent needles extending across a common plane. A carriage can move yarn feeders, such as standard and / or combined yarn feeders, along the front and rear needle beds to supply yarn to the needles. Typically, both standard and combined yarn feeders supply yarn for the needles to knit, tuck, and / or float, while combined yarn feeders may also supply yarn to pass through or embed between knitted structures. Although a V-bed flat knitting machine has been described herein, it should be understood that this is an example and other knitting machines can be used to form knitted parts or portions thereof.

[0089] Furthermore, step 710 may include radially knitting the knitting component on a knitting machine. Radial knitting may be performed as described with respect to knitting component 340 of FIG3.

[0090] Additionally, step 710 may include incorporating a tensile element similar to tensile element 150 and / or tensile element 450 into the knitted structure of the knitted part. In some examples, the tensile element is embedded without loops via a combined yarn feeder of the knitting machine and is embedded between loops formed on the front and / or rear beds of the knitting machine. In other instances, the tensile element may be incorporated by forming a repeating sequence of loop stitches and float stitches along the loop rows further described with respect to FIG9. Additionally, embodiments of step 710 may include knitting the knitted part with any of the yarn types described with respect to knitted parts 140, 440, or 640, and having any of the configurations of knitted parts 140, 440, or 640.

[0091] The knitted component formed in step 710 may include a first inner peripheral edge and a second inner peripheral edge. The first and second inner peripheral edges may be located within the throat region. For example, the first inner peripheral edge may be the inner edge of the knitted component in the throat region, and the second inner peripheral edge may be the outer edge of the knitted component in the throat region. Accordingly, the first and second inner peripheral edges may extend substantially parallel to each other.

[0092] At step 712, the first inner peripheral edge and the second inner peripheral edge are secured together. In an example, the first inner peripheral edge and the second inner peripheral edge are secured together by stitching. For example, Figure 8 depicts a knitted component 840 on a clamp 810, where the first inner peripheral edge 832 and the second inner peripheral edge 834 are stitched together to create a seam 850. Note that because the knitted component 840 is on top of the clamp 810, the outline of the clamp 810 is only visible through the knitted component 840 in Figure 8.

[0093] At step 714, the knitted component is secured to the clamp using pins along a portion of its periphery. For example, the pins may be arranged along the outer periphery of the knitted component. Additionally, in some aspects, the pins may be arranged along the fourth and fifth inner periphery edges, which are not fixed to each other and, once the upper is formed by the knitted component, can together form the ankle opening of the upper. The first and second inner periphery edges 832 and 834 are not directly pinned to the clamp. For example, in FIG8, the knitted component 840 is secured to the clamp 810 via pins 812 along the outer periphery 824 of the knitted component 840 and along the third and fourth inner periphery edges 836 and 838.

[0094] At step 716, one or more post-knitting treatments may be performed on the knitted part while it is secured to the jig. For example, heat (e.g., by steam) may be applied to at least partially melt or soften the fusible material knitted into the knitted part, as described with respect to knitted parts 140, 440, and / or 640. Additionally or alternatively, while the knitted part is on the jig, a separate polymer layer, such as polymer layer 500 or another similar polymer layer of some size, may be secured (e.g., thermally bonded) to the knitted part. Furthermore, the knitted part may be cooled to solidify the thermal bond while still being secured to the jig.

[0095] At step 718, after the knitted part is secured to the clamp, the first inner peripheral edge 832 and the second inner peripheral edge 834 are separated following the post-knitting process. For example, the seam between the first inner peripheral edge 832 and the second inner peripheral edge 834 can be removed. Step 718 can be performed by die-cutting the knitted part to cut the seam formed between the first inner peripheral edge 832 and the second inner peripheral edge 834, and in some respects, also to cut eyelets to attach ties to the knitted part. This step can be performed while the knitted part is still on the clamp or after the knitted part has been removed from the clamp.

[0096] Furthermore, aspects of method 700 may also include forming the knitted component into the shape of an upper, which can be done using a shoe last. Additionally, the upper may be attached to one or more sole structures, such as a strobel (midsole fabric), midsole, and / or outsole.

[0097] Forming the upper from knitted components according to method 700 helps ensure a clean, straight line along the throat area. Specifically, before securing the knitted components to the clamp, the first and second inner peripheral edges in the throat area are sewn together, and a post-knitting heat treatment is applied to remove any fan-shaped notches or curves that may naturally form along the first and second inner peripheral edges during the knitting process. When the fan-shaped notches are not removed before heating the knitted components, the heating process may retain the fan-shaped notches or curved shapes of the edges through the melting and cooling of the fusible yarn and / or the application of a polymer (skin) layer. Although the fan-shaped notches can be removed from the edges when the knitted components are pinned to the clamp, it typically requires numerous pins along the first and second inner peripheral edges to effectively remove them, and the use of additional pins adds manufacturing time. In particular, the time required to pin the first and second peripheral edges sufficient to remove the fan-shaped notches is greater than the time required to stitch the first and second peripheral edges together.

[0098] Further embodiments of this disclosure relate to a knitted structure and a knitting method analogous to embedding tensile elements. Specifically, tensile elements such as tensile elements 150 and 450 described herein can be embedded in the knitted structure such that the tensile elements float and / or are woven between loops formed of other yarns, without the tensile elements themselves becoming entangled in the loop rows. An alternative structure could be to knit the tensile elements into the knitted structure in a manner simulating the strength that can be provided by embedding tensile elements.

[0099] In some aspects of the knitted components, uppers, and footwear articles discussed herein, the knitted component or a portion thereof may include a stretch lining, such as a raised stretch lining, to impart stretch properties. In one aspect, the stretch lining may be located at a position along the inward-facing surface of the knitted component and / or raised along the inward-facing surface of the knitted component.

[0100] Additionally, in some aspects of the knitted components, uppers, and footwear articles discussed herein, the clamping yarn may be located in different areas of the inward-facing and / or outward-facing surfaces of the knitted component, for example, along the forefoot area (e.g., in the toe area) and / or along the upper.

[0101] Additionally, in some aspects of the knitted components, uppers, and footwear articles discussed herein, the forefoot area (e.g., the toe box and / or vamp) may include yarns and / or fabrics (e.g., polyester, nylon) with limited or substantially no tensile properties to achieve greater reinforcement, durability, and abrasion and / or wear resistance. This may be used in combination with other aspects described herein.

[0102] Figure 9 shows a close-up view of a portion of an example knitted part 940 having a tensile element 950, which has a pseudo-embedded structure or an analogous embedded structure. Specifically, each loop row of the tensile element 950 includes a sequence of knitted stitches 952 (e.g., knitted loops) and float stitches 954, wherein the sequence repeats along the length of the loop row. In the example, the sequence includes a knitted stitch and a float stitch extending across multiple loop rows. The number of loop rows the float stitch extends across can correspond to the number of needles along the needle bed (in which the tensile element floats between two knitted stitches). The number of loop rows each float stitch extends across can range from 3 to 8, from 4 to 7, and from 5 to 6. In one example, each float stitch of the tensile element extends across 5 loop rows. Accordingly, the tensile element can be knitted using a knitting sequence of a knitted stitch formed on one needle and a float stitch extending across five needles.

[0103] By incorporating numerous float stitches along the loop rows with tensile elements, it is helpful to simulate the strength and tensile resistance imparted when tensile elements are embedded in a knitted structure. However, knitting the tensile elements with occasional stitches (loops) can help maintain the tensile elements along the loop rows with straighter or cleaner yarn. Furthermore, the tensile elements can be combined with knitted stitches and floats rather than with an insert, either using a combined yarn feeder or a regular yarn feeder on the knitting machine. This provides greater flexibility in terms of which knitting machines can be used to form the knitted part 940 and / or how a specific knitting machine can be used.

[0104] In some respects, the positions of the knitted stitches in adjacent loop rows of the tensile element 950 can be offset, so that they appear at different needle positions. For example, if the knitted stitches in the loop row of the tensile element 950a are at needle positions 2, 8, and 14, the knitted stitches in the loop row of the adjacent tensile element 950b can be at positions 3, 9, and 15.

[0105] For simplicity, the tensile element 950 following an analogous embedded structure is only schematically depicted in Figure 9; however, it should be understood that the loop rows in the knitted component may include additional yarns knitted with the tensile element 950. For example, the tensile element 950 may be knitted on a first needle bed while another yarn is knitted on the first needle bed using a different stitch sequence. This other yarn on the first needle bed (referred to herein as the first yarn) may be made of fusible yarns (including clamping yarns), high-tenacity yarns, monofilament yarns, or yarns having a combination of these characteristics as described in this disclosure. The first yarn may be knitted using a knitted stitch or a combination of knitted stitches and tuck stitches. In some aspects, the first yarn loops on multiple consecutive needles on the first needle bed, then pleats on needles on a second needle bed, and continues looping on needles on the first needle bed. The tuck stitch of the first yarn to the second needle bed can help hold the float of the tensile element 950 in place. In some loop rows, the first yarn may be knitted only on the first needle bed without pleating on the second needle bed.

[0106] In some aspects, the knitting component 940 is also used to form a second yarn knitted on a second needle bed. This second yarn can be knitted using knitting stitches and / or tuck stitches. In some aspects, the second yarn is knitted on the second needle bed (its needle position is the same as the needle position of the first yarn knitted on the first needle bed), and switches to knitting on the first needle bed when the first yarn switches to knitting on the second needle bed. Examples of the second yarn may include yarns made of fusible yarns (including clamping yarns), high-tenacity yarns, monofilament yarns, or combinations thereof as described in this disclosure. In one embodiment, the first yarn is a clamping yarn, and the second yarn is a high-tenacity yarn whose melting or decomposition temperature is at least higher than that of the fusible material on the first yarn.

[0107] The knitted part 940 of Figure 9 is radially knitted, such that the tensile element 950 extends radially from the outer periphery 924 along the loop rows to a common area, such as the throat area 926. However, it should be understood that the same knitting sequence of the tensile element 950 can be applied to non-radial knitted parts, such as those in which the loop rows of the tensile elements extend parallel to each other (e.g., parallel along an inside-to-outside axis) without converging toward a common area.

[0108] Figure 10 depicts another example knitted component 1040 having a tensile element 1050 according to various aspects herein. The knitted component 1040 can be used to form an upper for footwear articles (such as footwear 100 or footwear 400). In addition to those indicated below with respect to the tensile element 1050, the knitted component 1040 may have any of the features described together with other knitted components disclosed herein, including knitted components 140, 340, 440, 640, 840, and 940.

[0109] The tensile element 1050 in the knitted component 1040 can be formed using yarn such as braided yarn, or using yarn with a cross-section having a significantly larger diameter than the cross-section of the other yarn strands forming the knitted component 1040. Additionally, the tensile element 1050 with this structure can be incorporated into the knitted structure by knitting (e.g., intertwining the tensile element 1050 with the loops of adjacent loop rows), rather than by embedding it between intertwined loop rows of other yarns without forming loops. For example, the tensile element 1050 can be knitted according to the knitting sequence of the tensile element 950 in FIG. 9. As a result, when the knitted component 1040 is formed as an upper, the tensile element 1050 can form a raised structure extending away from the foot receiving cavity. When the knitted component 1040 is worn on the upper, the raised tensile element 1050 can generate more spin when it comes into contact with a ball such as a soccer ball. In some respects, polymer layers (e.g., skins) that may include aspects of the polymer layer 500 described in Figures 5 and 6 may be applied to the knitted part 1040 and to at least a portion of the raised tensile element 1050.

[0110] Additional exemplary properties of the clamping yarn

[0111] As discussed above, the knitted components disclosed herein may include, individually or selectively combined with yarns described in combination with other materials (e.g., yarns not falling beneath fibers, filaments, and second yarns or tensile elements described herein as clamping yarns) (hereinafter referred to as clamping yarns). In some aspects, the yarns and / or fibers described herein may be used to provide specific functions. For example, in some aspects, the fibers or yarns described herein may be fused to form a surface or at least a recirculation area having water-resistant or waterproof properties, restraining properties, specific adhesion frictional properties, "ball contact" properties, and providing a high coefficient of friction. In addition to the materials and properties of the clamping yarns disclosed above, the following properties may also be found in examples of clamping yarns.

[0112] In one aspect, the clamping yarn described herein has a breaking strength of an applied force of about 0.6 to about 0.9 kg, or an applied force of about 0.7 to about 0.9 kg, or an applied force of about 0.8 to about 0.9 kg, or an applied force greater than 0.9 kg.

[0113] The clamped yarn includes or consists substantially of clamping material. The clamping material is a thermoplastic material for an elastomer because the clamping material includes one or more thermoplastic elastomers or consists substantially of one or more thermoplastic elastomers. In some aspects, the clamped material has a melting temperature of less than 115 degrees Celsius, less than 110 degrees Celsius, or less than 100 degrees Celsius.

[0114] A clamping yarn comprising or consisting substantially of a clamping material is understood to include a coating of clamping material, or to include one or more clamping fibers (where each of the various clamping fibers includes clamping material), or to include both a clamping material coating and clamping fibers. The clamping fibers of the clamped yarn may include multiple short clamping fibers, or may include multiple long clamping filaments, or may include a single long clamping filament (i.e., monofilament), or may include a combination of short clamping fibers and one or more filaments. Similarly, the clamped yarn may include a single clamped filament, or may include multiple clamped fibers or clamped filaments, or may include one or more core yarns. When the clamping yarn includes one or more core yarns, each of the one or more core yarns may be at least partially coated with clamping material. Alternatively, when the clamping yarn includes one or more core yarns, the one or more core yarns may form an adder yarn and the joiner yarn may be coated at least in part with a clamping material.

[0115] In one aspect, when the clamped yarn consists essentially of clamped fibers, 95% or more of the fibers present in the clamped yarn are clamped fibers. In other aspects, when the clamped yarn includes two or more types of fibers, at least one of those two or more types of fibers is a clamped fiber. When the clamped yarn includes two or more types of fibers, the clamped fibers may account for at least 10% by weight, or at least 25% by weight, or at least 50% by weight, or at least 75% by weight of the fibers present in the clamped yarn.

[0116] In one aspect, the clamped yarn comprises a core coated by clamping material. The clamped yarn core includes a core material wherein the core material includes different types of polymers and / or has different properties from the clamped material. The core material may be a polymeric material comprising one or more polymers, or may include a non-polymer material. When the core material is a polymer, the polymer present in the core material can be a different type of polymer than the polymer present in the clamped material. For example, the core material may include one or more polyester homopolymers or polyamide homopolymers, and the clamping material may be substantially free of polyester homopolymers or polyamide homopolymers. When the core material is a thermoplastic material, the core material can have a higher deflection or melting temperature than the clamped material. When the core material is a non-polymer or thermoset material, the degradation temperature of the core material can be higher than the melting temperature of the clamped material. The core material may be inelastic or less elastic than the clamped material (e.g., with a lower elongation percentage).

[0117] In one aspect, the core of the clamped yarn comprises one or more fibers. In that aspect, the clamping material may completely or partially coat the core. One or more core fibers may be multiple short fibers, such as multiple short fiber length fibers spun into a single yarn, or multiple short fiber length fibers spun into two or more yarns, where two or more yarns are added together. One or more core fibers may be multiple filaments. Multiple filaments can be aligned, or can be aligned and tangled. One or more core fibers may be a single long monofilament.

[0118] In one aspect, the clamped yarn is a coated yarn, wherein the core yarn comprises a second polymer composition as a core material and a coating disposed on the core yarn, the coating comprising a first polymer composition as a clamping material, wherein the first polymer composition has a clamping material melting temperature. In one aspect, the core material is thermoplastic and has a deformation temperature greater than at least 20 degrees Celsius, at least 50 degrees Celsius greater, at least 75 degrees Celsius greater, or at least 100 degrees Celsius greater than the clamping melting temperature of the first polymer composition. The clamping material includes one or more thermoplastic elastomers or consists substantially of one or more thermoplastic elastomers. Alternatively, in addition to including one or more thermoplastic elastomers, the clamping material may include one or more additional polymers, or one or more additional nonpolymer additives, or may include both. One or more thermoplastic elastomers of the clamped material may include one or more thermoplastic polyurethane (TPU) elastomers, or one or more thermoplastic styrene elastomers, or a combination of both. In some aspects, one or more thermoplastic elastomers are two or more thermoplastic elastomers, such as two or more TPU elastomers, or two or more styrene elastomers, or a combination of two TPU elastomers and one styrene elastomer, or two styrene elastomers and one TPU elastomer.

[0119] As used herein, a polymer composition (such as a clamping composition or a core composition) is understood to comprise a polymer component consisting of all polymers present in the polymer composition. The polymer component may consist of a single polymer or may consist of two or more polymers. In one aspect, the polymer component consists of one or more polymers of a single type. For example, the polymer component of a core material may consist of one or more polyesters, or one or more polyethers, or one or more polyamides, or one or more polyurethanes, or one or more polyolefins. The polymer component of a core material may consist of one or more polyesters. The polymer component of a core material may consist of polyethylene terephthalate (PET). The polymer component of a clamping material may consist of one or more TPU elastomers or one or more styrene elastomers. The polymer component of a clamping material may consist of one or more polyester-polyurethane elastomers. The polymer component of a clamping material may consist of one or more styrene-butadiene-styrene (SBS) elastomers.

[0120] The core material of the core fiber or core yarn can be any material that retains its strength at the temperature at which the clamping material is applied to the core fiber or core yarn. The core fiber coated with the clamping material and / or the fiber used to form the core yarn can be a natural fiber or a regenerated fiber or filament, or a synthetic fiber or filament. In one aspect, the core fiber or core yarn comprises or is substantially composed of natural or regenerated materials, such as cotton, silk, wool, or rayon, which are not thermoplastic and therefore have a degradation temperature but no melting or deformation temperature. In another aspect, the core material of the core fiber or core yarn comprises or is substantially composed of one or more synthetic thermosetting materials, such as thermosetting polyurethane or thermosetting polyurea, which also have a degradation temperature but no melting or deformation temperature. In yet another aspect, the core material of the core fiber or core yarn comprises or is substantially composed of one or more synthetic thermoplastics, such as polyester, polyamide, polyurethane, polyolefins, copolymers thereof, and mixtures thereof. In one aspect, the core material comprises one or more polyesters or one or more polyamides, or is substantially composed of one or more polyesters or one or more polyamides. In one example, the one or more polyesters comprise polyethylene terephthalate (PET) or are substantially composed of PET. In one aspect, the core material is a thermoplastic material and has a deformation temperature greater than 200 degrees Celsius, or greater than 220 degrees Celsius, or greater than 240 degrees Celsius, or from about 200 degrees Celsius to about 300 degrees Celsius.

[0121] In one aspect, the core yarn has a linear density of about 100 denier to about 300 denier, or about 100 to about 250 denier, or about 100 to about 200 denier, or about 100 to 150 denier, or about 150 to 300 denier, or about 200 to 300 denier, or about 250 to 300 denier. In another aspect, the core yarn has a thickness of about 60 micrometers to 200 micrometers, about 60 to 160 micrometers, about 60 to 120 micrometers, about 60 to 100 micrometers, about 100 to 200 micrometers, or about 140 to 200 micrometers. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material or is substantially composed of a core material comprising one or more synthetic polymers. One or more synthetic polymers may comprise polyamide, polyester, polyether, polyurethane, polyolefin, and combinations thereof. One or more polyurethanes may comprise polyethylene terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature at least 20°C, at least 50°C, at least 75°C, or at least 100°C greater than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0122] In one aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier. In one aspect, the core yarn has an elongation percentage of about 20% to about 30%, about 22% to about 30%, about 24% to about 30%, about 20% to about 28%, or about 20% to about 26%. In one aspect, the core yarn has a toughness of about 1 g / denier to about 10 g / denier, about 3 g to about 10 g / denier, about 5 g to about 10 g / denier, about 1 g to about 7 g / denier, or about 1 g to about 5 g / denier. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material or is substantially composed of a core material comprising one or more synthetic polymers. One or more synthetic polymers may comprise polyamide, polyester, polyether, polyurethane, polyolefin, and combinations thereof. One or more polyurethanes may comprise polyethylene terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature at least 20°C, at least 50°C, at least 75°C, or at least 100°C greater than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0123] In one aspect, a coating (e.g., a first polymer composition as a coating material) can be extruded onto a core yarn through an annular die or orifice, such that the coating is axially centered around the core yarn, thereby producing a clamping yarn. The thickness of the coating applied to the core yarn can vary depending on the application of the yarn. In one aspect, the clamping yarn has a nominal average outer diameter of up to 1.00 mm, or up to about 0.75 mm, or up to about 0.5 mm, or up to about 0.25 mm, or up to about 0.2 mm, or up to about 0.1 mm. In another aspect, the coating has a nominal average outer diameter of about 0.1 mm to about 1.00 mm, or about 0.1 mm to about 0.80 mm, or about 0.1 mm to about 0.60 mm. In yet another aspect, the coating on the yarn has an average radial coating thickness of about 50 micrometers to about 200 micrometers, or about 50 micrometers to about 150 micrometers, or about 50 micrometers to about 125 micrometers. The core yarn may comprise one or more natural or regenerated fibers or be substantially composed of one or more natural or regenerated fibers. The core yarn may include or consist substantially of a core material, which may include one or more synthetic polymers. The one or more synthetic polymers may include polyamide, polyester, polyether, polyurethane, polyolefin, or any combination thereof. The one or more polyurethanes may include polyethylene terephthalate (PET) or consist substantially of PET. The core yarn or core material, or both, may have a degradation or deformation temperature at least 20°C, at least 50°C, at least 75°C, or at least 100°C greater than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0124] In one aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier, and the coating has a nominal average outer diameter of about 0.10 mm to about 0.50 mm, or about 0.10 mm to about 0.25 mm, or about 0.10 mm to about 0.20 mm. In another aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier, and the coating has a nominal average outer diameter of about 0.10 mm to about 0.50 mm, or about 0.10 mm to about 0.25 mm, or about 0.10 mm to about 0.20 mm. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material or is substantially composed of a core material comprising one or more synthetic polymers. One or more synthetic polymers may include polyamide, polyester, polyether, polyurethane, polyolefin, and combinations thereof. One or more polyurethanes may include polyethylene terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature that is at least 20°C, at least 50°C, at least 75°C, or at least 100°C greater than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0125] In another aspect, the clamping yarn has a net total diameter of from about 0.2 to about 0.6 mm, or from about 0.3 to about 0.5 mm, or from about 0.4 to about 0.6 mm. In some aspects, a lubricant, including but not limited to mineral oil or silicone oil, is present on the yarn in amounts from about 0.5% to about 2% by weight, or from about 0.5% to about 1.5% by weight, or from about 0.5% to about 1% by weight. In some aspects, the lubricating composition is applied to the surface of the fusible clamping yarn before or during the fabric formation process. In some aspects, the thermoplastic composition and the lubricating composition are miscible when the thermoplastic composition is reflowed and recured in the presence of the lubricating composition. After reflow and recuring, the reflowed and cured composition may include the lubricating composition.

[0126] In another aspect, the clamping yarn has a net total diameter of 0.2 to 0.6 mm, or 0.3 to 0.5 mm, or 0.4 to 0.6 mm.

[0127] In some aspects, the lubricant, including but not limited to mineral oil or silicone oil, is present in the yarn at a concentration of about 0.5% by weight to about 2% by weight, or from about 0.5% by weight to about 1.5% by weight, or from about 0.5% by weight to about 1% by weight. In some aspects, the lubricating composition is applied to the surface holding the yarn before or during the fabric formation process. In some aspects, the thermoplastic composition and the lubricating composition are miscible when the thermoplastic composition is reflowed and recured in the presence of the lubricating composition. After reflow and recuring, the reflowed and cured composition may include the lubricating composition.

[0128] In one aspect, the core yarn has an elongation percentage of about 8% to about 30%, about 10% to about 30%, about 15% to about 30%, about 20% to about 30%, about 10% to about 25%, or about 10% to about 20%. In another aspect, the core yarn has a toughness of about 1 g / denier to about 10 g / denier, about 2 g / denier to about 8 g / denier, about 4 g / denier to about 8 g / denier, or about 2 g / denier to about 6 g / denier. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material or is substantially composed of a core material comprising one or more synthetic polymers. The one or more synthetic polymers may comprise polyamide, polyester, polyether, polyurethane, polyolefin, or any combination thereof. The one or more polyurethanes may comprise polyethylene terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature that is at least 20 degrees Celsius, at least 50 degrees Celsius, at least 75 degrees Celsius, or at least 100 degrees Celsius greater than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200 degrees Celsius, greater than 220 degrees Celsius, greater than 240 degrees Celsius, or between about 200 degrees Celsius and about 300 degrees Celsius.

[0129] In one aspect, the clamping material has a melting temperature from about 100 degrees Celsius to about 210 degrees Celsius, optionally from about 110 degrees Celsius to about 195 degrees Celsius, from about 120 degrees Celsius to about 180 degrees Celsius, or from about 120 degrees Celsius to about 170 degrees Celsius. In another aspect, the clamping material has a melting temperature greater than about 120 degrees Celsius and less than about 170 degrees Celsius, and optionally greater than about 130 degrees Celsius and less than about 160 degrees Celsius.

[0130] On the other hand, when the melting temperature of the clamping material is greater than 100 degrees Celsius, the integrity of the article formed or incorporated with the coating material is maintained if the article is briefly exposed to relatively high temperatures (e.g., during transport or storage). On the other hand, when the melting temperature of the clamping material is greater than 100 degrees Celsius or greater than 120 degrees Celsius, articles formed or incorporated with the first polymer composition as the clamping material can be steam-treated without melting or unintentionally fusing any higher melting temperature (e.g., polyester) components incorporated in the article for purposes such as filling, strip surfaces, or comfort features, as well as yarns for fit and conformability features.

[0131] In one aspect, when the melting temperature of the clamping material is greater than 120 degrees Celsius, articles incorporating materials with higher deformation or melting temperatures (e.g., the first or second polymer composition) are less likely to soften and / or become sticky during use on hot paved surfaces, stadium surfaces, artificial or natural football fields, or similar sports field surfaces, tracks, or fields. In another aspect, the higher the melting temperature and the greater the enthalpy of fusion of the first or second polymer composition, the greater the ability of footwear articles or sports equipment incorporating or constructed from the first or second polymer composition to withstand contact heating offset, friction surface heating events, or environmental heating offset. In another aspect, such thermal offset can occur when the article comes into contact with a hot ground, stadium, or turf surface, or when the article comes into contact with another surface such as the ground, another shoe, ball, etc., and friction heating occurs due to friction or abrasion.

[0132] On the other hand, when the melting temperature of the clamping material is less than about 210 degrees Celsius, or less than 200 degrees Celsius, or less than 190 degrees Celsius, or less than 180 degrees Celsius, or less than 175 degrees Celsius but greater than 120 degrees Celsius, or greater than 110 degrees Celsius, or greater than 103 degrees Celsius, yarn coated with the clamping material can be melted for the purpose of molding and / or thermoforming a given area of ​​the fabric knitted therefrom, so as to impart ideal design and aesthetic features in a short period of time.

[0133] On one hand, the holding material's melting temperature below 140 degrees Celsius prevents or mitigates the risk of dye migration from packaged yarns, such as packaged polyester yarns incorporated into footwear or other articles. On the other hand, dye migration from packaged yarns or fibers is a diffusion-limited process, and short-term exposure to temperatures above 140 degrees Celsius (such as during thermoforming) will not cause extensive damage, discoloration, or otherwise render the appearance of the footwear or other articles unacceptable. However, on the other hand, if the holding material's melting temperature exceeds approximately 210 degrees Celsius, thermal damage and dye migration may occur.

[0134] On the one hand, a high enthalpy of melting indicates that a longer heating time is required to ensure that the polymer or polymeric material melts completely and flows well. On the other hand, a low enthalpy of melting requires less heating time to ensure complete melting and good flow.

[0135] On the other hand, high exothermic cooling indicates a rapid transition from melt to solid. Higher recrystallization temperatures indicate that the polymer or polymer material can cure at higher temperatures. In one respect, high-temperature curing is beneficial for thermoforming. In another respect, recrystallization above 95 degrees Celsius promotes rapid solidification after thermoforming, reduces cycle time, reduces cooling requirements, and improves the stability of shoe components during assembly and use.

[0136] In one aspect, the viscosity effects of the clamping materials disclosed herein include the properties of the articles of manufacture and the processing of the clamping materials. In another aspect, high viscosity at low shear rates (e.g., less than 1 reciprocal second) indicates resistance to flow and displacement, and a more solid-like behavior. On the other hand, low viscosity at higher shear rates (e.g., greater than 10 reciprocal second) makes it suitable for high-speed extrusion. In one aspect, as viscosity increases, the ability to flow and deform sufficiently to coat the core yarn or the area of ​​the fabric incorporating the coated yarn becomes challenging. On the other hand, materials exhibiting a high shear thinning index (e.g., where the viscosity at 10 or 100 reciprocal second is lower than that at 1 reciprocal second) may be difficult to extrude, and melt fracture may occur if coated or extruded at excessively high speeds.

[0137] In some aspects, the clamping yarn exhibits a toughness greater than 1 g / denier. In one aspect, the clamping yarn exhibits a toughness from about 1 g / denier to about 5 g / denier. In one or more aspects, the clamping yarn exhibits a toughness from about 1.5 g / denier to about 4.5 g / denier. In one aspect, the clamping yarn exhibits a toughness from about 2 g / denier to about 4.5 g / denier.

[0138] As used herein, “toughness” refers to the property of a fiber or yarn and is determined using the corresponding test methods and sampling procedures described below. Specifically, the toughness and elongation of the yarn sample are determined according to the test methods described in detail in EN ISO 2062, where the preload is set to 5 grams. Elongation is recorded at the maximum tensile force applied before breakage. Toughness can be calculated as the ratio of the load required to break the sample to the linear density of the sample.

[0139] In some respects, it may be desirable to utilize clamping yarns suitable for use on commercial knitting equipment. The independent shrinkage rate of a yarn at 50 degrees Celsius is a property that can predict suitability for use on commercial knitting machines. In some respects, clamping yarns can exhibit an independent shrinkage rate of less than 15% when heated from 20 degrees Celsius to 70 degrees Celsius. In various respects, clamping yarns can exhibit an independent shrinkage rate of approximately 0% to approximately 60%, approximately 0% to approximately 30%, or approximately 0% to approximately 15% when heated from 20 degrees Celsius to 70 degrees Celsius. As used herein, the term "independent shrinkage rate" refers to the properties of the yarn and the corresponding test methods described below:

[0140] Yarn Shrinkage Test. The independent shrinkage rate of yarn can be determined by the following method. Prepare a yarn sample according to the yarn sampling procedure described below and cut it into lengths of approximately 30 mm at approximately room temperature (e.g., 20 degrees Celsius) with minimal tension. Place the cut sample in an oven at 50 degrees Celsius or 70 degrees Celsius for 90 seconds. Remove the sample from the oven and measure it. Using the measurements of the sample before and after the oven, calculate the shrinkage percentage by dividing the measurement after the oven by the measurement before the oven and multiplying by 100.

[0141] Yarn sampling procedure. Before testing, store the yarn to be tested at room temperature (20°C to 24°C) for 24 hours. Discard the first 3 meters of material. Cut the sample yarn into lengths of approximately 30 mm at approximately room temperature (e.g., 20°C) with minimal tension.

[0142] In one or more aspects, the independent shrinkage rate of a yarn at 70 degrees Celsius can be a useful indicator of the yarn's ability to be exposed to certain environmental conditions without any significant change in its physical structure. In some aspects, the clamped yarn exhibits an independent shrinkage rate from about 0% to about 60% when heated from 20 degrees Celsius to 70 degrees Celsius. In one or more aspects, the clamped yarn exhibits an independent shrinkage rate from about 0% to about 30% when heated from 20 degrees Celsius to 70 degrees Celsius. In another aspect, the clamped yarn exhibits an independent shrinkage rate from about 0% to about 20% when heated from 20 degrees Celsius to 70 degrees Celsius.

[0143] As discussed above, in some respects, the clamping material (e.g., the first polymer composition) and the core material (e.g., the second polymer composition) have different properties. In various respects, these different properties allow the clamping fibers and yarns described herein to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from their structure prior to the thermoforming process (e.g., thermoforming from clamping yarn to reflow clamping material), whereas when the thermoforming process is carried out at a temperature below the melting or deformation temperature of the uncoated fibers or yarns, the uncoated fibers or yarns do not deform or melt during such processes and can retain their structure (e.g., as fibers or yarns). In such respects, the reflow clamping material formed from the clamping fibers or yarns during the thermoforming process can be integrally connected to the unchanged structure (e.g., yarn or fiber), which can provide a three-dimensional structure and / or other properties for a specific point on footwear articles.

[0144] The clamping materials for clamping yarns described herein include one or more thermoplastic elastomers. In one aspect, an "elastomer" is defined as a material having an elongation at break greater than 400% as determined using ASTM D-412-98 at 25 degrees Celsius. In another aspect, the elastomer is formed as a sheet having a tensile strength of 10 to 35 kgf, or from about 10 to about 25 kgf, or from about 10 to about 20 kgf, or from about 15 to about 35 kgf, or from about 20 to about 30 kgf. In another aspect, the tensile strength at break or ultimate tensile strength is greater than 70 kgf / cm², or greater than 80 kgf / cm², if adjusted for cross-sectional area. In another aspect, the elastomer sheet has a tensile strain of 450% to 800%, or from 500% to 800%, or from 500% to 750%, or from 600% to 750%, or from 450% to 700%. On the other hand, the elastomer plate has a load of 3 to 8 kgf / mm at 100% strain, or about 3 to about 7 kgf / mm, about 3.5 to about 6.5 kgf / mm, or about 4 to about 5 kgf / mm.

[0145] In one aspect, the elastomeric plate has a toughness from 850 kg-mm to 2200 kg-mm, or from about 850 kg-mm to about 2000 kg-mm, or from about 900 kg-mm to about 1750 kg-mm, or from about 1000 kg-mm to about 1500 kg-mm, or from about 1500 kg-mm to about 2000 kg-mm. In another aspect, the elastomeric plate has a stiffness from about 35 to about 155, or from about 50 to about 150, or from about 50 to about 100, or from about 50 to about 75, or from about 60 to about 155, or from about 80 to about 150. In yet another aspect, the elastomeric plate has a tear strength from about 35 to about 80, or from about 35 to about 75, or from about 40 to about 60, or from about 45 to about 50.

[0146] In various aspects, exemplary thermoplastic elastomers include homopolymers and copolymers. The term "polymer" refers to a polymeric molecule having one or more monomeric species, and includes homopolymers and copolymers. The term "copolymer" refers to a polymer having two or more monomeric species, and includes terpolymers (i.e., copolymers having three monomeric species). In some aspects, thermoplastic elastomers are random copolymers. In one aspect, thermoplastic elastomers are block copolymers. For example, a thermoplastic elastomer can be a block copolymer having repeating blocks (segments) of polymeric units having the same chemical structure that are relatively hard (hard segments), and repeating blocks of polymeric segments that are relatively soft (soft segments). In various aspects, in block copolymers (including block copolymers having repeating hard and soft segments), physical crosslinking can be present within or between blocks, or within and between blocks. Specific examples of hard segments include isocyanate segments and polyamide segments. Specific examples of soft segments include polyether segments and polyester segments. As used herein, polymer segments can be specific types of polymer segments, such as isocyanate segments, polyamide segments, polyether segments, polyester segments, etc. It should be understood that the chemical structure of the segment is derived from the stated chemical structure. For example, an isocyanate segment is a polymeric unit comprising an isocyanate functional group. When referring to a block of a polymer segment with a specific chemical structure, the block may contain up to 10 mol% of segments with other chemical structures. For example, as used herein, a polyether segment should be understood to include up to 10 mol% of non-polyether segments.

[0147] In one aspect, the clamping material (e.g., a first polymer composition) comprises a polymer component consisting of all the polymers present in the clamping material. Optionally, the polymer component may include two or more polymers.

[0148] When two or more polymers share segments having chemical structures falling within the same general polymer structure (e.g., polyester, polyamide, polyolefin, polyurethane, polystyrene, etc.), they can be considered polymers of the same "type". In one aspect, the shared segments can be polyester, polyamide, polyolefin, polyurethane, polystyrene, etc. According to this aspect, the polymer composition can be described as consisting of polyester, polyamide, polyolefin, polyurethane, polystyrene, etc. When none of the two or more polymers share segments having chemical structures falling within the same general polymer structure, the two or more polymers can be considered distinct from each other.

[0149] On the other hand, two or more polymers can share a common chemical structure because they all comprise segments with the same chemical structure, but each polymer can include a different number of segments, thus resulting in different molecular weights. For example, they may all be in the form of polyethylene terephthalate (PET), or they may all be in the form of nylon 6,6, or they may all be in the form of polyester-polyurethane copolymers, or they may all be in the form of ethylene styrene / butene styrene (SEBS) copolymers, etc. According to this aspect, the polymer composition can be described as consisting of PET, or as consisting of nylon 6,6, or as consisting of polyester-polyurethane, or as consisting of SEBS copolymers, etc.

[0150] In various aspects, the thermoplastic elastomer may include one or more of the following: thermoplastic copolyester elastomers, thermoplastic polyether block amide elastomers, thermoplastic polyurethane elastomers, polyolefin-based copolymer elastomers, thermoplastic styrene copolymer elastomers, thermoplastic ionomer elastomers, or any combination thereof. In one aspect, the first polymer composition comprises a thermoplastic elastomer styrene copolymer. In another aspect, the thermoplastic elastomer styrene copolymer may be a styrene-butadiene-styrene (SBS) block copolymer, a styrene-ethylene / butene-styrene (SEBS) copolymer, a styrene-acrylonitrile (SAN) copolymer, or any combination thereof. In one aspect, the clamping material comprises a thermoplastic elastomer polyester polyurethane, a thermoplastic polyether polyurethane, or any combination thereof. In some aspects, the thermoplastic elastomer polyester polyurethane may be an aromatic polyester, an aliphatic composition, or a combination thereof. It should be understood that other thermoplastic polymer materials not specifically described below may also be contemplated for use in the clamping materials and / or core materials described herein. In one aspect, the clamping material comprising the thermoplastic elastomer has a melting temperature greater than about 110 degrees Celsius and less than about 170 degrees Celsius. In another aspect, the clamping material comprising the thermoplastic elastomer has a melting temperature of about 110 degrees Celsius to about 170 degrees Celsius, about 115 degrees Celsius to about 160 degrees Celsius, about 120 degrees Celsius to about 150 degrees Celsius, about 125 degrees Celsius to about 140 degrees Celsius, about 110 degrees Celsius to about 150 degrees Celsius, or about 110 degrees Celsius to about 125 degrees Celsius.

[0151] In various aspects, when determined according to ASTM D3418-97 as described below, the thermoplastic elastomer has a glass transition temperature (Tg) of less than 50 degrees Celsius. In some aspects, when determined according to ASTM D3418-97 as described below, the thermoplastic elastomer has a glass transition temperature (Tg) of about -60 degrees Celsius to about 50 degrees Celsius, about -25 degrees Celsius to about 40 degrees Celsius, about -20 degrees Celsius to about 30 degrees Celsius, about -20 degrees Celsius to about 20 degrees Celsius, or about -10 degrees Celsius to about 10 degrees Celsius. In one aspect, the glass transition temperature of the thermoplastic elastomer is selected such that when an article incorporating the clamping material disclosed herein is bonded to footwear articles, the thermoplastic material remains above its glass transition temperature during normal wear (i.e., the thermoplastic elastomer is in its more rubbery and less brittle state).

[0152] In one aspect, the thermoplastic elastomer includes: (a) a plurality of first segments; (b) a plurality of second segments; and optionally, (c) a plurality of third segments. In various aspects, the thermoplastic elastomer is a block copolymer. In some aspects, the thermoplastic elastomer is a multiblock copolymer. In other aspects, the thermoplastic elastomer is a random copolymer. In still other aspects, the thermoplastic elastomer is a condensation copolymer.

[0153] In another aspect, the thermoplastic elastomer has a weight-average molecular weight of about 50,000 Daltons to about 1,000,000 Daltons; about 50,000 Daltons to about 500,000 Daltons; about 75,000 Daltons to about 300,000 Daltons; and about 100,000 Daltons to about 200,000 Daltons.

[0154] In another aspect, the thermoplastic elastomer has the following ratio of first segment to second segment: from about 1:1 to about 1:2 by weight of each of the first segment and the second segment; or from about 1:1 to about 1:1.5 by weight of each of the first segment and the second segment.

[0155] In another aspect, the thermoplastic elastomer has the following ratio of first segment to third segment: from about 1:1 to about 1:5 by weight of each of the first and third segments; from about 1:1 to about 1:3 by weight of each of the first and third segments; from about to about 1:2 by weight of each of the first and third segments; and from about to about 1:3 by weight of each of the first and third segments.

[0156] In another aspect, the thermoplastic elastomer has a first segment derived from a first component having a number average molecular weight of about 250 Daltons to about 6,000 Daltons; about 400 Daltons to about 6,000 Daltons; about 350 Daltons to about 5,000 Daltons; or about 500 Daltons to about 3,000 Daltons.

[0157] In some aspects, the thermoplastic elastomer includes phase-separated domains. For example, a plurality of first segments can be phase-separated into domains primarily comprising the first segments. Furthermore, a plurality of second segments derived from segments with different chemical structures can be phase-separated into domains primarily comprising the second segments. In some aspects, the first segments may include hard segments, and the second segments may include soft segments. In other aspects, the thermoplastic elastomer may include phase-separated domains comprising a plurality of first copolyester units.

[0158] In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a glass transition temperature from about 20 degrees Celsius to about -60 degrees Celsius. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a Taber abrasion resistance from about 10 mg to about 40 mg as determined by ASTM D3389. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has an indicated hardness (Shore A) from about 60 to about 90 as determined by ASTM D2240. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a specific gravity from about 0.80 g / cm³ to about 1.30 g / cm³ as determined by ASTM D792. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a melt flow index of about 2 g / 10 min to about 50 g / 10 min obtained at 160°C using a test weight of 2.16 kg. In another aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a melt flow rate greater than about 2 g / 10 min obtained at 190°C or 200°C using a test weight of 10 kg. In another aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a modulus of about 1 MPa to about 500 MPa.

[0159] [Example: Thermoplastic polyurethane elastomer] []

[0160] In some aspects, one or more thermoplastic elastomers used in the clamping material for clamping yarns include one or more thermoplastic polyurethane (TPU) elastomers or are substantially composed of one or more TPU elastomers. The thermoplastic polyurethane elastomer may be a thermoplastic polyurethane copolymer comprising hard segments and soft segments, including blocks of hard segments and blocks of soft segments. Hard segments may include segments derived from isocyanates or consist of segments derived from isocyanates. In the same or alternative aspects, soft segments may include segments derived from polyols or consist of segments derived from polyols, such as polyether segments or polyester segments, or a combination of polyether segments and polyester segments. In one aspect, one or more thermoplastic elastomers include or are substantially composed of elastomeric thermoplastic polyurethane, which comprises hard segments and soft segments, such as elastomeric thermoplastic polyurethane having repeating blocks of hard segments and repeating blocks of soft segments.

[0161] In various respects, one or more thermoplastic polyurethane elastomers are produced by polymerizing one or more isocyanates with one or more polyols to generate polymer chains having urethane bonds (—N(CO)O—), wherein each isocyanate-derived segment preferably comprises two or more isocyanate (—NCO) groups, such as 2, 3, or 4 isocyanate groups per segment (although monofunctional isocyanates may optionally be included, for example, as chain-terminating units). Additionally, the isocyanate-derived segments may also be extended with one or more chain extenders to bridge two or more isocyanate functional groups.

[0162] The term "aliphatic" refers to saturated or unsaturated organic molecules that do not include cyclic conjugated ring systems with delocalized π electrons. Examples of suitable aliphatic diisocyanates for producing thermoplastic polyurethane elastomers include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), succinate diisocyanate (BDI), dicyclohexylmethane diisocyanate (HMDI), 2,2,4-trimethylhexamethylene diisocyanate (TMDI), methylcyclohexane diisocyanate, methyltricyclodecane diisocyanate, norbornane diisocyanate (NDI), cyclohexane diisocyanate (CHDI), 4,4'-dicyclohexylmethane diisocyanate (H12MDI), dodecane diisocyanate, lysine diisocyanate, and combinations thereof.

[0163] The term "aromatic" refers to a cyclic conjugated ring system with delocalized π electrons, which exhibits greater stability than a hypothetical ring system with localized π electrons. Examples of suitable aromatic diisocyanates for producing thermoplastic polyurethane elastomers include toluene diisocyanate (TDI), adducts of TDI and trimethylolpropane (™P), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some aspects, thermoplastic polyurethane elastomers are substantially free of aromatic groups.

[0164] In certain aspects, thermoplastic polyurethane elastomers are produced from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. For example, clamping materials may include one or more thermoplastic polyurethane elastomers produced from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof.

[0165] In some respects, crosslinked thermoplastic polyurethane elastomers (e.g., partially crosslinked polyurethane elastomers that retain thermoplastic properties) or crosslinkable thermoplastic polyurethane elastomers may be used according to this disclosure. Crosslinked or crosslinkable polyurethane elastomers may be produced using polyfunctional isocyanates. Examples of suitable triisocyanates for producing polyurethane elastomers include adducts of TDI, HDI, and IPDI with trimethylolpropane (TMP), urea diketone (i.e., dimer isocyanates), polymeric MDI, and combinations thereof.

[0166] When chain extenders are used to form thermoplastic polyurethane elastomers, the specific chain extender polyols used can be, for example, aliphatic, aromatic, or polyether. Examples of suitable chain extender polyols for producing one or more thermoplastic polyurethane elastomers include ethylene glycol, lower oligomers of ethylene glycol (e.g., diethylene glycol, triethylene glycol, and tetraethylene glycol), 1,2-propanediol, 1,3-propanediol, lower oligomers of propylene glycol (e.g., dipropylene glycol, tripropylene glycol, and tetrapropylene glycol), 1,4-butanediol, 2,3-butanediol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol, 1,4-cyclohexanediol, 2-ethyl-1,6-hexanediol, 1-methyl-1,3-propanediol, 2-methyl-1,3-propanediol, dihydroxyalkylated aromatic compounds (e.g., bis(2-hydroxyethyl) ethers of hydroquinone and resorcinol, xylene-α,α-diol, bis(2-hydroxyethyl) ethers of xylene-α,α-diol, and combinations thereof).

[0167] Optionally, in some instances, one or more thermoplastic polyurethane elastomers include thermoplastic polyurethane elastomers with a relatively high degree of hydrophilicity. For example, the thermoplastic polyurethane elastomer may be a thermoplastic polyether polyurethane comprising segments including polyether groups, polyester groups, polycarbonate groups, aliphatic groups, or aromatic groups, wherein the aliphatic or aromatic groups are replaced by one or more side groups (i.e., relatively "hydrophilic" groups) with a relatively high degree of hydrophilicity. The relatively "hydrophilic" groups may be selected from the group consisting of: hydroxyl, polyether, polyester, polylactone (e.g., polyvinylpyrrolidone (PVP)), amino, carboxyl, sulfonate, phosphate, ammonium (e.g., tertiary ammonium and quaternary ammonium), zwitterions (e.g., betaine, such as poly(carboxybetaine) (pCB) and ammonium phosphonates, such as phosphatidylcholine), and combinations thereof. In such examples, the relatively hydrophilic group or segment can form parts of the main chain of the thermoplastic polyurethane elastomer, or can be grafted onto the main chain as a side group. In some examples, the hydrophilic side group or segment can be bonded to an aliphatic or aromatic group via a linker.

[0168] In some instances, at least one segment of the thermoplastic polyurethane elastomer comprises a polyether segment (i.e., a segment having one or more ether groups). Suitable polyethers include, but are not limited to, polyethylene oxide (PEO), polypropylene oxide (PPO), polytetrahydrofuran (PTHF), polytetramethylene oxide (PTmO), and combinations thereof. As used herein, the term "alkyl" refers to a straight-chain and branched saturated hydrocarbon group containing 1 to 30 carbon atoms, for example, 1 to 20 carbon atoms or 1 to 10 carbon atoms. The term Cn signifies an alkyl group having "n" carbon atoms. For example, C4 alkyl refers to an alkyl group having 4 carbon atoms. C1-7 alkyl refers to an alkyl group having a number of carbon atoms covering the entire range (i.e., 1 to 7 carbon atoms) and all subgroups (e.g., 1 to 6, 2 to 7, 1 to 5, 3 to 6, 1, 2, 3, 4, 5, 6, and 7 carbon atoms). Non-limiting examples of alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl (2-methylpropyl), tert-butyl (1,1-dimethylethyl), 3,3-dimethylpentyl, and 2-ethylhexyl. Unless otherwise indicated, an alkyl group may be an unsubstituted alkyl group or a substituted alkyl group.

[0169] In some aspects, one or more thermoplastic polyurethane elastomers include one or more polyester segments. These polyester segments can be derived from the polyesterification of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol, 1,5-diethylenediol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanediol, and combinations thereof) with one or more dicarboxylic acids (e.g., adipic acid, succinic acid, sebacic acid, octanoic acid, methyl adipic acid, glutaric acid, pimelic acid, azelaic acid, thiodipropionic acid, and citralic acid, and combinations thereof). The polyester segments can also be derived from polycarbonate prepolymers such as poly(hexamethylene carbonate) glycol, poly(propylene carbonate) glycol, poly(tetramethylene carbonate) glycol, and poly(nonylmethylene carbonate) glycol. Suitable polyesters may include, for example, polyethylene adipate (PEA), poly(1,4-butanediol adipate), poly(tetramethylene adipate), poly(hexamethylene adipate), polycaprolactone, polyhexamethylene carbonate, poly(propylene carbonate), poly(tetramethylene carbonate), poly(nonylmethyl carbonate), and combinations thereof.

[0170] In all respects, thermoplastic polyurethane elastomers include one or more polycarbonate segments. These one or more polycarbonate segments can be derived from the reaction of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol, 1,5-diethylenediol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanediol, and combinations thereof) with ethylene carbonate.

[0171] As described herein, thermoplastic polyurethane elastomers can be physically crosslinked, for example, through nonpolar or polar interactions between urethane groups on or between polymers. In these respects, soft segments can be covalently bonded to hard segments. In some respects, thermoplastic polyurethane elastomers having physically crosslinked hard and soft segments can be hydrophilic thermoplastic polyurethane elastomers (i.e., thermoplastic polyurethane elastomers disclosed herein that include hydrophilic groups).

[0172] In one respect, prior to thermoforming, the thermoplastic polyurethane elastomer is an aromatic polyester thermoplastic elastomer polyurethane or an aliphatic polyester thermoplastic elastomer polyurethane, having the following properties: (1) a glass transition temperature from about 20°C to about -60°C; (2) a Tiber abrasion resistance from about 10 mg to about 40 mg as determined by ASTM D3389; (3) an indicated hardness (Shore A) from about 60 to about 90 as determined by ASTM D2240; and (4) a hardness from about 0.80 g / cm³ to about 1.30 g / cm³ as determined by ASTM D792. (5) Specific gravity of g / cm3; (6) Melt flow index of about 2 g / 10 min to about 50 g / 10 min obtained at 160 degrees Celsius using a test weight of 2.16 kg; (7) Melt flow rate of more than about 2 g / 10 min obtained at 190 degrees Celsius or 200 degrees Celsius using a test weight of 10 kg; and (8) Modulus of about 1 MPa to about 500 MPa.

[0173] Commercially available thermoplastic polyurethane elastomers suitable for use in this disclosure include, but are not limited to, those traded under the name “TECOPHILIC”, such as TG-500, TG-2000, SP-80A-150, SP-93A-100, SP-60D60 (Lubrizol, Countryside, Illinois), “ESTANE” (e.g., 58238, T470A; Lubrizol, Countryside, Illinois), and “ELASTOLLAN” (e.g., 9339, 1370A; BASF).

[0174] [Example: Thermoplastic styrene copolymer elastomer] []

[0175] In some aspects, one or more thermoplastic elastomers comprise or are substantially composed of one or more thermoplastic elastomer styrene polymers, including one or more thermoplastic styrene copolymers. Examples of such copolymers include, but are not limited to, styrene-butadiene-styrene (SBS) block copolymers, styrene-ethylene / butene-styrene (SEBS) copolymers, polyacetal (POM) copolymers, styrene-acrylonitrile (SAN) copolymers, and combinations thereof. Exemplary commercially available thermoplastic elastomer styrene copolymers include MONOPRENE IN5074, SP066070, and SP16975 (Teknor Apex, Pottacket, Rhode Island, USA), which are styrene-ethylene / butene-styrene (SEBS) resins. In some aspects, blends, alloys, and mixtures of one or more thermoplastic elastomers are melt-compatible or can be compatible with additives, oils, or grafted chemical moieties to achieve miscibility.

[0176] On the other hand, one or more thermoplastic elastomer styrene copolymers may include SBS block copolymers or consist essentially of SBS block copolymers, which include a first polystyrene block, a polybutadiene block, and a second polystyrene block.

[0177] On the other hand, one or more thermoplastic elastomers may include SEBS block copolymers or consist substantially of SEBS block copolymers, wherein the SEBS block copolymers include a first polystyrene block, a polyolefin block, and a second polystyrene block, wherein the polyolefin block includes alternating polyethylene blocks and polybutene blocks.

[0178] In one aspect, one or more SEBS copolymers have a density from about 0.88 g / cm³ to about 0.92 g / cm³. In another aspect, the density of one or more SEBS copolymers can be as low as 15% to 25% lower than that of crosslinked rubber, crosslinked polyurethane, and thermoplastic polyurethane materials. Where the polymer composition of the clamping material includes one or more SEBS copolymers or is substantially composed of one or more SEBS copolymers, the density of the clamping material is lower than that when other thermoplastic elastomers such as TPU elastomers are used. The lower density clamping material achieves similar performance while saving weight and unit part cost for the same volume of material used.

[0179] The reference to "a compound" refers to one or more molecules of that compound, and is not limited to a single molecule of that compound. Furthermore, the one or more molecules can be the same or different, as long as they fall within the category of that compound. Thus, for example, "polyamide" is interpreted as including one or more polymer molecules of polyamide, wherein the polymer molecules can be the same or different (e.g., different molecular weights and / or isomers).

[0180] The terms “at least one” and “one or more” are used interchangeably and have the same meaning, including both single and multiple elements, and can also be indicated by the suffix “(s)” at the end of the element. For example, “at least one polyamide,” “one or more polyamides,” and “polyamide” are used interchangeably and have the same meaning.

[0181] Unless otherwise specified, the temperatures mentioned herein are determined at standard atmospheric pressure (i.e., 1 ATM).

[0182] [Property Analysis and Characterization Procedures] []

[0183] The evaluation of the various properties and characteristics described in this article is carried out through the various test procedures described below.

[0184] Sample coefficient of friction. The static or dynamic coefficient of friction (COF) of a fabric or board sample can be determined using the test method ASTM D1894. In this method, the sample is cut to a specified size and mounted on a slide, with a 100-gram weighted plate placed on the slide. During the test, the weighted slide is pulled across the test surface of the material being tested. For example, the static and dynamic wet and dry COFs can be determined by pulling the slide across a concrete surface to determine the COF of the sample and the concrete. The coefficient of friction of the sample relative to the surface is captured by recording the normal force (100 grams plus the slide weight) and measuring the force required to pull the slide across the test surface. The coefficient of friction (COF) is then calculated based on the ratio of the two forces. The dry COF is determined by testing a dry sample relative to a dry test surface, and the wet COF is determined by testing a water-wetted sample relative to a test surface wetted with room temperature water, where wetting of the sample is performed by immersing it in room temperature water for 10 minutes.

[0185] Fabric-Ball Friction Coefficient Test. The static and dynamic coefficients of friction (COF) of a sample prepared using the component sampling procedure or fabric sampling procedure described below relative to a sample from an insert of a “MERLIN” soccer ball (NIKE Inc., Beaverton, Oregon, USA) can be determined using a modified version of the test method for sample friction described in ASTM D1894. In this method, the sample is cut to size and mounted on an acrylic substrate, and the ball material is cut to size and mounted on a skateboard. Once the ball material has been mounted on the skateboard, the skateboard has a 3.9-inch × 1-inch contact imprint and a weight of approximately 0.402 kg. During the test, the sample and ball material are positioned such that the outward-facing surface of the ball material contacts the outward-facing surface of the sample intended to form the footwear article, and the skateboard is pulled across the sample. Dry sample and dry ball material are used to determine the static or dynamic dry COF. To determine the static or dynamic wet COF, both the sample and ball material are immersed in room temperature water for 10 minutes and then tested immediately. Each measurement is repeated at least three times, and the results are averaged.

[0186] Melting and Glass Transition Temperature Testing. The melting and / or glass transition temperature of samples prepared according to the material sampling procedure described below were determined using a commercially available differential scanning calorimeter (“DSC”) according to ASTM D3418-97. Briefly, 10 to 60 mg of sample was placed in an aluminum DSC pan, and the cap was sealed with a coil press. The DSC was configured to scan from -100°C to 225°C at a heating rate of 20°C / min, held at 225°C for 2 minutes, and then cooled to 25°C at a rate of -20°C / min. The DSC curves generated from this scan were then analyzed using standard techniques to determine the glass transition temperature and melting temperature. The enthalpy of melting was calculated by integrating the endothermic reaction of melting and normalizing it to the mass of the sample. The enthalpy of crystallization upon cooling was calculated by integrating the endothermic reaction of cooling and normalizing it to the mass of the sample.

[0187] Deformation Temperature Test. The Vicat softening temperature of a sample prepared according to the material sampling procedure or component sampling procedure described below is determined according to the test method described in ASTM Tm D1525-09, "Standard Test Method for Vicat Softening Temperature of Plastics," preferably using load A and rate A. In short, the Vicat softening temperature is the temperature at which a flat-tipped needle penetrates the sample to a depth of 1 mm under a specific load. This temperature reflects the expected softening point when the material is used in high-temperature applications. It is considered to be the temperature at which the sample is penetrated to a depth of 1 mm by a flat-tipped needle with a circular or square cross-section of 1 square millimeter. For the Vicat A test, a load of 10 Newtons (N) is used, while for the Vicat B test, the load is 50 Newtons. The test involves placing the test sample in the test apparatus such that the penetrating needle is positioned on its surface at least 1 mm from the edge. A load is applied to the sample according to the requirements of the Vicat A or Vicat B test. The sample is then placed in an oil bath at 23°C. The oil bath is heated at a rate of 50°C or 120°C per hour until the needle penetrates 1 mm. The thickness of the test samples must be between 3 and 6.5 mm, and the width and length must be at least 10 mm. No more than three layers can be stacked to achieve the minimum thickness.

[0188] Melt Flow Index Test. The melt flow index of a sample prepared according to the material sampling procedure described therein is determined using Procedure A, as detailed in ASTM D1238-13, "Standard Test Method for Determining Melt Flow Rate of Thermoplastic Plastics by Extrusion Plasticity Tester." In short, the melt flow index measures the rate at which a thermoplastic plastic is extruded through an orifice at a specified temperature and load. In the test method, approximately 7 grams of material is loaded into the barrel of a melt flow apparatus that has been heated to the specified temperature. The specified weight of material is applied to the plunger, forcing the molten material through the die. The extrudate is collected at a time and weighed. For a given applied load and temperature, the melt flow index value is calculated in g / 10 minutes. As described in ASTM D1238-13, the melt flow index can be determined using a weight of 2.16 kg at 160°C or a weight of 10 kg at 200°C.

[0189] Melting polymer viscosity testing. Testing is performed using 2 mm plates or films prepared according to the plate or film sampling procedure described below. A 50 mm sample disk is cut from the plate or film using a circular die. The test sample is mounted on a 50 mm diameter aluminum parallel plate on an ARES-G2 (displacement-controlled) rheometer. The top plate is lowered so that the test sample contacts both disk surfaces under a defined normal force load, and the stage is heated to 210°C. The sample is equilibrated until melted within a defined residence time of several minutes, and an oscillating shear frequency scan is applied at low strain amplitude to collect rate-dependent data. The ratio of applied shear stress required to generate oscillating motion at a given shear frequency produces the measured viscosity value. Shear rate-dependent viscosity data can be collected from 0.1 counts to 1000 counts.

[0190] Plate Modulus Test. The modulus of a sample prepared according to the plate or film sampling procedure described below is determined according to the test method described in ASTM D412-98, "Standard Test Methods for Vulcanized Rubber and Thermoplastic Rubber and Thermoplastic Elastomers—Tension," with the following modifications. The sample size is ASTM D412-98 die C, and the sample thickness used is 2.0 mm ± 0.5 mm. The clamping type used is a pneumatic clamp with a metal serrated clamping surface. The clamping distance used is 75 mm. The loading rate used is 500 mm / min. The modulus (initial) is calculated by taking the slope of stress (MPa) against strain in the initial linear region. This test can also be used to determine other tensile properties, such as breaking strength, breaking strain, load at 100% strain, toughness, stiffness, tear strength, etc.

[0191] Yarn denier and thickness testing. To determine the denier, yarn samples were prepared according to the yarn sampling procedure described below. The known length of the yarn sample and its corresponding weight were measured. This was converted to grams per 9000 meters of yarn. To determine the thickness of the coated yarn, the yarn was first cut with a razor and observed under a microscope, where the coating thickness was determined proportionally to the diameter of the core yarn.

[0192] Yarn modulus, toughness, and elongation testing. Determine the yarn modulus of the samples prepared according to the yarn sampling procedure described above, and test the yarn modulus according to the test method described in EN ISO 2062 (Fabrics—Nails)—"Determination of single-end breaking force and elongation at break using a constant rate of elongation (CRE) tester". Use the following modifications to the test method. Prepare five test specimens with a sample length of 600 mm. The equipment used is an Instron universal testing system. Install an Instron pneumatic cord clamp or similar pneumatic clamp with a clamping distance of 250 mm. When using an Instron pneumatic cord clamp, set the clamping distance to 145 ± 1 mm and the gauge length to 250 ± 2 mm. Set the preload to 5 grams and the loading rate to 250 mm / min. Calculate the modulus (initial) by taking the slope of stress (MPa) versus strain in the initial linear region. Record the maximum tensile force value. The toughness and elongation of the yarn samples were determined according to the test methods described in detail in EN ISO 2062, where the preload was set to 5 grams. Elongation was recorded at the maximum tensile force applied before breakage. In some respects, toughness was calculated as the ratio of the load required to break the sample to the linear density of the sample.

[0193] Specific Gravity Test. Specific gravity (SG) is determined using volume displacement according to the test method described in ASTM D792. For example, the SG of samples obtained using a plate sampling program or component sampling program is measured using a digital balance or a Densicom tester (Qualitest, Plantation, Florida, USA). Each sample is weighed (g) and then immersed in a distilled water bath (22°C ± 2°C). To avoid error, air bubbles are removed from the sample surface, for example by wiping the sample with isopropyl alcohol before immersion in water, or by using a brush to remove air bubbles after immersion. The weight of the sample in distilled water is recorded. Specific gravity is calculated using the following formula:

[0194]

[0195] Indicative hardness testing. The hardness of a material can be determined using the Shore A scale, according to the test methods described in ASTM D-2240 "Indicative Hardness".

[0196] Yarn Shrinkage Test. The independent shrinkage rate of yarn can be determined by the following method. Prepare a yarn sample according to the yarn sampling procedure described below and cut it into lengths of approximately 30 mm at approximately room temperature (e.g., 20 degrees Celsius) with minimal tension. Place the cut sample in an oven at 50 degrees Celsius or 70 degrees Celsius for 90 seconds. Remove the sample from the oven and measure it. Using the measurements of the sample before and after the oven, calculate the shrinkage percentage by dividing the measurement after the oven by the measurement before the oven and multiplying by 100.

[0197] Stoll abrasion test. The Stoll abrasion test can be used to measure abrasion resistance, including resistance to simulated footwear upper scuffing, using samples prepared according to the component sampling procedure, plate or film sampling procedure, or fabric sampling procedure described below. The minimum number of samples used for the Stoll abrasion test is 3. The samples used herein are hand-cut or die-cut into circles with a diameter of 112 mm. The Stoll abrasion test is described more fully in ASTM D3886 and can be performed on an Atlas universal abrasion tester. In the Stoll abrasion test, an abrasive medium is moved over a fixed test sample, and the visual appearance of the sample is monitored. The Stoll abrasion test is performed under pressure to simulate wear under normal use.

[0198] DIN Abrasion Test. Samples were prepared according to the component sampling procedure, plate or film sampling procedure, or fabric sampling procedure described below. Abrasion loss was tested on cylindrical samples with a diameter of 16 ± 0.2 mm and a minimum thickness of 6 mm using an ASTM standard hole drill. Abrasion loss was measured on a Gotech GT-7012-D abrasion testing machine using ASTM D 5963-97a Method B. The test was performed at 22 degrees Celsius over a 40-meter abrasion path. The standard rubber #1 used in the test had a density of 1.336 g / cm³. Lower abrasion loss indicates better abrasion resistance.

[0199] Permeability Testing. The permeability of a sample is determined as follows, using a sample prepared according to the component sampling procedure, plate or membrane sampling procedure, or fabric sampling procedure described below. The sample to be tested is mounted on a support base at a 45-degree angle to the horizontal plane. The support base includes an inner ring for the sample holder with a diameter of 152 mm. Allow the sample to equilibrate in a laboratory environment for at least 2 hours prior to testing. The test sample is cut into a circle with a diameter of 220 mm. For thicker or stiffer materials (such as leather or hard synthetic leather), three slits are cut into the outer edge of the sample. The sample can be hand-cut or die-cut. For softer materials, test samples are cut to the same size, and the length direction is marked on the test sample. The backing paper is prepared from white or off-white tissue paper, coffee filter paper, or similar thin absorbent paper. The backing paper is also cut into a circle with a diameter of 220 mm. One backing paper is prepared for each test sample, and the backing paper cannot be reused. The backing paper and sample are placed in a sample holder, which in turn is placed in a spray test apparatus. The sample length should be parallel to the water flow direction. Adjust the funnel to a height of 6 inches (152.4 mm) between the spray nozzle and the test sample. The spray nozzle must be above the center of the test sample. Add 250 ± 2 mL of distilled water to the funnel to spray the water onto the test sample. Evaluate the water repellency of the top surface within 10 seconds of the spray ending. After evaluating the top surface, remove the sample holder from the support base and evaluate the backing paper to determine if water has penetrated through the sample. Report the permeability after visual evaluation and rate the sample as "pass" or "fail" based on the degree of wetting. The sample is considered to have passed if no adhesion or wetting of the top surface is observed, if slight random adhesion or wetting of the top surface is observed, or if wetting of the top surface is observed at the spray point. Further wetting beyond the spray point and / or including the rear surface indicates that the sample has failed the permeability test.

[0200] Fabric-Ball Impact Test. Prepare a test sample of the fabric according to the component sampling procedure or fabric sampling procedure described below. Mount the 10-inch × 8-inch test sample of the fabric onto the outer surface of a metal cylinder with a 10-inch circumference. Mount the test sample and cylinder onto a robot arm that swings at a speed of 50 mph and impacts the equator of a stationary ball. The ball used is a legally sized Nike "MERLIN" soccer ball inflated to 0.80 bar. A high-speed camera is used to record the ball's position immediately following the impact. Using the ball's spatial position and rotation over multiple frames of images recorded by the high-speed camera, software is then used to calculate the ball's velocity and spin rate immediately following the impact. Each measurement is repeated at least three times, and the results are averaged.

[0201] Upper-ball impact test. The upper of a full men's size 10.5 soccer boot or a men's size 10.5 soccer boot was mounted on a robotic arm and positioned so that the ball impacted the boot on the inside of the upper, on or near the laces (if the boot includes a lace-up structure), and the upper impacted the ball's equator as the robotic arm swung at a rate of 50 mph. The ball used was a legally sized Nike "MERLIN" soccer ball inflated to 0.80 bar. A high-speed camera was used to record the ball's position immediately following the impact. Using the ball's spatial position and rotation across multiple frames of images recorded by the high-speed camera, software was used to calculate the ball's velocity and spin rate immediately following the impact. Each measurement was repeated at least three times, and the results were averaged.

[0202] [Sampling Program] []

[0203] Using the above tests, the various properties of the materials disclosed herein and articles formed therefrom can be characterized using samples prepared with the following sampling procedure:

[0204] Material sampling procedures. Material sampling procedures can be used to obtain pure samples of polymer compositions or polymers, or in some cases, samples of the materials used to form polymer compositions or polymers. Materials are provided in the form of media, such as flakes, granules, powders, pellets, etc. If the source of the polymer material or polymer cannot be obtained in pure form, a sample can be cut from a part or component containing the polymer material or polymer (such as a composite element or shoe sole structure) to isolate the material sample.

[0205] Plate or film sampling procedure. Prepare a sample of the polymer composition or polymer. Then mold the polymer or a portion of the polymer composition into a film or plate of a size suitable for the testing equipment. For example, when using a Ross flexure tester, make the plate or film sample size suitable for the inside of the Ross flexure tester by thermoforming the polymer composition or polymer in a mold to give the sample a size of about 15 cm × 2.5 cm and a thickness of about 1 mm to about 4 mm. For a plate sample of polymer, the sample can be prepared by the following steps: melting the polymer, loading the molten polymer into a mold, re-curing the polymer into the shape of the mold, and removing the cured molded sample from the mold. Alternatively, the sample of polymer can be melted and then extruded into a film, which is then cut to a certain size. For a sample of polymer composition, the sample can be prepared by the following steps: blending the components of the polymer composition together, melting the thermoplastic component of the polymer composition, loading the molten polymer composition into a mold, re-curing the polymer composition into the shape of the mold, and removing the cured molded sample from the mold. Alternatively, a sample of the polymer material can be prepared by mixing and melting the components of the polymer composition, and the molten polymer composition can then be extruded into a film, which is then cut to a specified size. For the film sample of the polymer or polymer composition, the film is extruded into a web or sheet having a substantially constant film thickness (within ±10% of the average film thickness) and cooled to solidify the resulting web or sheet. A sample with a surface area of ​​4 square centimeters is then cut from the resulting web or sheet. Alternatively, if the source of the film material is not available in a pure form, the film can be cut from a substrate of the footwear component or from a backing substrate of the co-extruded sheet or web, thereby isolating the film. In either case, a sample with a surface area of ​​4 square centimeters is then cut from the resulting isolated film.

[0206] Component Sampling Procedure. This procedure can be used to obtain samples of material from components of footwear, apparel, sports equipment, or other footwear products, including polymer compositions or fabrics, or samples of portions of fabrics (such as thermoformed mesh). A blade is used to cut samples of material from the product or component, including material in a non-wetted state (e.g., at 25 degrees Celsius and 20% relative humidity). If the material is bonded to one or more additional materials, the procedure may include separating the additional materials from the material being tested. For example, to test material on the ground-facing surface of a shoe sole structure, the opposite surface may be peeled, abraded, scratched, or otherwise cleaned to remove any adhesives, yarns, fibers, foams, etc., attached to the material being tested. The resulting sample includes the material and may include any additional materials bonded to it.

[0207] A sample is taken at a location along the article or component that provides a substantially constant material thickness (within ±10% of the average material thickness) for the material present on the article or component, such as in footwear, in the forefoot, midfoot, or heel area of ​​the ground-facing surface. For many of the above test protocols, a sample with a surface area of ​​4 square centimeters (cm²) is used. The sample is cut to a size and shape suitable for the test equipment (e.g., a dog bone-shaped sample). Where the material is not present in any segment of the article or component with a surface area of ​​4 square centimeters, and / or where the material thickness is not substantially constant for segments with a surface area of ​​4 square centimeters, a sample size with a smaller cross-sectional surface area can be obtained and the area-specific measurement adjusted accordingly.

[0208] Yarn sampling procedure. Before testing, store the yarn to be tested at room temperature (20°C to 24°C) for 24 hours. Discard the first 3 meters of material. Cut the sample yarn into lengths of approximately 30 mm at approximately room temperature (e.g., 20°C) with minimal tension.

[0209] Fabric sampling procedure. Before testing, store the fabric to be tested at room temperature (20 to 24 degrees Celsius) for 24 hours. Cut the fabric sample at approximately room temperature (e.g., 20 degrees Celsius) with minimal tension to the size specified by the test method to be used.

[0210] [Example Terms] []

[0211] Clause 1: An upper comprising: a knitted component having a plurality of intertwined rows of loops defining a plurality of wedge-shaped portions of the knitted component, each of the plurality of wedge-shaped portions being defined by a portion of an outer periphery of the knitted component, a portion of an inner periphery of the knitted component, a first row of knitted loops extending from the outer periphery to the inner periphery, and a second row of knitted loops extending from the outer periphery to the inner periphery.

[0212] Clause 2: The upper as described in Clause 1, wherein the portion defining the wedge-shaped portion of the inner periphery has a shorter length than the portion defining the wedge-shaped portion of the outer periphery.

[0213] Clause 3: The upper according to any one of Clauses 1 to 2, wherein each wedge portion includes a full-length coil row positioned between the first coil row and the second coil row and extending from the outer periphery to the inner periphery, and includes a portion-length coil row positioned between the first coil row and the second coil row and extending from the outer periphery and terminating before the inner periphery.

[0214] Clause 4: The upper according to any one of Clauses 1 to 3, wherein at least some of the wedge-shaped portions of the knitted component form the forefoot area of ​​the upper.

[0215] Clause 5: The upper according to any one of Clauses 1 to 4, wherein at least some of the wedge-shaped portions of the knitted component form the midfoot area of ​​the upper.

[0216] Clause 6: The upper according to any one of Clauses 1 to 3, wherein at least some of the wedge-shaped portions of the knitted component form the heel area of ​​the upper.

[0217] Clause 7: The upper according to any one of Clauses 1 to 6, wherein the knitted component includes a restraint region, the restraint region including a first material, the first material being at least partially fused to one or more intertwined yarns of the knitted component, wherein the first material includes a thermoplastic elastomer.

[0218] Clause 8: The upper according to Clause 7, wherein the first material is at least partially fused to one or more intertwined yarns of the knitted component on the outward-facing surface of the upper.

[0219] Clause 9: The upper according to any one of Clauses 7 to 8, wherein the portion of the knitted component having the first material has a different coefficient of friction relative to the portion of the knitted component not having the first material.

[0220] Clause 10: The upper as described in Clause 9, wherein the portion of the knitted component having the first material has a greater coefficient of friction than the portion of the knitted component not having the first material.

[0221] Clause 11: The upper according to any one of Clauses 7 to 10, wherein the constrained area includes at least one tensile element formed at least partially fused to at least one of the one or more yarns of the first material.

[0222] Clause 12: The upper according to any one of Clauses 7 to 11, wherein the restraining region is a first restraining region located on the outer side of the upper and at least partially in the forefoot area, wherein the upper further comprises a second restraining region extending on the inner side of the upper and at least partially in the forefoot area.

[0223] Clause 13: The upper according to Clause 12, wherein the first material is at least partially fused to one or more intertwined yarns in the first constraint region, the second constraint region, and a portion of the forefoot region between the first constraint region and the second constraint region.

[0224] Clause 14: The upper according to any one of Clauses 7 to 13, wherein the first material forms a coating comprising the thermoplastic elastomer, the coating surrounding a core yarn having a second material that excludes the thermoplastic elastomer and has a greater melting temperature than the first material.

[0225] Clause 15: The upper according to any one of Clauses 7 to 14, wherein the thermoplastic elastomer is thermoplastic polyurethane.

[0226] Clause 16: The upper according to any one of Clauses 7 to 14, wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

[0227] Clause 17: An upper comprising: a knitted component forming at least a forefoot region and a midfoot region of the upper and having an outer periphery, the forefoot region and the midfoot region being integrally knitted, the knitted component having an outward-facing surface and an inward-facing surface opposite to the outward-facing surface, each row of loops in the forefoot region and the midfoot region extending in a direction from the outer periphery toward a common portion of the knitted component such that the rows of loops in the forefoot region extend diagonally relative to the rows of loops in the midfoot region; the knitted component having a constrained region extending from the outer periphery toward the common portion, the constrained region comprising a first material at least partially fused to one or more intertwined yarns of the knitted component, the first material comprising a thermoplastic elastomer.

[0228] Clause 18: The upper as described in Clause 17, wherein the first material is located on the outward-facing surface of the knitted component.

[0229] Clause 19: The upper according to any one of Clauses 17 to 18, wherein the constrained area has a different coefficient of friction than the portion of the knitted component without the first material.

[0230] Clause 20: The upper according to any one of Clauses 17 to 19, wherein the constrained area has a greater coefficient of friction than the portion of the knitted component without the first material.

[0231] Clause 21: The upper according to any one of Clauses 17 to 20, wherein the thermoplastic elastomer is thermoplastic polyurethane.

[0232] Clause 22: The upper according to any one of Clauses 17 to 20, wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

[0233] Clause 23: The upper according to any one of Clauses 17 to 22, wherein the common portion is the throat area.

[0234] Clause 24: The upper according to any one of Clauses 17 to 23, wherein the knitted component forms the heel area of ​​the upper, and each row of loops within the heel area extends in a direction toward the common portion.

[0235] Clause 25: The upper according to any one of Clauses 17 to 24, wherein the restraint area comprises a plurality of adjacent coil rows and extends from the outer periphery in the forefoot area to the common portion in the midfoot area.

[0236] Clause 26: The upper according to any one of Clauses 17 to 25, wherein the restraint region is a first restraint region located on the outer side of the upper, wherein the upper further includes a second restraint region extending from the outer periphery of the forefoot area on the inner side of the upper to the common portion of the midfoot area on the inner side of the upper, the first restraint region and the second restraint region each having a greater coefficient of friction than the portion of the knitted component without the first material.

[0237] Clause 27: The upper according to Clause 26, wherein the upper further comprises a third constraint region and a fourth constraint region, the third constraint region extending from the outer periphery of the heel area on the outer side of the upper to the common portion of the midfoot area on the outer side of the upper, and the fourth constraint region extending from the outer periphery of the heel area on the inner side of the upper to the common portion of the midfoot area on the inner side, the third constraint region and the fourth constraint region each having a greater coefficient of friction than the portion of the knitted component without thermoplastic elastomer material.

[0238] Clause 28: The upper according to Clause 27, wherein the first constraint region, the second constraint region, the third constraint region and the fourth constraint region are each separated from each other by a portion of the knitted component on the outward-facing surface where the thermoplastic elastomer material is not present.

[0239] Clause 29: The upper according to Clause 27, wherein the outward-facing surface of the knitted component includes one or more regions along the outer periphery of the knitted component, the one or more regions including the thermoplastic elastomer material at least partially fused to one or more intertwined yarns, wherein the one or more regions along the outer periphery are located between the first constraint region and the third constraint region, between the first constraint region and the second constraint region, and between the second constraint region and the fourth constraint region, wherein the one or more regions along the outer periphery extend from the outer periphery and terminate below the common portion.

[0240] Clause 30: The upper according to any one of Clauses 17 to 29, wherein the yarn at least partially fused to the first material includes a core yarn having a second material that excludes the thermoplastic elastomer and has a higher melting temperature than the first material.

[0241] Clause 31: The upper according to any one of Clauses 17 to 29, wherein one or more yarns at least partially fused to the first material comprises coated yarns having a core having a coating comprising the first material.

[0242] Clause 32: The upper according to any one of Clauses 17 to 31, wherein the one or more yarns at least partially fused to the first material include at least one tensile element extending from the outer periphery toward the common portion.

[0243] Clause 33: The upper according to Clause 32, wherein the one or more yarns comprise a core yarn and a second yarn, the core yarn and the second yarn each having a higher melting temperature than the first material, and the at least one tensile element comprises strands embedded along a row of coils formed by the coils of the core yarn and the second yarn.

[0244] Clause 34: The upper according to Clause 33, wherein at least one tensile element comprises strands forming a repeating sequence of knitted stitches and float stitches along the loop rows within the constrained area.

[0245] Clause 35: The upper according to any one of Clauses 17 to 34, wherein the one or more yarns comprise a high-tenacity yarn and a core yarn, the high-tenacity yarn and the core yarn each having a higher melting temperature than the first material, and the high-tenacity yarn having a tenacity of at least 5 g / denier.

[0246] Clause 36: The upper as described in Clause 35, wherein a portion of the outer-facing surface of the knitted component adjacent to the constrained area excludes the first material and includes the high-tenacity yarn.

[0247] Clause 37: The upper according to any one of Clauses 17 to 36, wherein the upper has a weight of 30 grams or less.

[0248] Clause 38: The upper according to any one of Clauses 17 to 37 further includes a polymer layer extending over at least a portion of the outer surface of the knitted component, the polymer layer comprising a polymer material having a melting temperature lower than that of the first material.

[0249] Clause 39: The upper according to Clause 38, wherein the polymer layer extends over at least a portion of the restraint area and includes a plurality of holes exposing portions of the restraint area.

[0250] Clause 40: A footwear article comprising an upper according to any one of Clauses 17 to 39, wherein the upper is attached to a sole structure.

[0251] Clause 41: An upper comprising: a knitted component forming at least a forefoot region and a midfoot region of the upper and having an outer periphery, the forefoot region and the midfoot region being knitted integrally, each row of loops in the knitted component in the forefoot region and the midfoot region extending in a direction from the outer periphery toward a common portion of the knitted component such that the rows of loops in the forefoot region extend diagonally relative to the rows of loops in the midfoot region; the knitted component having a first region and a second region, each of the first region and the second region having rows of loops extending from the outer periphery toward the common portion, the first region comprising a first yarn having a first material having a first melting temperature, and the second region comprising a second yarn having a second material having a second melting temperature greater than the first melting temperature, the first material not being present in the second region.

[0252] Clause 42: The upper as described in Clause 41, wherein the common portion is the throat area.

[0253] Clause 43: The upper according to any one of Clauses 41 to 42, wherein the first yarn comprises a core having a coating formed of the first material, the coating forming a surface that is at least partially fused in the first region.

[0254] Clause 44: The upper according to any one of Clauses 41 to 43, wherein the first region has a greater coefficient of friction than the second region.

[0255] Clause 45: The upper according to any one of Clauses 41 to 44, wherein the first material comprises a thermoplastic elastomer.

[0256] Clause 46: The upper as described in Clause 45, wherein the thermoplastic elastomer is thermoplastic polyurethane.

[0257] Clause 47: The upper as described in Clause 45, wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

[0258] Clause 47: The upper according to any one of Clauses 41 to 47, wherein the first region extends from the forefoot region to the midfoot region on the outer side of the upper.

[0259] Clause 49: The upper according to Clause 48 further includes a third region extending on the inner side from the forefoot region to the midfoot region, the third region including the first yarn, wherein the first region and the third region are separated by the second region.

[0260] Clause 50: The upper as described in Clause 49, wherein the first region and the third region each include at least one tensile element extending from the outer periphery toward the common portion.

[0261] Clause 51: The upper according to Clause 50, wherein the at least one tensile element comprises strands embedded along the loops of intertwined yarns.

[0262] Clause 52: The upper according to Clause 50, wherein the at least one tensile element comprises strands of yarn forming a repeating sequence of knitted stitches and float stitches along the loops of the intertwined yarns.

[0263] Clause 53: The upper according to any one of Clauses 49 to 52, wherein the upper further comprises a fourth region and a fifth region, the fourth region being on the outer side and extending from the heel region to the midfoot region, the fifth region being on the inner side and extending from the heel region to the midfoot region, the fourth region and the fifth region each comprising the first yarn.

[0264] Clause 54: A footwear article comprising an upper according to any one of Clauses 41 to 53, wherein the upper is attached to a sole structure.

[0265] Clause 55: An upper comprising: a knitted component including an outward-facing surface and an inward-facing surface, a first region of the outward-facing surface of the knitted component including a first material, the first material not present in a second region of the outward-facing surface of the knitted component, the first region having a greater coefficient of friction than the second region; and a polymer layer extending over a portion of the outward-facing surface of the knitted component, the polymer layer including pores, and wherein portions of the first material in the first region are exposed through at least some of the pores.

[0266] Clause 56: The upper according to Clause 55, wherein the first region comprises a thermoformed network of intertwined yarns formed by core yarns and a coating, the coating comprising the first material fused within the thermoformed network of intertwined yarns.

[0267] Clause 57: The upper according to any one of Clauses 55 to 56, wherein the first material comprises a thermoplastic elastomer.

[0268] Clause 58: The upper according to any one of Clauses 55 to 57, wherein the polymer layer comprises a second material having a lower melting temperature than the first material.

[0269] Clause 59: The upper according to any one of Clauses 55 to 58, wherein the polymer layer extends over the forefoot, midfoot and heel areas of the upper.

[0270] Clause 60: The upper as described in Clause 59, wherein the polymer layer extends over a portion of the heel area that is larger than the forefoot area.

[0271] Clause 61: The upper according to any one of Clauses 55 to 60, wherein the polymer layer extends over the portion of the midfoot area that is larger than the forefoot area.

[0272] Clause 62: The upper according to any one of Clauses 55 to 61, wherein the polymer layer extends in the forefoot area from the bite line where the upper meets the sole structure and terminates before the front end of the throat area of ​​the upper.

[0273] Clause 63: The upper according to any one of Clauses 55 to 62, wherein the holes in the polymer layer are located at least in the forefoot area.

[0274] Clause 64: The upper according to any one of Clauses 55 to 63, wherein the holes in the polymer layer are located in at least the midfoot area.

[0275] Clause 65: The upper according to any one of Clauses 55 to 64, wherein the perforation is excluded from the heel area.

[0276] Clause 66: The upper according to any one of Clauses 55 to 65, wherein the pores in the polymer layer comprise pores of different sizes.

[0277] Clause 67: The upper according to Clause 66, wherein the polymer layer includes a hole in the forefoot region of the upper, the hole being larger than the hole in the polymer layer in the midfoot region of the upper.

[0278] Clause 68: The upper according to any one of Clauses 55 to 67, wherein the density of the pores varies within the polymer layer.

[0279] Clause 69: The upper according to any one of Clauses 55 to 68, wherein the first region has a first percentage of surface area covered by the polymer layer, and the second region has a second percentage of surface area covered by the polymer layer, the second percentage being greater than the first percentage.

[0280] Clause 70: The upper according to any one of Clauses 55 to 69, wherein the polymer layer includes a graphic design.

[0281] Clause 71: A footwear article comprising an upper according to any one of Clauses 55 to 70, wherein the upper is attached to a sole structure.

[0282] Clause 72: An upper comprising: a knitted component forming at least a midfoot region and a throat region of the upper, the knitted component having a first row of loops extending continuously from an outer periphery to the throat region, the first row of loops including a first yarn and a tensile element, the tensile element being knitted with a sequence of one or more knitted stitches and a float stitch extending a plurality of loops, wherein the sequence is repeated multiple times between the outer periphery and the throat region, the number of loops in the plurality of loops being greater than the number of knitted stitches in the sequence.

[0283] Clause 73: The upper according to Clause 72, wherein the tensile element has at least one of a larger diameter, greater tensile strength, or greater toughness compared to the first yarn.

[0284] Clause 74: The upper according to any one of Clauses 72 to 73, wherein the knitted component comprises groups of tensile elements, each group forming the sequence.

[0285] Clause 75: The upper as described in Clause 74, wherein the coil rows of the tensile elements within each group are separated from each other by coil rows without float stitches.

[0286] Clause 76: The upper according to any one of Clauses 72 to 75, wherein the first yarn and the second yarn are included within the outward-facing surface of the knitted component.

[0287] Clause 77: The upper according to Clause 76, wherein the first loop row is knitted with a third yarn that forms the inward-facing surface of the knitted component.

[0288] Clause 78: The upper according to any one of Clauses 72 to 77, wherein at least a portion of the tensile element in the first row of coils is at least partially fused to the polymer material of the first yarn.

[0289] Clause 79: The upper according to any one of Clauses 72 to 78, wherein the knitted component further forms the forefoot area of ​​the upper, wherein each row of loops in the forefoot area and the midfoot area of ​​the knitted component extends in a direction from the outer periphery toward the throat area of ​​the knitted component, such that the rows of loops in the forefoot area extend diagonally relative to the rows of loops in the midfoot area.

[0290] Clause 80: A footwear article comprising an upper according to any one of Clauses 75 to 79, wherein the upper is attached to a sole structure.

[0291] Clause 81: An upper comprising: a knitted component forming at least a forefoot region and a midfoot region of the upper and having an outer periphery, the forefoot region and the midfoot region being integrally knitted, each row of loops in the forefoot region and the midfoot region extending in a direction from the outer periphery toward a common portion of the knitted component such that the row of loops in the forefoot region is angled relative to the row of loops in the midfoot region; the knitted component comprising a first material at least partially fused to one or more intertwined yarns, the first material comprising a thermoplastic elastomer.

[0292] Clause 82: The upper according to Clause 81, wherein the knitted component has an outward-facing surface and an inward-facing surface opposite to the outward-facing surface, and wherein the knitted component includes a constrained region on the outward-facing surface, the constrained region having a different coefficient of friction than the remaining area of ​​the upper.

[0293] Clause 83: The upper according to any one of Clauses 81 to 82, wherein the one or more intertwined yarns comprise partially melted coated yarns having a partially melted coating around a core, wherein the first material forms the partially melted coating.

[0294] Clause 84: The upper according to Clause 83, wherein the one or more intertwined yarns include a restraint region, the restraint region including a tensile element knitted with the partially melted coated yarn.

[0295] Clause 85: The upper according to Clause 84, wherein the knitted component includes at least one restrained region without a tensile element, the restrained region having the tensile element having a different coefficient of friction on the outward-facing surface of the knitted component than the restrained region without the tensile element.

[0296] As used herein, the phrase “and / or” relating to two or more elements should be interpreted as referring to only one element or a combination of elements. For example, “element A, element B, and / or element C” can include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or element A, B, and C. Additionally, “at least one of element A or element B” can include at least one of element A and at least one of element B, or at least one of element A and at least one of element B. Furthermore, “at least one of element A and element B” can include at least one of element A and at least one of element B, or at least one of element A and at least one of element B.

[0297] This detailed description is provided to satisfy legal requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways and in combination with other current or future techniques to include different steps, different combinations of steps, different elements and / or different combinations of elements that are similar to or equivalent to those described in this disclosure. The examples herein are intended in all respects to be illustrative and not restrictive. In this sense, alternative examples or embodiments will be readily apparent to those skilled in the art to which this subject matter pertains without departing from the scope of this document.

[0298] 100: Footwear products 102: Sole Structure 104: Shoe Upper 106: Occlusal line 108: Forefoot area / zone 109: Central forefoot area 110: Midfoot area / area 112: Heel area / zone 114: Outer side / lateral side 116: Inner / Lateral 124: outer perimeter 125: Ankle opening 126: Shoe Throat Area 132: Lace 134: Inner and outer perimeter 140: Knitted parts 142: Surface 150: Tensile element 152a: First Constraint Region / Constraint Region 152b: Second Constraint Region / Constraint Region 152c: Third Constraint Region / Constraint Region 152d: Fourth Constraint Region / Constraint Region 152e: Fifth Constraint Region / Constraint Region 308: Forefoot area 310: mid-foot area 312: Heel area 314: Outer side 316: Inner side 318: Axis 321: First axis / axis 323: Second axis / axis 324: Outer perimeter 326: Shoe throat area 334: Inner perimeter 340: Knitted parts 342: Coil rows 342a: Coil row 342b: Coil row 342c: Coil row 342d: Coil row 342e: Coil row 344: Knitting direction 361: Bed of Needles 362: Knitting Machine 400: Footwear Products 402: Sole Structure 404: Shoe upper 406: Occlusal line 408: Forefoot area 410: mid-foot area 412: Heel area 414: Outer side 416: Inner side 424: Outer perimeter 425: Ankle opening 426: Shoe throat area 434: Inner Periphery 440: Knitted parts 442: Surface 450: Tensile element 452a: First Constraint Region / Constraint Region 452b: Second Constraint Region / Constraint Region 452c: Third Constraint Region / Constraint Region 452d: Fourth Constraint Region / Constraint Region 500: Polymer layer 510: Kong 510a: Hole 510b: Hole 600: Footwear Products 602: Sole Structure 604: Shoe Upper 606: Occlusal line 608: Forefoot area 610: mid-foot area 612: Heel area 618: Frontend 626: Shoe Throat Area 628: Frontend 640: Knitted parts 642: Surface 700: Method 710: Steps 712: Steps 714: Steps 716: Steps 718: Steps 810: Fixture 812: Sales 824: Outer perimeter 832: First inner perimeter edge 834: Second inner perimeter edge 836: Third inner perimeter edge 838: Fourth inner perimeter edge 840: Knitted parts 850: Seam 924: Outer perimeter 926: Shoe Throat Area 940: Knitted parts 950: Tensile element 950a: Tensile element 950b: Tensile element 952: Knitting stitch 954: Floating line trace 1040: Knitted parts 1050: Tensile element

Claims

1. A shoe upper, comprising: A knitted component forming at least a forefoot area and a midfoot area of ​​the shoe upper and having an outer periphery, the forefoot area and the midfoot area being knitted integrally, the knitted component having an outward-facing surface and an inward-facing surface opposite to the outward-facing surface, each row of loops in the forefoot area and the midfoot area extending in a direction from the outer periphery toward a common portion of the knitted component such that the rows of loops in the forefoot area extend diagonally relative to the rows of loops in the midfoot area, the common portion being a throat area, and the knitted component having a constrained region extending from the outer periphery toward the common portion, the constrained region comprising a first material at least partially fused to one or more intertwined yarns of the knitted component, the first material comprising a thermoplastic elastomer.

2. The upper according to claim 1, wherein the first material is located on the outward-facing surface of the knitted component.

3. The upper according to claim 1 or 2, wherein the constrained area has a different coefficient of friction than the portion of the knitted component without the first material.

4. The upper according to claim 1 or 2, wherein the constrained area has a greater coefficient of friction than the portion of the knitted component without the first material; and / or wherein the thermoplastic elastomer is thermoplastic polyurethane, or wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

5. The upper according to claim 1 or 2, wherein the knitted component forms the heel area of ​​the upper, and each row of loops within the heel area extends in a direction toward the common portion; and / or wherein the constrained area comprises a plurality of adjacent rows of loops and extends from the outer periphery in the forefoot area to the common portion in the midfoot area.

6. The upper according to claim 1 or 2, wherein the constraint region is a first constraint region located on the outer side of the upper, wherein the upper further includes a second constraint region extending from the outer periphery of the forefoot region on the inner side of the upper to the common portion of the midfoot region on the inner side of the upper, the first constraint region and the second constraint region each having a greater coefficient of friction than the portion of the knitted component without the thermoplastic elastomer.

7. The upper according to claim 1 or 2, wherein the upper further comprises a third constraint region and a fourth constraint region, the third constraint region extending from the outer periphery of the heel area on the outer side of the upper to the common portion of the midfoot area on the outer side of the upper, and the fourth constraint region extending from the outer periphery of the heel area on the inner side of the upper to the common portion of the midfoot area on the inner side, the third constraint region and the fourth constraint region each having a greater coefficient of friction than the portion of the knitted component without the first material.

8. The upper according to claim 1 or 2, wherein the first constraint region, the second constraint region, the third constraint region and the fourth constraint region are each separated from each other by a portion of the knitted component on the outward-facing surface where the first material is not present.

9. The upper according to claim 7, wherein the outward-facing surface of the knitted component includes one or more regions along the outer periphery of the knitted component, the one or more regions including the thermoplastic elastomer at least partially fused to the intertwined one or more yarns, wherein the one or more regions along the outer periphery are located between the first constraint region and the third constraint region, between the first constraint region and the second constraint region, and between the second constraint region and the fourth constraint region, wherein the one or more regions along the outer periphery extend from the outer periphery and do not extend to the inner periphery of the common portion.

10. The upper according to claim 1 or 2, wherein the first material is a coating of yarn, the yarn comprising a core yarn having a second material that excludes the thermoplastic elastomer and has a higher melting temperature than the first material.

11. The upper according to claim 1 or 2, wherein the first material is a coating of a coated yarn having a core comprising the coating of the first material.

12. The upper according to claim 1 or 2 further includes at least one tensile element extending from the outer periphery toward the common portion within the constrained area.

13. The upper according to claim 12, wherein the one or more yarns comprise a core yarn and a second yarn, the core yarn and the second yarn each having a higher melting temperature than the first material, the at least one tensile element comprising strands embedded along a row of loops formed by the loops of the core yarn and the second yarn; and / or wherein the at least one tensile element comprises strands forming a repeating sequence of knitted stitches and float stitches along the row of loops within the constrained region.

14. The upper according to claim 1 or 2, wherein the one or more yarns comprise a high-tenacity yarn and a core yarn, each having a higher melting temperature than the first material, the high-tenacity yarn having a tenacity of at least 5 g / denier; and / or wherein a portion of the outer-facing surface of the knitted component adjacent to the constrained region excludes the first material and includes the high-tenacity yarn; and / or further comprises a polymer layer extending over at least a portion of the outer surface of the knitted component, the polymer layer comprising a polymer material having a melting temperature lower than the first material; and / or wherein the polymer layer extends over at least a portion of the constrained region and includes a plurality of holes exposing portions of the constrained region.

15. A footwear article comprising an upper according to any one of claims 1 to 14, wherein the upper is attached to a sole structure.

16. An upper, comprising: A knitted component forming at least the midfoot area and throat area of ​​the upper, the knitted component having a first row of loops extending continuously from the outer periphery to the throat area, the first row of loops including a first yarn and a tensile element, the tensile element being knitted with a sequence of one or more knitted stitches and float stitches extending a plurality of loops, wherein the sequence is repeated multiple times between the outer periphery and the throat area, the number of loops in the plurality of loops being greater than the number of knitted stitches in the sequence.

17. The upper according to claim 16, wherein the tensile element has at least one of a larger diameter, greater tensile strength, or greater toughness compared to the first yarn.

18. The upper according to claim 16, wherein the knitted component includes groups of the tensile elements, each group forming the sequence.

19. The upper according to claim 18, wherein the coil rows of the tensile elements within each group are separated from each other by coil rows without the float stitches.

20. The upper according to claim 16, wherein the first yarn and the second yarn are included within the outward-facing surface of the knitted component.

21. The shoe upper according to claim 16, wherein the first loop rows are knitted with a third yarn, the third yarn forming the inward-facing surface of the knitted component.

22. The upper according to claim 16, wherein at least a portion of the tensile element in the first row of coils is at least partially fused to the polymer material of the first yarn.

23. The upper according to claim 16, wherein the knitted component further forms a forefoot region and a midfoot region of the upper, wherein each row of loops in the forefoot region and the midfoot region of the knitted component extends in a direction from the outer periphery of the upper toward the throat region of the knitted component, such that the rows of loops in the forefoot region extend diagonally relative to the rows of loops in the midfoot region.

24. The upper according to claim 16, wherein the knitted component is a single, integrally knitted element.

25. The upper according to claim 16, wherein the number of coil rows is in the range of 3 to 8.

26. The upper according to claim 25, wherein the number of coils is 5.

27. The upper according to claim 25, wherein the sequence is a knitted stitch and a floating stitch extending across 5 loops.

28. The upper according to claim 16, wherein a plurality of coil rows include tensile elements woven together with a knitting sequence, wherein the positions of the float stitches in adjacent tensile elements are offset from each other.

29. The upper according to claim 16, wherein the first yarn is knitted using the knitting stitch and tuck stitch.

30. A footwear article comprising the upper of claim 16, wherein the upper is attached to a sole structure.

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