Knitted component for an article of footwear having a combination of two or more materials

Abstract

The present application relates to a knitted component for an article of footwear having two or more material compositions. The knitted component (104, 204) for an article of footwear (100, 200) may have an on-foot portion (156) and an underfoot portion (154, 254); a first yarn (144, 146, 148), wherein the first yarn at least partially forms the on-foot portion and at least partially forms the underfoot portion; and a second yarn (144, 146, 148), wherein the second yarn at least partially forms the on-foot portion and at least partially forms the underfoot portion. The first yarn may include a first material composition having a first melting point, and the second yarn may include a second material composition having a second melting point. The first melting point may be at least 20 degrees Celsius higher than the second melting point.

Description

[0001] This application is a divisional application of an application with an application date of May 3, 2018, application number 201880029824.8, and invention name “Knitted component for footwear having a composition of two or more materials”.

[0002] Related Applications

[0003] This application claims the benefit of U.S. Provisional Application Serial No. 62 / 502,362, filed May 5, 2017, which is hereby incorporated by reference in its entirety. background

[0004] Conventional footwear generally includes two main elements: an upper and a sole structure. The upper is fixed to the sole structure and forms a cavity within the footwear for comfortably and securely receiving the foot. The sole structure is fixed to the lower surface of the upper so as to be positioned between the upper and the ground. In some footwear articles, the sole structure may include a midsole and an outsole. The midsole may be formed of a polymer foam material that attenuates ground reaction forces to relieve stress on the foot and leg during walking, running, and other ambulatory movements. The outsole may be fixed to the lower surface of the midsole and form a portion of the sole structure that engages the ground, the portion that engages the ground being formed of a durable and wear-resistant material.

[0005] The upper of an article of footwear generally extends over the instep and toe regions of the foot, along the medial and lateral sides of the foot, and around the heel region of the foot. An ankle opening in the heel region generally provides access to a cavity within the upper. A lacing system is generally incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the cavity within the upper. The upper may include a tongue extending under the lacing system to enhance the adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.

[0006] Brief Overview

[0007] A general aspect of the present disclosure includes a knitted component for an article of footwear, the knitted component having an overfoot portion and an underfoot portion; a first yarn, wherein the first yarn at least partially forms the overfoot portion and at least partially forms the underfoot portion; and a second yarn, wherein the second yarn at least partially forms the overfoot portion and at least partially forms the underfoot portion. The first yarn may include a first material composition having a first melting point, and the second yarn may include a second material composition having a second melting point. The first melting point may be at least 20 degrees Celsius higher than the second melting point.

[0008] Another general aspect of the present disclosure includes a knitted component having an above-foot portion; a first below-foot segment extending from a first side of the above-foot portion, the first below-foot segment having a first end; and a second below-foot segment extending from a second side of the above-foot portion, the second below-foot segment having a second end. The first end can be configured to be secured to the second end such that the first below-foot segment and the second below-foot segment form an below-foot portion of an article of footwear, wherein at least one of the first below-foot segment and the second below-foot segment is formed from both a first material composition and a second material composition, and wherein the first material composition and the second material composition have different melting points.

[0009] Another general aspect of the present disclosure includes an article of footwear having a knitted component having an above-foot portion and an under-foot portion. The knitted component may have a fusion zone at least partially located on the under-foot portion, wherein the fusion zone is at least partially formed by a first yarn and a second yarn, wherein the first yarn comprises a first material composition having a first melting point, wherein the second yarn comprises a second material composition having a second melting point, and wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0010] Another general aspect of the present disclosure includes a knitted component having a first region located between a second region and a third region, wherein the first region has a first number of courses per unit length, wherein the second region has a second number of courses per unit length, and wherein the third region has a third number of courses per unit length. The first number of courses per unit length may be less than the second number of courses per unit length and the third number of courses per unit length, such that the first region of the knitted component includes a tendency to bend. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a diagram showing a side view of an article of footwear according to an embodiment of the present disclosure.

[0012] Figure 2 It is shown Figure 1 Illustration of an enlarged view of a first area of ​​an exterior surface of an article of footwear.

[0013] Figure 3 It is shown Figure 1 Illustration of an enlarged view of another area of ​​an exterior surface of an article of footwear.

[0014] Figure 4 It is shown Figure 1 Illustration of an enlarged view of yet another area of ​​an exterior surface of an article of footwear.

[0015] Figure 5 is shown for forming a Figure 1 Illustration of an embodiment of a knitted component of an upper of an article of footwear.

[0016] Figure 6 It is shown Figure 5 Illustration of knitted components being manipulated into wearable shapes.

[0017] Figure 7 It is shown Figure 1 Illustration of a bottom view of an article of footwear.

[0018] Figure 8 is an illustration showing a bottom view of a second embodiment of an article of footwear according to the present disclosure.

[0019] Fig. 9 Four embodiments of yarns that may be used to form knitted components according to the present disclosure are shown. Detailed Description

[0020] Various aspects are described below with reference to the accompanying drawings, in which like elements are generally identified by like numbers. The relationship and function of the various elements may be better understood with reference to the following description. However, the various aspects are not limited to those illustrated in the accompanying drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale, and in some cases, details that are not necessary for understanding the aspects disclosed herein may have been omitted.

[0021] Certain aspects of the present disclosure relate to knitted textiles or other textiles used in articles, and in particular in constructing uppers for articles of footwear. The uppers can be used with any type of footwear. Illustrative, non-limiting examples of articles of footwear include basketball shoes, cycling shoes, cross-training shoes, global football (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski boots or snowboard boots, tennis shoes, running shoes, and walking shoes. The uppers can also be incorporated into non-sports footwear and shoes, such as dress shoes, loafers, and sandals.

[0022] Figure 1 1 is a diagram showing an article of footwear 100 formed with an upper 102, wherein upper 102 is generally formed as a knitted component 104. As shown, upper 102 may be secured to at least one sole structure, such as first sole structure 106 and second sole structure 108. First bite line 110 may be located where an edge of first sole structure 106 joins upper 102, and second bite line 112 may be located where an edge of second sole structure joins upper 102. Upper 102 may be secured to at least one of the sole structures using any suitable technique, such as by using an adhesive, by sewing, etc.

[0023] Knitted component 104 may additionally include a shoe throat area 114 extending from an ankle opening 116 and an ankle opening 116 leading to a cavity 118, and a shoe collar 120 may at least partially surround the ankle opening 116. The cavity 118 of article of footwear 100 may be configured (e.g., sized and shaped) to receive and hold a person's foot. The shoe throat area 114 may be generally disposed in a mid-shoe area 122 of the upper 102. The mid-shoe area 122 of the upper 102 may be positioned between a heel area 124 and a forefoot area 126 (the forefoot area 126 may include a toe area 128). In some embodiments, an optional shoe tongue, such as the shoe tongue 130 depicted, may be disposed in the shoe throat area 114. The shoe tongue 130 may be any type of shoe tongue, such as a shoe tongue (gusseted tongue) or a rolled shoe tongue (burrito tongue) sewn with a triangular cloth.

[0024] The article of footwear 100 may include a fastening element (not shown). Any suitable type of fastening element may be used, such as laces, a cable-tensioning system, and / or any other suitable device. The upper 102 may be configured to be secured to and communicate with the fastening element so that the fastening element may adjust and / or tighten the upper 102 around the wearer's foot. For example, the upper 102 may include a set of holes 132 for receiving the fastening element, but other suitable elements for communicating with the fastening system may alternatively be used.

[0025] At least a portion of the upper 102, and potentially substantially the entire upper 102, can be formed by a knitted component 104 (or another suitable textile component). The knitted component 104 can be formed as an integrated one-piece element during a knitting process such as a weft knitting process (e.g., with a knitting flat machine or a circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine can substantially form the knitted structure of the knitted component 104 without requiring a large amount of post-knitting processes or post-knitting steps. Optionally, two or more parts of the knitted component 104 can be separately formed into different integrated one-piece elements, and then the corresponding elements are attached.

[0026] Forming the upper 102 with a knitted component 104 can provide the upper 102 with favorable properties, including but not limited to a certain degree of elasticity (e.g., as expressed in Young's modulus), breathability, flexibility, strength, hygroscopicity, weight, wear resistance, and / or combinations thereof. These properties can be achieved by selecting a specific single or multi-layer knitted structure (e.g., a rib knitted structure, a single jersey knit structure, or a double jersey knitted structure), by changing the size and tension of the knitted structure, by using one or more yarns formed by a specific material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a specific size (e.g., denier), and / or combinations thereof. The knitted component 104 can also provide desired aesthetic properties by incorporating yarns of different colors, textures, or other visual properties arranged in a specific pattern. The yarn itself and / or the knitted structure formed by one or more yarns of the knitted component 104 can vary at different locations so that the knitted component 104 has two or more parts with different properties (e.g., a portion of the throat area 114 forming the upper 102 can be relatively elastic, while another portion can be relatively inelastic). In some embodiments, the knitted component 104 can incorporate one or more materials that have properties that change in response to a stimulus (e.g., temperature, humidity, electric current, magnetic field, or light). For example, the knitted component 104 can include a yarn formed by at least one thermoplastic polymer material or material composition (e.g., at least one polyurethane, polyamide, polyolefin, and / or nylon) that transitions from a solid state to a softened state or liquid state when subjected to certain temperatures at or above its melting point, and then transitions back to a solid state when cooled. One or more thermoplastic polymer materials can provide at least a portion of the knitted component 104 for thermal processing (e.g., heating and then cooling), thereby forming a zone of a combined material or continuous material (referred to herein as a "fusion zone" and depicted as a fusion zone 134), which presents certain advantageous properties, including, for example, a relatively high degree of rigidity, strength, and water resistance. In this description, the term "fusion zone" generally refers to a zone where a portion of the material of the upper 102 (e.g., a material originally contained in different individual yarns of the knitted component 104) is partially or substantially combined together. "Fusion zone" does not need to be formed by any specific process. In a non-limiting example, when at least a portion of the material originally contained in the yarn is combined, two or more separated yarns including monofilament yarns and / or multifilament yarns can form a fusion zone so that at least a portion of the separated yarns become continuous with each other.Furthermore, after combining to form the fused zone, the materials of the initially separate yarns may become visually and / or physically indistinguishable, although this may not be the case in all embodiments.

[0027] The fused zone 134 can have any suitable size and shape, and the upper 102 can have multiple fused zones (which can be discrete and separated by areas without fused material). As shown, the fused zone 134 can have different areas with different properties (such as a first area 136, a second area 138, and a third area 140). For example, the first area 136 can have a relatively high density of fused material (defined as the amount (mass) of fused thermoplastic polymer material composition per unit surface area) so that the first area has relatively low elasticity, low rigidity, high strength, and high water resistance. The second area 138 can have a lower density of fused material than the first area 136, and therefore can be more elastic, potentially less rigid, and potentially less water resistant than the first area 136. Similarly, the third area can have a lower density of fused material than the first area 136 and the second area 138. More or less than three areas can be included, and Figure 1 The specific orientation, order, and position of each of the regions are included merely as non-limiting examples.

[0028] The fusion zone 134 can define a portion of the outer surface 142 of the upper 102. In at least some locations of the knitted component 104, the fusion zone 134 can be generally limited to the outer surface 142 of the knitted component 104, and the inner surface (at Figure 6 ) may not include fusion zone 134. The inner surface of the knitted component may relatively face outer surface 142 and may at least partially form cavity 118 of the article of footwear. In other words, the inner surface may be located between outer surface 142 and cavity 118 (e.g., such that fusion zone 134 is separated from the cavity at least at one location).

[0029] Advantageously, the inner surface can include softness, abrasion resistance, and other comfort-related properties that can be associated with the knitted component 104 in areas without the fused regions 134. A multi-layer knitted component having a fused region located on an outer surface (but not necessarily an inner surface) is fully described in U.S. Patent Application No. 15 / 443,808, filed on February 27, 2017, which is incorporated herein by reference in its entirety.

[0030] When thermoplastic polymer material or thermoplastic polymer composition is included in yarn, any part of yarn can have one or more thermoplastic polymers (collectively referred to as "thermoplastic polymer material composition"), and in some embodiments, substantially whole yarn can be formed by thermoplastic polymer material composition. Optionally, yarn can have polyester core and thermoplastic polymer sheath. The thermoplastic polymer material composition of sheath can have a melting temperature less than the melting temperature or decomposition temperature of polyester core. For example, in some embodiments, the melting temperature of thermoplastic polymer material composition can have a melting temperature less than about 100 degrees Celsius of the melting temperature of polyester core, but any other suitable melting temperature difference is expected. All melting points and other temperatures mentioned herein are approximate and based on the atmospheric pressure at sea level. In one example, the melting temperature of polyester core can be about 260 degrees Celsius, and the decomposition temperature can be about 350 degrees Celsius or greater. The melting temperature of the thermoplastic polymer material composition can be, for example, between about 80 degrees Celsius and about 200 degrees Celsius, such as from about 120 degrees Celsius to about 180 degrees Celsius. In an exemplary embodiment, the yarn can include thermoplastic polyurethane, which can be specifically manufactured by Sambu Fine Chemical Co., LTD. Thermoplastic polyurethane coated yarns are sold.

[0031] Figure 2 1 is a diagram showing an enlarged view of the first region 136 of the fusion zone 134. Figure 2 As shown in, in some embodiments, more than one thermoplastic polymer material composition may be included. For example, when the upper 102 is formed by the knitted component 104, the knitted component 104 may include more than one yarn type, wherein different yarn types include different material compositions. Therefore, it is envisioned that the knitted component 104 may include a first yarn 144 including a first material composition and a second yarn 146 having a second material composition, wherein the first material composition and the second material composition have different melting points. In a non-limiting exemplary embodiment, the first material composition may include a composition of a thermoplastic polyurethane material having a melting point of about 140 degrees Celsius or lower, such as about 120 degrees Celsius. The second material composition may include different compositions of thermoplastic polyurethane materials having a melting point of about 195 degrees Celsius or lower, such as about 175 degrees Celsius. Therefore, the second melting point may be higher than the first melting point (e.g., at least 5 degrees Celsius, at least 10 degrees Celsius, at least 20 degrees Celsius, at least 50 degrees Celsius, at least 100 degrees Celsius or even higher). Other suitable material compositions having different melting points may additionally or alternatively be included.

[0032] Including multiple thermoplastic polymer material compositions may be beneficial in providing the upper with desired properties that may be difficult to achieve when only one composition is used. For example, a fusion zone formed with a thermoplastic polymer material composition having a relatively low melting point (e.g., 120 degrees Celsius) may have the desired water-resistant properties, but it may be susceptible to wear. A thermoplastic polymer material composition having a higher melting temperature (e.g., 175 degrees Celsius) may lack the desired degree of water resistance, but may be associated with a high degree of wear resistance. Therefore, by including two material compositions in the fusion zone, the fusion zone can have the desired water resistance properties as well as the desired wear resistance. Although this paragraph uses wear resistance and water resistance as examples, other properties may be additionally or alternatively associated with a fusion zone formed by a specific material composition having a specific melting point.

[0033] In the first region 136, the ratio of one material composition to another material composition (measured as the mass ratio of one material composition to another material composition per unit surface area) can be any suitable ratio. For example, in some non-limiting exemplary embodiments, the ratio of the first thermoplastic polymer material composition (of the first yarn 144) to the second thermoplastic polymer material composition (of the second yarn 146) can be about 1:1, but other ratios (e.g., 1:0.1, 1:0.25, 1:0.5, 1:0.75, 1:1, 1:1.5, 1:2, 1:5, 1:10, etc.) are also contemplated. The ratio can be determined by the amount of first yarn 144 used relative to the amount of second yarn 146, the amount of the first thermoplastic polymer material composition per unit length of the first yarn 144, and / or the amount of the second thermoplastic polymer material composition per unit length of the second yarn 146, etc. Additionally, the ratio of one material composition to another material composition may vary throughout the article of footwear 100, and even throughout the first area 136 of the fusion zone 134, particularly when different properties are desired at different locations within the fusion zone 134 (e.g., different material compositions are desired).

[0034] Figure 31 is an illustration of an enlarged view of a second region 138 showing a fusion zone 134. As shown, in the second region 138, the amount of the first thermoplastic polymer material composition per unit surface area can be less than the amount in the first region 136, which may be due to the use of less first yarn 144 in the second region 138 than in the first region 136 (per unit surface area). Similarly, the amount of the second thermoplastic polymer material composition per unit surface area can be less in the second region 138 than in the first region 136. The knitted component 104 may also include a third yarn 148 formed of a third material composition different from the first material composition and the second material composition. In one example, the third yarn 148 may be substantially formed of a material having a melting point (e.g., if the material is a thermoplastic polymer material) and / or a decomposition point (e.g., if the material is a thermosetting material) higher than the melting point of the first yarn 144 and the second yarn 146. Illustrative, non-limiting examples of materials from which the third yarn 148 may be formed may include thermosetting polymer materials and natural fibers, such as cotton, silk, and wool; or thermoplastic polymer materials having relatively high melting points, such as polyester. These materials tend to remain stable when subjected to moderate levels of heat. Note that reference herein to the first yarn 144 and the second yarn 146 as being formed of a thermoplastic polymer material composition does not limit the third yarn 148 to also being a separate thermoplastic polymer material composition having an even higher melting point, even when the third yarn 148 will not generally form a fusion zone when thermally processed according to the present disclosure.

[0035] Advantageously, when the first yarn and / or the second yarn are heat-processed, the relatively high melting point and / or decomposition point of the third yarn 148 can indicate that the third yarn 148 remains relatively stable. Therefore, the general properties that the third yarn has before the heat-processing step can be maintained during and after the heat-processing. In some embodiments, the third yarn 148 can have a melting point and / or decomposition temperature of about 140 degrees Celsius or higher, about 175 degrees Celsius or higher, about 200 degrees Celsius or higher, about 250 degrees Celsius or higher or even higher. A specific example is a yarn formed substantially by polyester, which can have a melting point of about 250 degrees Celsius and a boiling point or decomposition point of about 350 degrees Celsius.

[0036] When the knitted component 104 includes a knitted structure formed on two needle beds (e.g., a double-sided plain knitted structure), the material ratio can be changed by changing the yarn exposed on the outer surface 142. For example, in the first area 136 of the fusion zone 134, the third yarn 148 can be knitted mainly on the rear needle bed of the knitting machine so that the third yarn is mainly located on the inner side of the knitted component. In the second area 138, a larger portion of the third yarn 148 can be incorporated into the outer side of the knitted component 104 (e.g., by knitting the third yarn 148 with the front needle bed of the knitting machine), while a larger portion of the first yarn 144 and / or the second yarn 146 can be incorporated into the inner side. The process for changing the amount of different yarn types on the corresponding sides of the component is fully described in U.S. Patent Application No. 15 / 443,808 (in the above, which is incorporated into this description by reference).

[0037] refer to Figure 1 , in some embodiments, the ratio of the fused material to the non-fused material present in the region of the knitted component 104 can be changed. For example, when moving from the bite line toward the shoe throat area 114, the amount and / or density of the fused thermoplastic polymer material composition may be reduced. For illustration, the first region 136 may be mainly formed by the fused thermoplastic polymer material composition. In the second region 138, the knitted component 104 may include a relatively reduced amount of thermoplastic polymer material composition, and the third region 140 may include even less fused thermoplastic polymer material than the second region 138. In a non-limiting example, the ratio of the fused thermoplastic polymer material composition to other materials can be about 90:10 (or greater) in the depicted first region 136, about 50:50 in the second region 138, and about 25:75 in the third region 140. Other ratios in the first region 136, the second region 138, and / or the third region 140 are contemplated. It is also contemplated that one or more of the regions may be gradiently decreasing in ratio of fused material to another material, and that in some embodiments, the different regions may not be discrete and / or may not be invisible or otherwise discernible.

[0038] It is also contemplated that, instead of (or in addition to) varying the amount of thermoplastic polymer material, different areas of the knitted component 104 having the thermoplastic polymer material composition may be processed differently (e.g., more heat and / or pressure may be applied in one or more areas than in other areas). In some embodiments, some selected areas of the knitted component 104 may not form a fusion zone at all, even when including a thermoplastic polymer material composition. For example, if the knitted component 104 includes a thermoplastic polymer material composition in areas where the properties associated with the fusion zone are not required, those areas may be shielded from heat, for example, during a thermal processing step.

[0039] Figure 4 14. It is a diagram showing an enlarged view of the shoe throat area 114. The outer surface of the knitted component 104 at the shoe throat area 114 can be formed completely by the third yarn 148 (and / or can include the unfused portion of the first yarn 144 and / or the second yarn 146). Advantageously, the shoe throat area 114 can include the required elasticity for providing a comfortable and / or adjustable fit around the wearer's foot for the footwear article 100. At least one surface of the shoe throat area 114 can be mainly formed by polyester, but other suitable materials can be included additionally or selectively. Similarly, the shoe collar 120 and / or the shoe tongue 130 of the knitted component 104 can exclude the fusion zone 134, so that they have a relatively high degree of elasticity, flexibility, resilience, breathability, adjustability, softness and wear resistance and / or other desired characteristics for accommodating the foot and providing a comfortable and / or adjustable fit. Other areas of the upper 102 can exclude the fusion zone additionally or selectively. It is contemplated that these areas may be covered with a film (eg, a spray-on or adhesive film) to protect the knitted component from abrasion (especially on the outer surface), but such a film is optional.

[0040] Figure 5 The knitted component 104 of the upper 102 is shown as it may appear after the knitting process (e.g., after leaving a flat-bed knitting machine) but before being manipulated into its wearable shape. Optionally, the knitted component 104 can be cut into its desired shape after knitting, but cutting is not required in some embodiments. The knitted component 104 can be heat-treated before being manipulated into its wearable shape to form a first area 136, a second area 138 and / or a third area 140 of a fusion zone 134. Heat treatment after the knitting step but before the upper 102 is manipulated into its wearable shape may be advantageous because when the knitted component 104 is generally flat, it can be relatively easily completed and relatively effective using a hot press or other device. A method for knitted components that can be heat-treated to form a fusion zone 134 is fully described in U.S. Patent Application No. 15 / 443,808 (in the above, which is incorporated by reference).

[0041] As shown, knitted component 104 may include at least one underfoot segment, such as depicted medial underfoot segment 150 and lateral underfoot segment 152. Medial underfoot segment 150 and lateral underfoot segment 152 may be constructed (e.g., sized, shaped, and positioned) to form an underfoot portion 154 of an article of footwear. Underfoot portion 154 (also shown) Figure 7The knitted component 104 may be configured to form an upper portion 156 associated with the remainder of the foot, the upper portion 156 including a dorsal surface (i.e., the top of the foot). The lower portion 154 may extend from the lateral side 158 of the upper 102 to the medial side 160 of the upper, and from the toe area 128 to the heel area 124.

[0042] In some embodiments, the heat processing step can be twice as many steps as molding at least one rib structure 162 or other features in the fusion zone 134. Therefore, it is envisioned that the hot press used for the heat processing step can have at least one mold, or alternatively, a separate mold can be applied to the thermoplastic polymer material composition during or after the application of heat. The rib structure 162 can be beneficial for providing the desired surface properties for the fusion zone 134. For example, the rib structure 162 can be constructed (e.g., sized, shaped and positioned) to provide grip or provide another desired function when performing sports activities (e.g., when kicking a ball). The rib structure 162 or other molded structures can additionally or alternatively provide the desired aesthetics to the outer surface 142 of the knitted component 104. In some embodiments, a logo, label or another suitable image or design can be molded in the fusion zone 134.

[0043] The fusion zone 134 may be at least partially located on the underfoot portion 154. As shown, the fusion zone 134 may extend upwardly on the underfoot portion 154, along the overfoot portion 156, and terminate at the edge of the throat area 114. In some embodiments (as depicted), the fusion zone 134 may substantially cover the entire underfoot portion 154. Advantageously, the fusion zone 134 may provide the underfoot portion 154 with the desired properties associated with the fusion zone 134, such as suitable strength, durability, flexibility, water permeability, stretchability, and the like. Because the underfoot portion 154 can bear the weight of the wearer when in use, the fusion zone 134 may be particularly thick and / or dense on the underfoot portion 154 relative to other locations to provide a relatively high degree of support, durability, protection, and even cushioning between the ground and the plantar aspect of the foot. For example, during thermal processing, it is contemplated that the hottest portion of the heat press may be applied to the underfoot portion 154 (since molten thermoplastic polymer material has a tendency to flow toward heat), thereby facilitating a dense and / or thick fusion zone 134 at the underfoot portion 154 .

[0044] Figure 61 is a diagram showing that knitted component 104 is folded or otherwise manipulated into a wearable shape. As shown, the outer surface 142 formed by knitted component 104 can face outward, and the inner surface 164 can face inward and ultimately define the cavity of the footwear article. The outer heel area 176 and the medial heel area 178 can be connected at this step to form a heel seam 166 in the heel area 124. Connecting the outer heel area 176 to the medial heel area 178 at the heel seam 166 can include sewing, adhesive bonding, thermal bonding, welding, using a mechanical clamp or any other suitable device or method, and it is envisioned that another device can be placed between the medial heel area 178 and the outer heel area 176. When the upper 102 is located on the last, the folding step / manipulation step and / or the step of forming the heel seam 166 can be at least partially performed. Examples of lasts and associated lasting processes are described in US Patent Application Serial No. 12 / 848,352, filed on August 2, 2010 and issued as US Patent No. 8,595,878, which is incorporated herein by reference in its entirety.

[0045] Similarly, the lateral instep section 152 and the medial instep section 150 may be joined at this step to form an instep seam 168 on the instep portion 154 of the upper 102. Joining the lateral instep section 152 to the medial instep section 150 may include sewing, adhesive bonding, heat bonding, welding, using a mechanical clamp, or any other suitable device or method, and it is contemplated that another device may be placed between the medial instep section 150 and the lateral instep section 152. The folding step / manipulation step and / or the step of forming the instep seam 168 may be at least partially performed when the upper 102 is on a last (not shown).

[0046] Before, during or after the step of knitted component 104 being manipulated into its wearable shape, one or more insertion elements may be included. For example, a bottom layer 170 may be included to facilitate the wearable shape of the upper 102. The bottom layer 170 may be fixed to the knitted component (e.g., by sewing, using adhesives, etc.) and may provide suitable structure, durability, strength, rigidity, etc., particularly in the heel area 124 and the underfoot portion 154 (but also additionally or selectively in other areas). In some embodiments, the bottom layer 170 may be connected to the last during the lasting step, and then disengage from the last when the upper 102 is removed from the last. A second insertion element may be included to provide cushioning, to facilitate the connection of the lateral underfoot section 152 to the medial underfoot section 150, or for any other suitable purpose. More than or less than two insertion elements may be included for a wide range of functions.

[0047] like Figure 6As shown in , the tongue 130 and / or the throat area 114 of the knitted component 104 may include a knitted structure so that the tongue 130 has a tendency to bend. The tongue 130 may be configured to be pulled by the user to facilitate placing the foot in the upper 102. In this way, the tongue 130 may include a tendency to bend away from the user's leg so that it can be easily and effectively positioned and gripped. The tendency to bend can be formed by any suitable knitted structure (or other structure). For example, the tendency to bend can be provided by providing more horizontal rows on one surface (e.g., the bottom surface) of the tongue 130 than on another surface (e.g., the top surface), so that when the tongue 130 is forced to be in a flat state, the tension in the top surface is higher than the tension in the bottom surface. This structure and the associated knitting process are fully described in U.S. Provisional Patent Application No. 62 / 421,850 filed on November 14, 2016, which is incorporated herein by reference in its entirety.

[0048] Additionally or alternatively, the throat area 114 may include fewer rows than at least a portion of one of the lateral side 158 and the medial side 160 of the knitted component located adjacent to the throat area 114. For example, the throat area 114 may include one row for every two rows of the lateral side 158 and / or the medial side. Other ratios are also contemplated (e.g., the ratio of rows of the throat area to the adjacent portion may be approximately 0.1:1, 0.2:1, 0.5:1, 0.8:1, etc.). At least when the knitted component is forced into a flattened state, the resulting knitted component 104 may have a structure that provides a higher tension in the yarns in the throat area 114 than in the surrounding yarns due to fewer rows covering substantially the same distance (i.e., the distance along the knitting direction). When the knitted component 104 is deformed in a manner that causes the tongue 130 to be pulled upward, the higher tension in the tongue 130 and / or the throat area 114 can be equalized, and thus a natural tendency can be included in the knitted structure to bend the tongue 130. This feature can be enhanced when the throat area 114 and / or the tongue 130 are formed by a yarn having a relatively high elasticity. Therefore, it can be advantageous for the throat area 114 and / or the tongue 130 to include at least one yarn that is more elastic (before or after heat treatment) than the yarn that primarily forms the lateral side 158 and / or medial side 160 of the knitted component 104. Similarly, because heat treating the lateral side and medial side to form the fusion zone 134 can increase the rigidity of the lateral side 158 and medial side 160 and reduce their flexibility, forming the fusion zone 134 can enhance the tendency of the tongue 130 to bend.

[0049] Figure 7is a diagram showing a bottom view of article of footwear 100. As shown, underfoot seam 168 may be located on underfoot portion 154 where lateral underfoot section 152 and medial underfoot section 150 are secured. Underfoot seam 168 may be generally in the center of underfoot portion 154 and may extend along the longitudinal direction of article of footwear 100, but in other embodiments, underfoot seam 168 may be offset relative to the center of underfoot portion 154 and / or may extend in a different direction or be otherwise oriented.

[0050] The underfoot portion 154 can be configured to be attached to at least one sole structure (such as the first sole structure 106 and / or the second sole structure 108). The underfoot portion 154 can be connected to the first sole structure 106 and / or the second sole structure 108 using any suitable technique, such as by using an adhesive, by sewing, bonding, welding, etc. In this way, the underfoot portion 154 can be formed with a specific yarn and / or knitted structure so that the underfoot portion 154 has suitable surface properties for fully bonding and supporting the sole structure. The first sole structure 106 and the second sole structure 108 can be located in the forefoot area 126 and the heel area 124 of the underfoot portion 154, respectively. These corresponding positions may be advantageous because the forefoot area 126 and the heel area 124 are typically the main contact portions with the ground when the footwear article is in normal use.

[0051] As shown, the underfoot portion 154 may include an exposed area 172 in which the knitted component 104 faces the ground and is not covered by the sole structure. Advantageously, the exposed area 172 can provide the required flexibility and / or other required characteristics in the midfoot area 122 (or another position) so that the footwear article 100 can be flexed, stretched, etc. (e.g., during running). It is also envisioned that in some cases, such as when the cleats 174 of at least one of the first sole structure 106 and the second sole structure 108 are embedded in the ground, the exposed area 172 of the underfoot portion 154 can be configured to directly contact the ground. Therefore, the fusion zone 134 can be fully strong, durable, protective or otherwise configured to be used as the bottom terminal surface of the footwear article at least at one position of the underfoot portion 154.

[0052] Figure 82 is an illustration showing a bottom view of a second embodiment of an article of footwear 200 according to the present disclosure. As shown, article of footwear 200 can include an underfoot portion 254 having a base member 276. Lateral underfoot segment 252 and medial underfoot segment 250 of underfoot portion 254 can be formed with a knitted component according to the above description and can be secured to a first edge 278 and a second edge 280 of the base member, respectively. In some embodiments, lateral underfoot segment 252 and / or medial underfoot segment 250 can continue to extend adjacent to base member 276 (e.g., from Figure 8 208 (from the perspective of the shoe, such as being covered by the base element 276), and the lateral instep section 252 and the medial instep section 250 can meet to form a seam (or not meet). The base element 276 can be formed by any suitable material, such as a plastic material, a rubber material, a metal, a carbon fiber or other composite material, a textile material (such as a knitted material) or any other suitable material or material combination. Advantageously, the base element 276 can facilitate a firm, durable and otherwise sufficient fixation between the two instep sections of the instep portion 254, between the instep portion 254 and at least one of the first sole structure 206 and the second sole structure 208 (or another sole structure) and / or between any other fixed elements. The base element 276 can additionally or optionally provide cushioning and protection to the plantar aspect of the wearer's foot. In some embodiments, the base element 276 can be integral with the sole structure (e.g., integrally formed), but this is not necessary. The base element 276 can be fixed to the knitted component 204 during the lasting step or in another step.

[0053] Fig. 9 Four embodiments of yarns that may be used to form knitted components according to the present disclosure are shown. Fig. 9 The yarn depicted in can be included as any of the yarns described above (e.g., the first yarn 144, the second yarn 146, and / or the third yarn 148 described above), and / or can be included as another yarn.

[0054] The first yarn type 302 may include a generally circular cross-section. The first yarn type 302 may be formed at least in part by a thermoplastic polymer material composition or another material. As shown, the first yarn type 302 may be substantially formed by a single material or material composition and may not have different cores. Therefore, if the first yarn type 302 is formed by a thermoplastic polymer material composition, the entire first yarn type 302 may melt or at least partially melt when heated to a medium-high temperature (e.g., a temperature in the range of 120 degrees Celsius to about 200 degrees Celsius).

[0055] The second yarn type 304 can also include a substantially circular cross-section. The second yarn type 304 can be formed at least in part by a thermoplastic polymer material composition or another material. As shown, the second yarn type 304 can include two different materials or compositions, one of which forms a core 306 and a second material forms a sheath 308. Therefore, if the second yarn type 304 has a sheath 308 formed by a thermoplastic polymer material composition and a core formed by different materials (e.g., a material with a higher melting point and / or decomposition point), the sheath can melt or at least partially melt when heated to a medium-high temperature (e.g., a temperature in the range of 120 degrees Celsius to about 200 degrees Celsius), but the core 306 can remain stable. Advantageously, the material of the sheath 308 can form a fusion zone as described above, and the core 306 ensures that the yarn maintains its desired orientation, structure and other properties during and after the thermal processing step.

[0056] The third yarn type 310 can be similar to the first yarn type, but can have a trilobal cross-section. Advantageously, yarns having a trilobal cross-section can be used alone or in combination with other yarns of other cross-sections to form a knitted component having a desired water resistance. Fig. 9 As shown in , the spaces or cavities between the yarns can be minimized by the unique cross-sectional shape of the lobes of the trilobal cross-section, which can prevent and / or limit the flow of water or other fluids from one side of the associated knitted component to the other side. The advantages of the trilobal shape can be enhanced when the third yarn type 310 is at least partially melted and cooled to form a fusion zone as described above.

[0057] As with the second yarn type 304, the fourth yarn type 312 (which has a trilobal cross-section) can include a core 314 having a material different from that of the sheath 316. Thus, if the fourth yarn type 312 has a sheath 316 formed of a thermoplastic polymer material composition and a core 314 formed of a different material (e.g., a material having a higher melting point and / or decomposition point), the sheath 316 can melt or at least partially melt when heated to moderately high temperatures (e.g., a temperature in the range of 120 degrees Celsius to about 200 degrees Celsius), but the core 314 can remain stable. Advantageously, the material of the sheath 316 can form a fusion zone as described above, while the core 314 ensures that the yarn maintains its desired orientation, structure, and other properties during and after the thermal processing step.

[0058] According to the present disclosure, all structures and methods disclosed and claimed herein can be manufactured and executed without excessive experimentation. Although the present disclosure can be implemented in many different forms, the specific aspects of the present disclosure are described in detail herein. The present disclosure is an example of the principle of the disclosure, and is not intended to limit the present disclosure to the illustrated specific aspects. In addition, unless clearly stated to the contrary, the use of the term "one (a)" is intended to include "at least one" or "one or more". For example, "a yarn" is intended to include "at least one yarn" or "one or more yarns".

[0059] Any range given in absolute terms or in approximate terms is intended to encompass both, and any definition used herein is intended to be illustrative and not restrictive. Although the numerical ranges and parameters describing the broad scope of the present disclosure are approximate, the numerical values ​​described in the specific examples are reported as accurately as possible. However, any numerical value inherently contains certain errors that are inevitably caused by the standard deviation present in its corresponding test measurement. In addition, the full range disclosed herein should be understood to encompass any and all subranges (including all fractional values ​​and integer values) included therein.

[0060] In addition, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present disclosure and without reducing its expected advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

[0061] The present invention also relates to the following items:

[0062] 1. A knitted component, comprising:

[0063] an upper portion and a lower portion for forming respective upper and lower portions of an article of footwear;

[0064] a first yarn, wherein the first yarn at least partially forms the above-foot portion and at least partially forms the below-foot portion; and

[0065] a second yarn, wherein the second yarn at least partially forms the above-foot portion and at least partially forms the below-foot portion,

[0066] wherein the first yarn comprises a first material composition, the first material composition comprising a first melting point,

[0067] wherein the second yarn comprises a second material composition, the second material composition comprises a second melting point, and

[0068] Wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0069] 2. The knitted component of item 1, wherein the first melting point is approximately 195 degrees Celsius or less, and wherein the second melting point is approximately 140 degrees Celsius or less.

[0070] 3. The knitted component as described in item 1 also includes a third yarn having a third material composition, wherein the third material composition includes a third temperature equal to the lowest of the melting point and the decomposition point of the third material composition, and wherein the third temperature is higher than the first melting point.

[0071] 4. The knitted component of item 1, wherein the underfoot portion is formed by a first underfoot segment extending from a first side of the overfoot portion and a second underfoot segment extending from a second side of the overfoot portion.

[0072] 5. The knitted component of item 4, wherein the first end of the first underfoot section is secured to the second end of the second underfoot section at an underfoot seam.

[0073] 6. The knitted component of item 1, wherein the knitted component includes an exposed area on the underfoot portion.

[0074] 7. A knitted component as described in item 1, wherein the exposed area is positioned between a first sole structure and a second sole structure fixed to the underfoot portion of the knitted component, wherein the first sole structure is positioned on the forefoot area of ​​the underfoot portion, and wherein the second sole structure is positioned on the heel area of ​​the underfoot portion.

[0075] 8. The knitted component of item 7, wherein the first sole structure is positioned at a forefoot region of the knitted component and the second sole structure is positioned at a heel region of the underfoot portion.

[0076] 9. The knitted component of item 7, wherein the first sole structure and the second sole structure are separated by at least a portion of an exposed area on a midfoot region of the underfoot portion.

[0077] 10. A knitted component, comprising:

[0078] Upper part of the foot;

[0079] a first underfoot segment extending from a first side of the overfoot portion, the first underfoot segment having a first end; and

[0080] a second underfoot segment extending from a second side of the overfoot portion, the second underfoot segment having a second end, wherein the first end is configured to be secured to the second end such that the first underfoot segment and the second underfoot segment form an underfoot portion of the article of footwear,

[0081] At least one of the first underfoot segment and the second underfoot segment is formed of both a first material composition and a second material composition, wherein the first material composition and the second material composition have different melting points.

[0082] 11. A knitted component as described in item 10, wherein the first material composition is contained in a first yarn, wherein the second material composition is contained in a second yarn, and wherein the first yarn and the second yarn are looped around each other to form at least a portion of the knitted component.

[0083] 12. The knitted component of item 11, wherein the first material composition comprises a first melting point, wherein the second material composition comprises a second melting point, and wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0084] 13. The knitted component of item 12, wherein the first melting point is approximately 195 degrees Celsius or less, and wherein the second melting point is approximately 140 degrees Celsius or less.

[0085] 14. The knitted component as described in item 12 also includes a third yarn having a third material composition, wherein the third material composition includes a third temperature equal to the lowest of at least one of the melting point or decomposition point of the third material composition, and wherein the third temperature is higher than the first melting point.

[0086] 15. The knitted component of item 14, wherein the third temperature is at least 50 degrees Celsius higher than the first melting point.

[0087] 16. The knitted component of item 14, wherein the third material composition is formed substantially from polyester.

[0088] 17. The knitted component according to item 10,

[0089] wherein the knitted component has a first region and a second region,

[0090] wherein a first ratio of the amount of the first material composition to the amount of the second material composition per surface area is included in the first region,

[0091] wherein a second ratio of the amount of the first material composition to the amount of the second material composition per surface area is included in the second region,

[0092] Wherein, the first ratio is greater than the second ratio.

[0093] 18. A method comprising:

[0094] A knitted component is formed for an article of footwear, the knitted component comprising:

[0095] The upper and lower parts of the foot;

[0096] a first yarn, wherein the first yarn at least partially forms the above-foot portion and at least partially forms the below-foot portion; and

[0097] a second yarn, wherein the second yarn at least partially forms the above-foot portion and at least partially forms the below-foot portion,

[0098] wherein the first yarn comprises a first material composition, the first material composition comprising a first melting point,

[0099] wherein the second yarn comprises a second material composition, the second material composition comprises a second melting point, and

[0100] Wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0101] 19. The method of claim 18, wherein the first melting point is about 195 degrees Celsius or less, and wherein the second melting point is about 140 degrees Celsius or less.

[0102] 20. A method as described in item 18, wherein the knitted component also includes a third yarn having a third material composition, wherein the third material composition includes a third temperature equal to the lowest of the melting point and the decomposition point of the third material composition, and wherein the third temperature is higher than the first melting point.

Claims

1. A knitted component for an article of footwear, the knitted component comprising: an overfoot portion and an underfoot portion for forming respective overfoot and underfoot portions of an article of footwear, the overfoot portion comprising a fused zone, the fused zone comprising a first area and a second area; a first yarn, wherein the first yarn at least partially forms the first and second regions of the above-foot portion and at least partially forms the below-foot portion; as well as a second yarn, wherein the second yarn at least partially forms the first and second regions of the above-foot portion and at least partially forms the below-foot portion, wherein the first yarn comprises a first material composition, the first material composition comprising a first melting point, wherein the first material composition at least partially comprises a first thermoplastic polymer material, wherein the second yarn comprises a second material composition, the second material composition comprising a second melting point, wherein the second material composition comprises a second thermoplastic polymer material different from the first thermoplastic polymer material, wherein the first melting point is at least 20 degrees Celsius higher than the second melting point, wherein the knitted component further comprises a third yarn having a third material composition, the third material composition comprising a third temperature equal to the lowest of a melting point and a decomposition point of the third material composition, wherein the third temperature is higher than the first melting point, wherein, in the first area, the third yarn is mainly positioned on the inner side of the knitted component, and wherein in the second area, a larger part of the third yarn forms the outer side of the knitted component or is incorporated into the outer side of the knitted component, while a larger part of the first yarn and / or the second yarn is incorporated into the inner side of the knitted component, And wherein the amount of the first thermoplastic polymer material per unit surface area and the amount of the second thermoplastic polymer material per unit surface area are each less in the second region than in the first region.

2. The knitted component according to claim 1, wherein the above-foot portion includes a throat area, and wherein a density of the thermoplastic polymer material decreases when moving from a bite line toward the throat portion.

3. The knitted component according to claim 1, wherein the underfoot portion is formed by a first underfoot segment extending from a first side of the overfoot portion and a second underfoot segment extending from a second side of the overfoot portion.

4. The knitted component according to claim 3, wherein the first end of the first underfoot section is secured to the second end of the second underfoot section at an underfoot seam.

5. The knitted component according to claim 1, wherein the knitted component includes an exposed area on the underfoot portion.

6. A knitted component according to claim 5, wherein the exposed area is positioned between a first sole structure and a second sole structure of the underfoot portion fixed to the knitted component, wherein the first sole structure is positioned at the forefoot area of ​​the underfoot portion, and wherein the second sole structure is positioned at the heel area of ​​the underfoot portion.

7. The knitted component of claim 6, wherein the first sole structure and the second sole structure are separated by at least a portion of an exposed area on a midfoot region of the underfoot portion.

8. The knitted component of claim 1, wherein the third temperature is at least 50 degrees Celsius higher than the first melting point.

9. The knitted component of claim 1, wherein the first yarn and the second yarn are interlooped to form at least a portion of the knitted component.

10. The knitted component according to claim 1, further comprising a bottom layer adjacent the underfoot portion of the knitted component, the bottom layer being an insert element and facilitating maintenance of a wearable shape of an upper.

11. An article of footwear comprising a knitted component according to any one of claims 1 to 10.

12. A method of manufacturing an article of footwear, the method comprising: A knitted component is formed for an article of footwear, the knitted component comprising: an overfoot portion and an underfoot portion, the overfoot portion comprising a fusion zone, the fusion zone comprising a first region and a second region; a first yarn, wherein the first yarn at least partially forms the first and second regions of the abovefoot portion and at least partially forms the belowfoot portion; and a second yarn, wherein the second yarn at least partially forms the first and second regions of the above-foot portion and at least partially forms the below-foot portion, wherein the first yarn comprises a first material composition, the first material composition comprising a first melting point, wherein the first material composition at least partially comprises a first thermoplastic polymer material, wherein the second yarn comprises a second material composition, the second material composition comprising a second melting point, wherein the second material composition comprises a second thermoplastic polymer material different from the first thermoplastic polymer material, wherein the first melting point is at least 20 degrees Celsius higher than the second melting point, wherein the knitted component further comprises a third yarn having a third material composition, the third material composition comprising a third temperature equal to the lowest of a melting point and a decomposition point of the third material composition, wherein the third temperature is higher than the first melting point, wherein, in the first area, the third yarn is mainly positioned on the inner side of the knitted component, and wherein in the second area, a larger part of the third yarn forms the outer side of the knitted component or is incorporated into the outer side of the knitted component, while a larger part of the first yarn and / or the second yarn is incorporated into the inner side of the knitted component, And wherein the amount of the first thermoplastic polymer material per unit surface area and the amount of the second thermoplastic polymer material per unit surface area are each less in the second region than in the first region.

13. An article of footwear, comprising: an overfoot portion and an underfoot portion, the overfoot portion comprising a fusion zone, the fusion zone comprising a first region and a second region; a first yarn, wherein the first yarn at least partially forms the first and second regions of the above-foot portion and at least partially forms the below-foot portion; as well as a second yarn, wherein the second yarn at least partially forms the first and second regions of the above-foot portion and at least partially forms the below-foot portion, wherein the first yarn comprises a first material composition, the first material composition comprising a first melting point, wherein the first material composition at least partially comprises a first thermoplastic polymer material, wherein the second yarn comprises a second material composition, the second material composition comprising a second melting point, wherein the second material composition comprises a second thermoplastic polymer material different from the first thermoplastic polymer material, wherein the first melting point is at least 20 degrees Celsius higher than the second melting point, wherein the article of footwear further comprises a third yarn having a third material composition, the third material composition comprising a third temperature equal to the lowest of a melting point and a decomposition point of the third material composition, wherein the third temperature is higher than the first melting point, wherein, in the first area, the third yarn is mainly positioned on the inner side of the article of footwear, and wherein in the second area, a larger part of the third yarn forms the outer side of the article of footwear or is incorporated into the outer side of the article of footwear, while a larger part of the first yarn and / or the second yarn is incorporated into the inner side of the article of footwear, And wherein the amount of the first thermoplastic polymer material per unit surface area and the amount of the second thermoplastic polymer material per unit surface area are each less in the second region than in the first region.

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