Knitted components with foam surface features

Abstract

A knitted component includes a first region, wherein the first region includes more than one knitted loop containing a first yarn. The knitted component also includes a second yarn at least partially embedded in the first region of the knitted component such that the second yarn extends between at least a first loop and a second loop of the more than one knitted loops. The second yarn has a foamable material that includes a foaming agent and a thermoplastic polymer.

Description

[0001] Related Applications

[0002] This application claims the benefit of the following four (4) U.S. Provisional Patent Applications: U.S. Provisional Patent Application No. 62 / 937,133 filed on November 18, 2019, U.S. Provisional Patent Application No. 62 / 937,117 filed on November 18, 2019, U.S. Provisional Patent Application No. 62 / 937,092 filed on November 18, 2019, and U.S. Provisional Patent Application No. 62 / 939,110 filed on November 22, 2019. Each of the patent applications listed in this paragraph is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to knitted components and methods of making knitted components, such as knitted components for use in footwear applications, apparel applications, or the like.

[0004] background

[0005] A variety of articles are formed from textiles. For example, articles of clothing (e.g., shirts, pants, socks, footwear, jackets and other outerwear, underpants and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and decorative items for furniture (e.g., chairs, couches, vehicle seats) are often at least partially formed from textiles. These textiles are often formed by weaving or interlooping (e.g., knitting) one or more yarns, which is often accomplished by a mechanical process involving a loom or knitting machine. One particular object that can be formed from a textile is an upper for an article of footwear.

[0006] Knitting is an example of a process that can form a textile. Knitting can generally be classified as weft knitting or warp knitting. In both weft knitting and warp knitting, one or more yarns are manipulated to form more than one intermeshed loops defining a plurality of courses and wales. In the more general weft knitting, the courses and wales are perpendicular to each other and can be formed by a single yarn or a plurality of yarns. In warp knitting, the wales and courses extend approximately parallel.

[0007] Although knitting can be done by hand, commercial manufacturing of knitted components is usually done by knitting machines. An example of a knitting machine for producing weft knitted components is a V-bed flat knitting machine, which includes two needle beds angled relative to each other. Tracks extend above and parallel to the needle beds and provide attachment points for feeders, which move along the needle beds and supply yarn to the needles in the needle beds. Standard feeders have the ability to supply yarns that are used for knitting, tucks, and floats. In the case where inlay yarns are incorporated into knitted components, inlay feeders are usually used. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The embodiments of the present disclosure may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily to scale, but emphasis is placed on illustrating the principles of the present disclosure. In addition, in the drawings, the same reference numerals represent similar or identical features in some cases.

[0010] Figure 1 is an illustration showing a knitted component including embedded foamable yarn according to certain aspects of the present disclosure.

[0011] Figure 2 is a diagram showing an article having a knitted component with foam protrusions extending from a surface thereof according to certain aspects of the present disclosure.

[0012] Figure 3 is an illustration showing an article having a knitted component with foam protrusions extending from a surface thereof according to certain aspects of the present disclosure.

[0013] Figure 4 is an illustration showing an article having a knitted component and a foam surface according to certain aspects of the present disclosure.

[0014] Figure 5 is an illustration showing an article having a knitted component with foam protrusions extending from a surface thereof according to certain aspects of the present disclosure.

[0015] Figure 6 is an illustration showing an article having a knitted component with foam protrusions extending from a surface thereof according to certain aspects of the present disclosure.

[0016] Figure 7is a diagram showing an article having a knitted component with a tubular knitted structure forming a pocket along with a foamed interior of the pocket in accordance with certain aspects of the present disclosure.

[0017] Figure 8 is an illustration showing an upper for an article of footwear having an embedded foamable yarn according to certain aspects of the present disclosure.

[0018] Fig. 9 is an illustration showing an upper for an article of footwear having a knitted component and foam projections extending from a surface thereof, according to certain aspects of the present disclosure.

[0019] Figure 10-Figure 14 is an illustration showing a knitting pattern for forming a knitted component with embedded foamable yarn according to certain aspects of the present disclosure.

[0020] Detailed Description

[0021] Aspects are described below with reference to the accompanying drawings, in which like elements are generally identified by like numbers. The relationships and functions of the various elements of the various aspects may be better understood by reference to the following detailed description. However, the various aspects are not limited to those aspects illustrated in the accompanying drawings or explicitly described below. It should also be understood that the drawings are not necessarily to scale, and in some cases, details that are not necessary for understanding the aspects disclosed herein, such as conventional manufacturing and assembly, may have been omitted.

[0022] Embodiments of the present invention generally relate to textiles.Textiles can be defined as structures made of fibers, filaments or yarns characterized by flexibility, fineness and a high ratio of length to thickness.Textiles generally fall into two categories.The first category includes textiles directly produced by a web of filaments or fibers by randomly (or non-randomly) interlocking or interconnecting to construct nonwoven fabrics and felts.The second category includes textiles formed by mechanical manipulation of yarns (e.g., by interlacing or mutual looping), thereby producing, for example, woven fabrics or knitted fabrics.

[0023] Textiles can include one or more yarns. Generally, yarn is defined as a component with a considerable length and a relatively small cross-section formed by at least one filament or more than one fiber. Fiber has a relatively short length and requires a spinning process or a twisting process to produce a yarn with a suitable length for use in textiles. Common examples of fibers are cotton and wool. However, filaments have an indefinite length and can only be combined with other filaments to produce yarns suitable for use in textiles. Modern filaments include more than one synthetic material, such as rayon, nylon, polyester and polyacrylic acid, with silk being the main, naturally occurring exception. Yarn can be formed by a single filament, which is conventionally referred to as a "monofilament yarn", or more than one single filament grouped together. Yarn can also include a single filament formed by different materials, or yarn can include filaments each formed by two or more different materials. Similar concepts also apply to yarns formed by fibers. Therefore, yarn can have a variety of configurations that roughly meet the definition provided above.

[0024] Although embodiments of the present invention may be formed with any type of textile, the following description generally refers to knitted textiles or "knitted components". Figure 1 , certain articles can be at least partially formed as a knitted component 100, and can potentially be completely formed as a knitted component 100. Advantageously, forming an article including a knitted component 100 can impart favorable advantages, including but not limited to a particular degree of elasticity (e.g., expressed in terms of Young's modulus), breathability, flexibility, strength, hygroscopicity, weight, abrasion resistance, and / or combinations thereof. These properties can be achieved by selecting a particular single-layer knit structure or a multi-layer knit structure (e.g., a rib knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed from a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), and / or combinations thereof. The weight of the article (e.g., such as Figure 8The upper 300 shown in FIG. 1 , and thus the total weight of the article of footwear) can be reduced relative to alternative items (e.g., conventional non-knitted uppers and / or other components commonly used in footwear). Knitted component 100 can also provide desired aesthetic properties by incorporating yarns having different colors, textures, or other visual properties arranged in a particular pattern. The yarns themselves and / or the knitted structure formed by one or more yarns of the knitted component can be varied at different locations to provide different knitted portions with different properties.

[0025] In some embodiments, and with reference to Figure 1 , when the knitted component 100 is knitted and removed from the knitting machine, the knitted component 100 may include at least one foamable yarn 102. In addition, the knitted component 100 may include more than one first yarn 104 (for example, wherein the reference to "second yarn" may refer to the foamable yarn 102) forming more than one row and / or more than one intermeshing loop of the knitted component 100. For example, the first yarn 104 may be formed of a polyester material and / or another suitable material understood by those skilled in the art. The first yarn 104 may not be a foamable yarn. In this article, the foamable yarn 102 may be defined as a yarn comprising a foamable material, wherein the foamable material comprises a thermoplastic polymer and a foaming agent. Examples of foamable yarns are described in U.S. Provisional Application No. 62 / 937,092, filed on November 18, 2019, and entitled “FOAMABLE YARNS, TEXTILES AND ARTICLES INCORPERATING FOAMABLE YARNS, AND THE PROCESS OF MANUFACTURING THE SAME,” which is incorporated into the description above.

[0026] As described herein, a thermoplastic material (eg, a thermoplastic polymer) is a substance that can become plastic when heated and harden when cooled without undergoing a chemical transformation. Thermoplastic polymers can include natural polymer materials, recycled materials, synthetic polymer materials, or some combination thereof.

[0027] Natural polymer materials can be plant-derived or animal-derived. Plant-derived natural polymer materials can include cotton, flax, hemp, jute or similar materials. Animal-derived natural polymer materials can include spider silk, silk, sheep wool, alpaca wool or similar materials. Regenerated materials are produced by dissolving the cellulose regions of plant fibers in chemicals and making them into fibers again (by the viscose method). Since the regenerated material is composed of cellulose like cotton and hemp, it is also called "regenerated cellulose fiber". Regenerated materials can include materials such as rayon and modal, as well as others.

[0028] The synthetic polymer material may include any of a variety of homopolymers or copolymers or combinations of homopolymers and copolymers. For example, the thermoplastic polymer may include: a thermoplastic polyurethane homopolymer or a thermoplastic polyurethane copolymer; a thermoplastic polyethylene homopolymer or a thermoplastic polyethylene copolymer; a thermoplastic polypropylene homopolymer or a thermoplastic polypropylene copolymer; a thermoplastic polyester homopolymer or a thermoplastic polyester copolymer; a thermoplastic polyether homopolymer or a thermoplastic polyether copolymer; a thermoplastic polyamide homopolymer or a thermoplastic polyamide copolymer; or any combination thereof. These may include homopolymers or copolyesters of polyethylene terephthalate, ethylene vinyl acetate, nylons such as nylon 6, nylon 11, or nylon 6,6, and others.

[0029] In addition, in other embodiments, thermoplastic materials include thermosetting thermoplastic materials (thermosettingthermoplastic material). As described herein, when exposed to specific thermosetting conditions, thermosetting materials can be cured, and at the point of the thermosetting conditions, the thermosetting thermoplastic material undergoes chemical changes. Thermosetting materials are uncured and can therefore be thermoplastic. Cured thermosetting materials have undergone chemical changes and are thermosetting. The thermosetting conditions that trigger the curing of thermosetting thermoplastic materials can include specific temperatures, the amount of UV light exposure, actinic radiation, microwave radiation, radio wave radiation, electron beam radiation, gamma beam radiation, infrared radiation, ultraviolet light, visible light or a combination thereof, and other conditions.

[0030] In some embodiments, thermosetting thermoplastic material also comprises a crosslinking agent. As understood in the art, a crosslinking agent is a chemical product that chemically forms a key between two hydrocarbon chains. The reaction can be exothermic or endothermic, depending on the crosslinking agent used. Those skilled in the art will be able to select any number of suitable crosslinking agents, which will be compatible with thermoplastic polymers and allow thermoplastic materials to crosslink under the processing conditions desired, and the processing conditions include temperature, pressure, UV light exposure and similar conditions.

[0031] In some cases, suitable cross-linking agents include homobifunctional cross-linking agents. Homobifunctional agents consist of identical reactive groups at both ends of a spacer arm. Examples of homobifunctional cross-linking agents include: dimethyl pimelimidate dihydrochloride, 3,3'-dithiodipropionic acid bis(N-hydroxysuccinimide ester), suberate bis(3-sulfo-N-hydroxysuccinimide ester) sodium salt, and others.

[0032] In other cases, suitable crosslinking agents include heterobifunctional crosslinking agents. Heterobifunctional crosslinking agents have two different reactive groups, which allows the crosslinking reaction to be carried out in a controlled two-step reaction. This can reduce the prevalence of dimers and oligomers during crosslinking. Examples of heterobifunctional crosslinking agents include: S-acetylthioglycolic acid N-hydroxysuccinimide ester, 5-azido-2-nitrobenzoic acid N-hydroxysuccinimide ester, 4-azidophenacyl bromide, bromoacetic acid N-hydroxysuccinimide ester, N-(3-dimethylaminopropyl)-N'-ethylcarbodiimide hydrochloride, iodoacetic acid N-hydroxysuccinimide ester, and others.

[0033] The foamable material of the foamable yarn 102 also includes a foaming agent. As understood in the art, a foaming agent is a substance that decomposes or vaporizes at an activation temperature to produce a certain amount of gas or vapor. Therefore, they can be classified as chemical foaming agents or physical foaming agents. Chemical foaming agents are compounds that can release gas at their activation temperature. Typically, this released gas does not chemically react with the thermoplastic polymer used as the polymer matrix. The process of releasing gas from the foaming agent is usually exothermic; however, certain compounds that decompose by thermal dissociation, such as bicarbonates, release gas in a reversible and endothermic reaction. Chemical foaming agents can also be subcategorized into inorganic foaming agents and organic foaming agents. Inorganic foaming agents are mainly used in rubber technology, but can be used in plastic applications to produce additional crosslinking during the foaming process.

[0034] Physical blowing agents are compounds that can change phase to gas when temperature, pressure, or temperature and pressure are changed. At a given pressure, the temperature at which the physical blowing agent changes to gas is the activation temperature. Physical blowing agents include low boiling hydrocarbons or supercritical fluids.

[0035] The choice of blowing agent can affect the quality, density, uniformity and cost of the foamed product. As discussed below, the characteristic property of these compounds is their decomposition temperature, which determines their practical use as blowing agents for a given thermoplastic material and for its processing conditions. In order for the yarn to form a stable foam, the thermoplastic material must be deformable or plastic at the activation temperature of the blowing agent. For this purpose, the deformation temperature of the thermoplastic material can be lower than the activation temperature of the blowing agent.

[0036] In some embodiments, the deformation temperature of the thermoplastic material is lower than the activation temperature of the blowing agent by more than about 10 degrees C. In some embodiments, the deformation temperature of the thermoplastic material is lower than the activation temperature of the blowing agent by more than about 20 degrees C. In other embodiments, the first thermoplastic material 110 has a softening temperature from about 50 degrees Celsius to about 145 degrees Celsius.

[0037] In some embodiments, the chemical blowing agent has an activation temperature that is at least 5 degrees C. above the melting temperature of the first thermoplastic material. In other embodiments, the activation temperature of the blowing agent is at least 10 degrees C. above the melting temperature of the first thermoplastic material. In additional embodiments, the activation temperature of the blowing agent is at least 20 degrees above the melting temperature of the first thermoplastic material.

[0038] Other properties that may be considered when selecting a chemical blowing agent include the following: affinity with the thermoplastic polymer, maximum production of gas; activation temperature at which the blowing agent evolves gas, rate of gas evolution, toxicity, corrosivity, odor of decomposition products, effect of decomposition products on color and other physicochemical properties of the thermoplastic polymer, cost, availability, stability against decomposition during storage, and others.

[0039] In some embodiments, the blowing agent comprises a chemical blowing agent. In some embodiments, the chemical blowing agent comprises sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, calcium azide, azodicarbonamide, hydrazocarbonamide, benzenesulfonylhydrazide, dinitrosopentamethylenetetramine, toluenesulfonylhydrazide, p,p'-oxybis(benzenesulfonylhydrazide), azobisisobutyronitrile, barium azodicarboxylate, or any combination thereof.

[0040] In some embodiments, the blowing agent comprises a physical blowing agent. In addition to partially halogenated fluorochlorocarbons, hydrocarbons (e.g., isobutylene and pentane) and inert gases, such as carbon dioxide or nitrogen, can be used as physical blowing agents. Inert gases provide many advantages, including low environmentally harmful output, low gas consumption, increased foam volume per weight of the blowing agent used, high cost effectiveness, non-flammable, non-toxic, chemically inert, leaving minimal or no residue in the polymer foam after processing. In addition, carbon dioxide has the advantage of having a higher solubility in many thermoplastic polymers than other inert gases such as nitrogen.

[0041] In some embodiments, the blowing agent is present in the first thermoplastic material in an amount effective to foam the first thermoplastic material into a cellular foam structure when the foamable yarn 102 is processed (as discussed in more detail below). The amount of blowing agent can be measured as the concentration of the blowing agent by weight in the thermoplastic material. The amount of blowing agent is considered effective when activating the blowing agent causes the volume of the thermoplastic material to increase by at least 10%.

[0042] In some embodiments, more than one foaming agent can be used. The combination of foaming agents can include at least two chemical foaming agents, at least two physical foaming agents or a combination of physical foaming agents and chemical foaming agents. Each foaming agent has an activation temperature at a given processing pressure. These activation temperatures can be roughly the same, or can be different. By using foaming agents with different activation temperatures, processing the foamable yarn into a porous foam structure can be carried out within a larger temperature operating window. In addition, by controlling the temperature to activate the first foaming agent and then increasing the temperature of the foamable yarn to activate the second foaming agent, a variety of different desired foam structures can be obtained. In some embodiments, the two foaming agents can have an activation temperature that differs at least about 5 degrees Celsius. In some embodiments, the two foaming agents can have an activation temperature that differs at least about 10 degrees Celsius. In some embodiments, the two foaming agents can have an activation temperature that differs at least about 20 degrees Celsius.

[0043] A wide range of additives can also be used in the foamable yarn 102. For example, a catalyst accelerates the reaction, or in some cases, reduces the reaction initiation temperature. As discussed above, a foaming agent that forms bubbles in a polymer or polymer mixture produces foam. A surfactant can be added to control the size of the bubbles. Depending on the application, other additives that can be used include crosslinking agents, chain extenders, fillers, flame retardants and coloring materials (such as dyes or pigments), ultraviolet light absorbers, antioxidants, lubricants, plasticizers, emulsifiers, rheology modifiers, fragrances, deodorants or halogen scavengers.

[0044] The molecular structure, amount and reaction temperature of each component determine the characteristics and subsequent uses of the foamable yarn 102 after processing. Therefore, each formulation can be designed with appropriate ingredients to obtain the desired properties of the final material. As an example, different foaming agents may need additional additives to maintain thermal properties. Finally, after the foamable yarn 102 is processed, the density of the foam is determined by the number and size of the holes, and the number and size of the holes are at least partially affected by the amount of foaming that occurs during processing. By mixing different combinations of starting materials, the reaction rate and total cure rate during processing can be controlled.

[0045] In some embodiments, the foamable yarn 102 can include a core having a material different from the foamable material. Advantageously, the core of the foamable yarn 102 can remain substantially intact when subjected to a certain amount of heat for processing the yarn, so that even when the foamable material softens due to its thermoplastic component being heated, the core of the foamable yarn 102 can maintain structural integrity, so that the core and / or processed foamable material (and / or the resulting foam) remain in a desired position. Examples of core materials and structures are described in U.S. Provisional Application No. 62 / 937,092, which is incorporated by reference into the description above.

[0046] During the manufacture of the knitted component 100, at least a portion of the foamable yarn 102 can be embedded between certain loops of the knitted component 100 on the knitting machine. For example, the foamable yarn 102 can be inserted into the horizontal rows of the knitted component while on the knitting machine, such as by using an embedding process. For example, the embedding process can include using an embedding feeder or other mechanical embedding device (e.g., a combination feeder) on the knitting machine during the knitting process to place the foamable yarn 102 between two needle beds (e.g., a front needle bed and a rear needle bed). An example of an embedding process, together with a combination feeder for implementing such a process, is described in U.S. Patent Application Publication No. 2013 / 0145652, published on June 13, 2013 and having applicant NIKE, Inc., which U.S. Patent Application Publication is hereby incorporated by reference in its entirety. Although embedding the foamable yarn 102 may be desirable, it is contemplated that the foamable yarn 102 may be attached to the remainder of the knitted component 100 in a different manner, such as by securing the foamable yarn 102 directly to the outer surface of the knitted component 100 using an adhesive, by embroidering or otherwise sewing the foamable yarn 102 so that it extends through the knitted component 100, etc. In addition, although not shown, it is contemplated that the foamable yarn may be included in at least one of the loops forming the rows of the knitted component 100.

[0047] Still refer to Figure 1In some embodiments, certain portions of the foamable yarn 102 can be exposed on the outer surface 112 of the knitted component 100. For example, the knitted component 100 includes a first portion 106 of the foamable yarn 102 located on the surface 112 (e.g., such that it is accessible from an external perspective). Similarly, the second portion 108, the third portion 110, etc. are exposed on the outer surface 112. The portion of the foamable yarn 102 between the first portion 106 and the second portion 108 (e.g., the depicted "covered portion 105") can be located below the outer surface 112 so that it is substantially covered by at least one loop of the first yarn 104. Advantageously, and as described in more detail below, such exposure of the foamable yarn 102 can allow, for example, the formation of foam protrusions and / or another foam surface feature on the surface 112 during post-knitting processing. In some applications, the portion of the foamable yarn 102 that remains below the surface 112 can be substantially protected from processing stimuli (e.g., heat) because it is covered by the loops of the knitted component 100. However, the covered portion of the foamable yarn 102 can still be at least partially processed (however, in some embodiments, the foam expansion can be limited, for example, by the surrounding knitted structure). Figure 10-Figure 14 A specific example of a knitting method for exposing the first portion 106, the second portion 108, etc. on the surface 112 is discussed.

[0048] Still refer to Figure 1 , may include more than one embedded foamable yarn 102 (e.g., extending substantially parallel as shown, or not extending substantially parallel). For example, different embedded foamable yarns 102 may extend through different rows of the knitted component 100 formed by the first yarn 104. Although the foamable yarn 102 is Figure 1 102. It is shown as a consistent yarn type in the knitted component 100, but it is expected that different types of foamable yarns 102 may be included. For example, certain areas of the knitted component 100 may include yarns of foamable materials with a relatively high density per unit length relative to other areas that are similarly constructed from a knitting perspective. For example, certain exposed areas (and resulting protrusions) may be at least 10%, at least 20%, at least 30%, at least 50%, at least 75%, at least 100%, or even more than other exposed areas of the foamable yarn 102. As a result, foam protrusions of different sizes can be formed in certain areas (as discussed below). For example, foam protrusions 212 may have a height of at least 2mm, such as at least 5mm, 10mm, 20mm or more. With regard to length and width, the length and / or width of the protrusion may be at least 2mm, such as at least 5mm, 10mm, 20mm or more.

[0049] Additionally or alternatively, it is contemplated that different knitting techniques may be used to control the amount of surface exposure of the foamable yarn 102. Figure 1 For example, a first area 116 of the knitted component 100 includes exposed portions that are longer than exposed portions in a second area 118. Once processed, the foam protrusions formed in the first area 116 will generally be larger (e.g., at least longer) in at least one dimension than the foam protrusions formed in the second area 118 because more foamable material is exposed on the surface 112 in the first area 116 relative to the second area 118.

[0050] Figure 2 An example of an article 200 is shown, which may be initially described in a manner similar to that described by Figure 1 The depicted knitted component 100 is formed as a knitted component. Figure 2 , the article 200 may generally include five (5) regions. The first region 202 may include more than one foam protrusion 212. The foam protrusion 212 may include a porous foam formed as a reaction product of foaming the foamable yarn 102, such as described above. In particular, referring to Figure 1 The exposed portions 106, 108, etc., may be exposed to a specific amount of heat and / or another stimulus to form Figure 1 The foamable material is activated after the knitted component 100 is formed. Specific activation parameters are described in detail in U.S. Provisional Application No. 62 / 937,092, which is incorporated by reference above. When the foamable material is activated, it can expand (e.g., away from Figure 1 The foam may be formed into a foamed surface 112 and then solidified or hardened in an expanded state (or otherwise acquire a relatively permanent material state) when it is allowed to cool. The resulting structure may be a protrusion, such as a foam protrusion 212 that forms a specific surface topography.

[0051] like Figure 2 As shown in FIG. 1 , the first region 202 may include protrusions 212 of substantially the same size, but this is optional. The first region 202 may optionally have a variable amount of foamable material exposed on the surface of the knitted component, and / or the processing procedures in different areas of the first region 202 may be changed so that the protrusions 212 vary. For example, the protrusions 212 may form a surface pattern optimized for a specific function.

[0052] Figure 2The second region 204 is similar to the first region 202, but the protrusions 212 are slightly smaller. This can be achieved by changing the knitting process (e.g., by exposing less of the foamable yarn insert on the surface) and / or by switching the type of foamable yarn during knitting. Similarly, the fourth region 208 and the fifth region 210 include protrusions 212 that are relatively spaced apart (e.g., by separating exposed portions of the embedded foamable yarn) and are relatively low in height. A variety of additional patterns and / or alternative patterns may be used. In addition, although in Figure 2 All of the protrusions 212 in are substantially hemispherical in shape, but it is contemplated that the shape of the protrusions 212 may be varied by using a particular knit structure, a particular material type, by using a molding machine or other similar device during the foam activation step, or by any other suitable method.

[0053] Figure 2 The third region 206 includes a foam surface 222 that is substantially formed from foam (e.g., a reaction product of the foamable yarn 102). The foam surface 222 can be formed by a variety of methods. For example, the foamable material used in the foamable yarn can have a sufficiently high concentration so that once it is processed and embodies an expanded state, the foam completely covers the outer surface of the knitted component 100. Alternatively, and as discussed in more detail below, it is contemplated that a unique knitting process can be used such that most or all of the surface 222 is formed from a foamable yarn 102 having less foam expansion (see, e.g., Fig.12 and related descriptions).

[0054] Figure 3-Figure 7 Various embodiments of articles 200 formed using the methods and processes described herein are shown. For example, Figure 3 An article 200 is shown having relatively small foam protrusions 212 extending from the surface 112 of the knitted component 100. As discussed above, locations between the foam protrusions 212 may include embedded yarns having a foamable material, for example, such that the foamable material and / or foam extends from one protrusion 212 through the knitted component 100 to the next protrusion 212. Although Figure 3 The protrusions are substantially the same size, but they may vary (e.g., due to the use of different yarns and / or by exposing different lengths of yarn comprising the foamable material during knitting). Although the foam protrusions 212 are shown on only one side of the fabric, they may additionally or alternatively be on the other side.

[0055] Figure 4An article 200 is shown having a foam surface 222 or a surface substantially covered with porous foam. Such an embodiment can be formed by using a sufficient amount of foamable material within the yarn so that once the yarn expands due to processing after knitting, for example, the yarn substantially covers the knitted loops. Although in the depicted embodiment the foam surface 222 is formed on only one side of the article 200, the opposing surface 224 can additionally or alternatively be covered in foam (e.g., once the knitted component is processed so that the foamable yarn forms a foam).

[0056] Figure 5-Figure 6 and Figure 3 are similar, but the foam protrusions are different sizes. For example, in Figure 5 In the embodiment, the foam protrusion 212 and Figure 3 The foam protrusions 212 are approximately the same height, but they are longer (e.g., because the foamable yarn is exposed for a longer distance). Figure 6 In the case of foam protrusions, the foam protrusions are substantially higher than Figure 3 or Figure 5 This can be achieved by using a foamable yarn with more foamable material per unit length, and / or by processing the foamable yarn differently to obtain a relatively high degree of expansion.

[0057] Figure 7 Different embodiments are shown, in which the porous foam 400 is located between the first layer 402 and the second layer 404 of the knitted component 100. For example, a foamable yarn (as described above) can be embedded through an area having a tubular knitted structure, in which the first layer 402 and the second layer 404 are formed. In particular, the first layer 402 can include more than one row formed by intermeshing loops (e.g., of the "first yarn" described above), and similarly, the second layer 404 can include more than one row formed by intermeshing loops. A pocket 408 can be formed between the first layer 402 and the second layer 404, particularly when the loops of the first layer 402 are not directly connected to the loops of the second layer 404 (e.g., not interlocked with the loops of the second layer 404). The pocket 408 can even exist before the post-knitting processing, and the foamable yarn can be located therein due to the embedding procedure. Once heated or otherwise processed, the foamable material of the foamable yarn can expand to fill the pocket 408. For example, such embodiments are advantageous for providing a foam pad within a knitted structure, although other functions and / or uses are additionally or alternatively contemplated.

[0058] The methods and features discussed above may be incorporated into any suitable article. For example, Figure 8 An upper 300 for an article of footwear is shown that includes more than one foamable yarn 102. The upper 300 is preferably Figure 8 300 in a pre-processed state (e.g., before the foam protrusions are formed after the knitting process). As shown, the embedded foamable yarn 102 can be exposed on the outer surface 320 of the upper 300 in a selected position. Any suitable position can be selected, such as in the mid-shoe area 324 and the toe area 326 in the depicted example (which is for illustration only). Advantageously, once the foam protrusions are formed, suitable surface properties can be provided on the outer surface 320 of the upper 300. Without limitation, the foam protrusions can form gripping elements (gripping elements) (e.g., suitable for kicking a football with a high degree of rotation, for gripping ropes, rock walls or other objects during a particular sports competition, etc.). If a relatively soft foam is used, it is also expected that the foamable yarn 102 can be exposed on the inner surface 328 of the upper 300 to provide cushioning and / or other comfort properties.

[0059] Fig. 9 Another embodiment of an upper 300 is shown, wherein the upper 300 is in a configuration that it may have just after knitting (and / or post-knitting processing) but before being folded or otherwise manipulated into a wearable shape. As shown, the upper 300 may include multiple areas with different surface properties (e.g., similar to Figure 2 ). The surface features are formed by foam protrusions 212 and / or foam surface 222. As shown, the upper can include a first area 306 having a set of foam protrusions 212 covering a toe area 326. A second area 308 located in a midfoot area 324 of the upper can include larger foam protrusions 212. A third area 310 can include a surface formed substantially of porous foam (as discussed above), which can be advantageous for providing cushioning where a fastening system is located (e.g., where the laces are tightened on a throat area 332 of the upper 300). The heel area 330 includes a fourth area 312 having relatively small foam protrusions 212. Notably, certain areas can lack protrusions, areas can be reorganized, and the like.

[0060] Figure 10-13 Some examples of knitting techniques that can be used to expose certain portions of the embedded foamable yarn on the surface of the knitted component are shown. Fig.10As shown, for example, an inlay jacquard procedure can be used to embed the foamable yarn 102 within loops of the first yarn 104 (e.g., including polyester and elastane in the depicted embodiment, although other suitable yarn types are also contemplated). As shown, a unique transfer process T can be used, which is key to ensuring that a certain length of the foamable yarn 102 will be exposed on the resulting surface. In particular, the transfer T causes certain loops of the row that would otherwise cover the foamable yarn 102 (e.g., where it is ultimately exposed) to be moved to the opposite needle bed, thereby providing apertures or "openings" in which more than one needle is skipped on one needle bed (e.g., so that nothing covers the embedded foamable yarn 102).

[0061] The resulting exposed length of the foamable yarn 102 can be equal to or greater than, for example, the length of a portion of a knitted course comprising at least two continuous loops, and may be much greater (e.g., at least three, four, five, ten, fifteen, or even twenty or more continuous loops). In metric units, the exposed length can be, for example, equal to at least 2 mm, and potentially much greater (e.g., approximately equal to or greater than 5 mm, 10 mm, 20 mm, or more). Fig.10 The process may correspond to, for example, Figure 2 The first region 202 may further include a fusible yarn 140, for example, which may cover and then "release" certain portions of the foamable yarn 102 (see FIG. Fig.12 ). Fusible yarn 140 may additionally or alternatively be included to provide stiffness, strength, and / or other advantageous characteristics to the knitted component once processed with heat (e.g., which may be the same heat used to activate the foamable yarn).

[0062] Fig.11 and Figure 13-14 shows that it is possible to form Fig.10 The process of forming the structure is similar to the knitted structure, and the general principle for forming the exposed portion of the foamable yarn 102 remains the same (e.g., by utilizing a transfer T). In particular, Fig.11 and Figure 13-14 Can correspond to Figure 2 The regions 204, 208 and 210 of the knitted fabric may be formed. However, it will be appreciated by those skilled in the art that various changes may be made to provide a knitted component having optimal properties. For example (and not limitation), other yarns such as Fig.11 The high tenacity yarn 103 is shown in Figure 1, which can provide a high degree of strength and stiffness.

[0063] Fig.12 is a knitting process that can be used to form a surface formed entirely or substantially of foam (e.g., once processed). Fig.12 , a foamable yarn 102 is embedded between rows formed by a first yarn 104 (e.g., polyester or other high melting point yarn, such as potentially including elastic fibers) and a fusible yarn 140 (e.g., formed from a thermoplastic material having a relatively low melting point suitable for thermal processing). Uniquely, the only loops formed on the front side of the embedded foamable yarn 102 are formed solely by the fusible yarn 140. Once removed from the knitting machine, the resulting knitted component may appear similar to other knitted components described using the knitting process depicted above. However, once heated, the fusible yarn 140 may be substantially melted or completely melted, thereby allowing the foamable material of the foamable yarn 102 to be "released" due to the deformation of the fusible yarn 140. Thus, the foamable material may substantially or completely cover the corresponding side of the fabric, thereby forming a foam surface similar to that described above (e.g., see Figure 2 The third area 206 and Fig. 9 The third area 310).

[0064] Although various embodiments of the present disclosure have been described, the present disclosure is not limited except in accordance with the attached claims and their equivalents. Those skilled in the relevant art will recognize that many changes and modifications may be made to the embodiments described above without departing from the scope of the invention as defined by the attached claims. In addition, the advantages described herein are not necessarily the only advantages of the present disclosure, and it is not necessarily expected that each embodiment of the present disclosure will achieve all of the advantages described.

[0065] The subject matter of the present disclosure may also relate to the following aspects and other aspects:

[0066] In a first aspect, a knitted component comprises the following: a first region,

[0067] wherein the first region comprises more than one knitted loops comprising a first yarn; and a second yarn, the second yarn being at least partially embedded in the first region of the knitted component such that the second yarn extends between at least a first loop and a second loop of the more than one knitted loops, wherein the second yarn comprises a foamable material comprising a blowing agent and a thermoplastic polymer.

[0068] Aspect 2 includes the knitted component of aspect 1, wherein the second yarn includes a first portion exposed on the first surface in the first region.

[0069] Aspect 3 includes the knitted component of aspect 2, wherein the first portion has a length greater than or equal to a length of a portion of a first row including at least three consecutive knit loops, the first row being in the first zone.

[0070] Aspect 4 includes the knitted component of aspect 2, wherein the second yarn further includes a second portion exposed on the first surface in the first area, and wherein the second yarn includes a covered portion extending from the first portion to the second portion.

[0071] A fifth aspect includes the knitted component of aspect 4, wherein the length of the second portion is greater than the length of the first portion.

[0072] Aspect 6 includes the knitted component of aspect 2, wherein a second row extends through a second area having a second surface, wherein the second yarn is at least partially embedded within the second row, and wherein the second yarn includes a second portion exposed on the second surface in the second area.

[0073] A seventh aspect includes the knitted component of aspect 6, wherein the second portion of the second yarn comprises a length greater than a length of the first portion of the second yarn.

[0074] Aspect 8 includes a knitted component of any of Aspects 1-7, wherein the first region includes a tubular knitted structure having a first layer and a second layer, wherein at least one of the first layer and the second layer includes the first yarn, and wherein at least a portion of the second yarn is located in a pocket between the first layer and the second layer.

[0075] Aspect 9 includes the knitted component of any of aspects 1-8, further comprising a third yarn included in at least one loop of the first row, wherein the third yarn includes a second thermoplastic polymer, and wherein the second thermoplastic polymer has a melting temperature of about 120°C or less.

[0076] Aspect 10 includes a knitted component comprising: a first area having a first surface, wherein the first area is at least partially formed by a first knit row, the first knit row having more than one loop formed by a first yarn; and a porous foam material at least partially surrounding the first yarn in the first area of ​​the knitted component, wherein the porous foam material forms a first protrusion extending from the first surface of the first area.

[0077] An 11th aspect includes the knitted component of aspect 10, wherein the at least one protrusion comprises a height of at least 2 mm.

[0078] A twelfth aspect includes the knitted component of any of aspects 10-11, wherein the porous foam material is a reaction product of foaming at least a portion of a second yarn, the second yarn comprising a first thermoplastic material.

[0079] A 13th aspect includes the knitted component of any of aspects 10-12, wherein the at least one protrusion has a length of at least 5 mm.

[0080] A fourteenth aspect includes the knitted component of any of aspects 10-13, wherein the at least one protrusion includes a first foam protrusion and a second foam protrusion, and wherein the second foam protrusion includes at least 20% more, by mass, of the porous foam material than the first foam protrusion.

[0081] Aspect 15 includes a knitted component of any of aspects 10-14, wherein the at least one protrusion includes a first foam protrusion and a second foam protrusion, and wherein a covered portion of the second yarn extends from the first foam protrusion to the second foam protrusion, and the covered portion includes at least one of the porous foam material and a foamable material having a foaming agent.

[0082] A sixteenth aspect includes the knitted component of any of aspects 10-15, wherein the covered portion of the second yarn is embedded through the knitted component.

[0083] Aspect 17 includes the knitted component of any of aspects 10-16, further comprising a third yarn included in at least one loop of the first knit course, wherein the third yarn includes a second thermoplastic polymer material, and wherein the second thermoplastic polymer material has a melting temperature of about 120°C or less.

[0084] Aspect 18 comprises a method comprising: knitting a course with a first yarn, wherein the course comprises more than one loop; at least partially embedding a foamable yarn within the first course; and transferring the loops of the first course from one needle bed to another needle bed such that at least a portion of the foamable yarn is exposed on a surface of the resulting knitted component.

[0085] A nineteenth aspect includes the method of aspect 18, further comprising heating the knitted component so that the foamable yarn forms at least one foam protrusion on a surface of the knitted component.

[0086] Aspect 20 includes the method of any of aspects 18-19, further comprising knitting at least one loop with a fusible yarn separate from the foamable yarn, and further comprising heating the fusible yarn so that the fusible yarn is deformed when the foamable material of the fusible yarn expands.

Claims

1. A knitted component, comprising: a first region and a second region, wherein the first region and the second region include more than one knitted loop comprising a first yarn; as well as a second yarn at least partially embedded in the first region and the second region of the knitted component such that the second yarn extends between at least a first knit loop and a second knit loop of the more than one knit loops, wherein the second yarn comprises a core material and a foamable material comprising a foaming agent and a thermoplastic polymer, and comprises a first portion exposed on a surface of at least a portion of the first region and a second portion exposed on a surface of at least a portion of the second region, wherein the foamable material of the second yarn has at least partially expanded to form more than one foam protrusion on the surface of at least a portion of the first region and on the surface of at least a portion of the second region, and Wherein at least a portion of the more than one foam protrusions in the first region are different in size and / or shape and / or spacing compared to at least a portion of the more than one foam protrusions in the second region.

2. The knitted component according to claim 1, wherein the first portion has a length equal to the length of a portion of a first row comprising at least three consecutive knit loops, the first row being in the first area.

3. A knitted component according to claim 1, wherein the second yarn further includes a second portion exposed on the surface in the first area, and wherein the second yarn includes a covered portion extending from the first portion in the first area to the second portion in the first area.

4. The knitted component according to claim 3, wherein a length of the second portion in the first area is greater than a length of the first portion in the first area.

5. The knitted component of claim 1, wherein a second row extends through the second region, wherein the second yarn is at least partially embedded within the second row.

6. The knitted component of claim 5, wherein the second portion of the second yarn in the second area comprises a length that is greater than a length of the first portion of the second yarn in the first area.

7. A knitted component according to claim 1, wherein the first area comprises a tubular knitted structure having a first layer and a second layer, wherein at least one of the first layer and the second layer comprises the first yarn, and wherein at least a portion of the second yarn is located in a pocket between the first layer and the second layer.

8. The knitted component according to claim 1, further comprising a third yarn included in at least one knit loop of the first row, wherein the third yarn comprises a second thermoplastic polymer, and wherein the second thermoplastic polymer has a melting temperature of 120°C or less.

9. A method for preparing a knitted component according to any one of claims 1 to 8, comprising: knitting a course with the first yarn, wherein the course includes more than one loop in a first region and a second region; causing the second yarn to be at least partially embedded within the course, wherein the second yarn is a foamable yarn comprising a core material and a foamable material comprising a foaming agent and a thermoplastic polymer; as well as transferring the loops of the course from one needle bed to another needle bed so that a first portion of the foamable yarn is exposed on the surface of at least a portion of the first area of ​​the resulting knitted component and a second portion of the foamable yarn is exposed on the surface of at least a portion of the second area of ​​the resulting knitted component, Processing the knitted component, wherein the exposure of the second yarn allows the second yarn to at least partially expand to form more than one foam protrusion on the surface of at least a portion of the first area and on the surface of at least a portion of the second area, and wherein at least a portion of the more than one foam protrusion in the first area is different in size and / or shape and / or spacing compared to at least a portion of the more than one foam protrusion in the second area.

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