Article of footwear having a knitted component and method of manufacturing the same

Abstract

The present application relates to articles of footwear having knitted components and methods of manufacturing the same. Disclosed herein are articles of footwear having integrally knitted uppers having features for increasing constriction around a wearer's foot, improving strength and durability, and incorporating haptic feedback by increasing coefficient of friction while removing weight due to traditional additional components. The knitted components can be radially knitted such that courses converge towards a common area, such as a throat area of the upper. Additionally, fusible yarns can be knitted at least on an exterior-facing surface of a constriction area of the knitted component to create additional locking along the lines of constriction. Furthermore, stretch elements can be incorporated within the constriction area to provide strength and locking along desired lines of constriction. Additionally, the fusible yarns can be grip yarns that create areas with greater coefficient of friction.

Description

[0001] This application is a divisional application of the application filed on October 22, 2022, with application number 202280063095.4 and invention title "Footwear Article with Knitted Components and Method for Manufacturing the Same Thereof". Background Technology

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

[0003] The footwear products and their manufacturing methods described herein are discussed in detail with reference to the accompanying drawings, wherein:

[0004] Figure 1A An exterior perspective view of footwear products based on various aspects of this article is depicted;

[0005] Figure 1B Depicting various aspects based on this article Figure 1A An inside view of footwear products;

[0006] Figure 2 Depicting various aspects based on this article Figure 1A Knitted components of footwear;

[0007] Figure 3 A schematic representation of the radially knitted component is depicted according to various aspects of this article;

[0008] Figures 4A to 4D Different views of footwear products are depicted according to various aspects of this article;

[0009] Figure 5 The polymer layers for footwear products are described according to various aspects of this article;

[0010] Figure 6 It describes the aspects of this article. Figure 5 An exterior perspective view of footwear with a polymer layer;

[0011] Figure 7 A flowchart depicts a method for manufacturing shoe uppers for footwear products according to various aspects of this article;

[0012] Figure 8 Describes the aspects used in this article for the purpose of... Figure 7 The knitted components on the clamps used to manufacture the shoe upper;

[0013] Figure 9 A close-up view of a portion of a footwear product with a replica embedded structure, according to various aspects of this article;

[0014] Figure 10 Example knitted components for footwear products are depicted according to various aspects of this article. Detailed Implementation

[0015] This detailed description relates to knitted components for footwear articles that provide restraint and support while maintaining the lightweight of the upper, reducing production time, and providing benefits such as improved recyclability. In at least some instances, the upper can be formed of a knitted component having radially extending rows of loops that converge toward a common area, such as the throat region of the upper, which can be arranged along a desired restraint line of the upper. Additionally, fusible yarns, such as clamping yarns, can be knitted at least on the outward-facing surface of the radially extending containment area of ​​the upper to create additional locking or restriction along the restraint line. Additionally, some examples herein also include radially extending tensile elements within the restraint area, such that these tensile elements can provide strength and locking along the desired restraint line, while also combining with the strength generated by the bonded fusible yarns. In contrast to the subject matter of this disclosure, conventional footwear may require several post-knitting processes, such as sewing or bonding additional components to the knitted components, to allow the footwear to provide a desired amount of restraint or other properties around the wearer's foot, such as water resistance and durability. These post-knitting additions can increase the weight of the upper, increase production time, and reduce the recyclability of the upper.

[0016] Therefore, examples of this disclosure include uppers formed of knitted components having radially extending rows of loops that can be aligned along desired constraint lines. Additionally, fusible yarns, such as clamping yarns, can be knitted at least on the outward-facing surface of the radially extending constraint area of ​​the upper. Fusible yarns can be used to create fused areas to produce additional locking along the constraint lines, and to increase abrasion resistance, water resistance, and other properties. Furthermore, in the case where the fusible yarn is a clamping yarn as described herein, the constraint area can have a greater coefficient of friction than the portion of the knitted component without fusible clamping material, which can provide additional benefits to increase the wearer's ability to effectively control a ball (such as a global soccer ball) using the upper.

[0017] Other examples include knitted components with stretching elements (such as embedded stretching elements) that can be fused with fusible yarns (such as clamping yarns) within the constrained area. The stretching elements can impart resistance to stretching and locking to the upper, which can be enhanced by the fusible material knitted along with the stretching elements. In some aspects, the stretching elements can be incorporated into a radially knitted upper such that the stretching elements extend radially along the upper along the desired constrained line.

[0018] Additional aspects of this disclosure include applying a polymer layer (e.g., a surface layer) to the outward-facing surface of the knitted component. In some aspects, the polymer layer includes pores that expose portions of the outward-facing surface comprising a fusible clamping material to maintain tactile properties (e.g., a higher coefficient of friction) generated by the fusible clamping material.

[0019] Another aspect of this disclosure includes incorporating stretch elements through knitting in a manner that can simulate the strength and resistance to stretch provided by embedded stretch elements but through knitting. For example, the stretch element can be formed by a repeating knitting sequence across a row of loops, wherein the knitting sequence is at least one knit stitch and a float stitch across multiple rows of loops (e.g., needle positions). For example, within a row of loops, the stretch element can have a repeating sequence of one knit stitch and one float stitch extending for five rows of loops.

[0020] As described herein, certain aspects of this disclosure relate to footwear articles or aspects thereof that are at least partially formed of knitted fabric. In illustrative examples, aspects relate to uppers formed at least partially of knitted components. As used herein, the term "upper" refers to a footwear component that extends over the instep and toe areas of the foot along the medial and lateral sides of the foot and around the heel area of ​​the foot to form a space for accommodating the wearer's foot. Illustrative, non-limiting examples of uppers may include uppers incorporated into basketball shoes, cycling shoes, cross-training shoes, global football (English football) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. Furthermore, in other aspects, uppers may also be incorporated into non-athletic footwear such as dress shoes, loafers, and sandals. Therefore, the concepts of footwear articles disclosed herein apply to a wide variety of footwear types. Although the accompanying drawings may illustrate footwear intended for use on only one of the wearer's feet (e.g., the left foot), those skilled in the art will recognize that the corresponding footwear for the other foot (e.g., the right foot) will be a mirror image of the right footwear.

[0021] Positional terms used when describing footwear or its aspects, such as top, bottom, front, side, rear, upper, lower, outer, inner, right, left, inside, outside, facing inward, and facing outward, are used relative to the footwear or upper intended for wearing when the wearer is standing upright, such that the wearer's foot is positioned within a foot-accommodating opening, and the wearer's ankle or leg extends through an ankle opening. For example, the "upward-facing surface" and / or "upper surface" of an upper refers to the surface oriented in an "upper" anatomical direction (i.e., towards the wearer's head) when the footwear is worn by the wearer. Similarly, the directional terms "downward" and / or "lower" refer to an anatomically "below" (i.e., towards the ground and away from the wearer's head). "Front" or "forward" means "front" (e.g., towards the toes), and "rear" means "rear" (e.g., towards the heel). "Inner" means "towards the midline of the body," and "outer" means "away from the midline of the body." "Longitudinal axis" refers to the centerline of the workpiece extending between the heel and forefoot areas. Similarly, "longitudinal length" refers to the length of the workpiece along the longitudinal axis, and "longitudinal direction" refers to the direction along the longitudinal axis. However, it should be understood that, for interpretive purposes, the use of positional terms does not depend on the actual presence of a person.

[0022] The term "knitted component" refers to a piece of fabric formed from at least one yarn, which is manipulated (e.g., using a knitting machine) to form multiple intermeshed loops defining loop rows and wales. As used herein, the term "loop row" refers to a main horizontal row of knitted loops (in upright fabric knitted on a knitting machine) produced by adjacent needles during the same knitting cycle. Loop rows can include one or more stitch types, such as knitted stitch, missed stitch, tuck stitch, transfer stitch, rib stitch, etc., terms known in the knitting industry. As used herein, the term "wales" is a main vertical row of knitted loops that intermesh or interlace, typically produced by the same needle in consecutive (but not necessarily all) loop rows or knitting cycles.

[0023] As used herein, the term "whole knit" can mean a knitted component having yarn from one or more rows of knitted loops in a first region or area interwoven with one or more rows of knitted loops in another region or area. The interweaving can be done through simple knitting stitches, tuck stitches, hold stitches, float stitches, or skip stitches, etc. In this way, the areas knitted together seamlessly transition.

[0024] In one aspect, a radial knitting process or a sequential knitting process can be performed such that the inner and outer sides of the knitted part can generally be formed sequentially, rather than simultaneously. For example, instead of forming the inner and outer sides simultaneously, the entire (or substantially all, e.g., within 5% of the length) inner side can be formed, followed by the entire (or substantially all, e.g., within 5% of the length) outer side. Alternatively, the outer side can be formed first, followed by the inner side. In some aspects, a portion of a first side (inner or outer) can be formed first, and then the second side (e.g., another side) can be formed by knitting the remaining portion of the first side before completing the knitted part. In some aspects, a reverse sequence can be used. Thus, multiple adjacent loop rows forming at least a portion of the first side (e.g., the inner or outer side) can be knitted before multiple adjacent loop rows forming at least a portion of the second side (e.g., another of the inner or outer sides).

[0025] As used herein, the term "radial extension" refers to the orientation of elongated structures (such as rows of knitted loops and / or embedded strands) extending outwards from the common portion of a knitted component. Specifically, if rows of knitted loops and / or embedded strands extend between the outer periphery of the knitted component and the common portion, then the rows of knitted loops and / or embedded strands can extend radially. Thus, rows of knitted loops and / or strands can extend outwards from the outer periphery toward the common portion, and, for example, do not extend continuously from the outer edge to the inner edge of the outer periphery across the body of the knitted component. When the knitted component is arranged in a flat configuration after knitting, the structure of the knitted component can extend radially from the common portion; however, it is also conceivable that determining whether these structures extend radially can be based on their orientation toward the common portion after the knitted component has been folded into the shape of an upper or part of an upper.

[0026] As used herein, the term "common portion" refers to a region of a knitted component toward which multiple similar structures (e.g., multiple rows of loops or multiple sections of embedded yarn) extend. Accordingly, rows of loops or sections of embedded yarn may extend from the outer periphery to a single common portion, rather than, for example, extending from the outer periphery to different portions along a common direction. The common portion is spaced apart from the outer periphery and, in different aspects, may be relatively centrally located within the knitted component. Thus, the common portion may surround and / or be directly adjacent to the longitudinal axis of the knitted component. In some examples disclosed herein, the common portion may include a throat area or a portion thereof.

[0027] As used herein, the term "throat area" refers to the area on the top (upward-facing) side of the upper, typically extending between the ankle opening and the forefoot area. The throat area may include an opening formed between the outer and inner sides of the upper when shaped as a footwear article, and in some aspects, the throat area may include a tongue extending across the opening in the throat area. In some aspects, the throat area does not have an opening but instead comprises a continuous, integral knitted area extending between the inner and outer sides of a knitted component (e.g., a knitted component that may be formed from elastic yarns, materials, and / or other components that include a degree of stretch).

[0028] As used herein, the term "perimeter" refers to the area that forms the boundary of the object referred to. For example, the perimeter of a knitted component is the area extending along the boundary of the structure. "Outer perimeter" can refer to portions of the perimeter of a knitted component that, once formed into a footwear article, are fixed to the sole structure or form seams between the two ends of the outer perimeter (so that when the footwear is worn, they can extend at least partially under the wearer's foot). Conversely, "inner perimeter" can refer to portions of the perimeter of a knitted component that, once formed into a footwear article, define openings, such as openings in the throat area and / or ankle openings. Perimeter (outer perimeter or inner perimeter) can refer to the edge of a knitted component or the peripheral area adjacent to that edge.

[0029] Different aspects are described below with reference to the accompanying drawings, in which the same elements are generally denoted by the same reference numerals. The relationship and function of the various elements in each aspect can be better understood by referring to the following detailed description. However, the aspects are not limited to those illustrated in the drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale, and in some cases, details unnecessary for understanding the aspects disclosed herein (such as conventional assembly) may be omitted. Additionally, various measurements are provided herein. Unless otherwise indicated, the terms “about” or “substantially” with respect to measurement mean within ±10% of the indicated value.

[0030] Figure 1A and Figure 1B Outer perspective and inner perspective views of a footwear article 100 and its components according to various aspects of the present invention are depicted. The footwear article 100 includes a sole structure 102 and an upper 104. The upper 104 is coupled to and extends from the sole structure 102, forming a foot-receiving cavity between the sole structure 102 and the upper 104. The area of ​​the sole structure 102 of the footwear article 100 where the upper 104 is coupled may be referred to as a bite-line 106. The upper 104 may be fixedly coupled to the sole structure 102 using any suitable technique, such as by using adhesives, by sewing, etc. It is contemplated that the upper 104 may extend partially or completely around the wearer's foot, may extend beneath the wearer's foot, and / or may be integral with the sole. An insole, which may or may not be used, may be referred to as a strobel. The insole comprises various materials, including fabrics, leather, foam, and / or other types of materials.

[0031] Footwear article 100 (and / or its components) may be divided into one or more zones (which may also be referred to as “regions” or “parts”). For example, in the posterior-posterior direction, footwear article 100 (and / or its components) may be divided into (and / or include) a forefoot zone 108, a midfoot zone 110, and a heel zone 112. The forefoot zone 108 of footwear article 100 may correspond to the forefoot portion of the foot, including the toe and the joints connecting the metatarsal and phalangeal bones of the foot. The midfoot zone 110 of footwear article 100 may correspond to the arch region of the foot. The heel zone 112 of footwear article 100 may correspond to the posterior portion of the foot, including the calcaneus. In the medial-lateral direction, footwear article 100 (and / or its components) may be divided into a lateral zone 114 and a medial zone 116, both of which extend through the forefoot zone 108, the midfoot zone 110, and the heel zone 112. More specifically, when footwear 100 is worn, the outer side 114 corresponds to the outer region of the foot (i.e., the side facing away from the other foot), while the inner side 116 corresponds to the inner region of the foot (i.e., the side facing the other foot). The outer side 114 and the inner side 116 are separated by a longitudinal axis 118. These areas 108, 110, and 112, as well as sides 114 and 116, are not intended to define precise areas of footwear 100, but rather to represent general areas of footwear 100 to aid in understanding the various descriptions provided herein.

[0032] When footwear 100 is worn, the sole structure 102 typically extends between the foot and the ground. The sole structure 102 may include multiple components such as an outsole, midsole, and insole or insole. Various materials can be used to form the sole structure 102, such as rubber, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), thermoplastic elastomers (e.g., polyether block amide), etc. The sole structure 102 may also include various other elements such as a heel stabilizer and a toe cap. The sole structure 102 may include various other features to reduce force, enhance stability, and / or provide adhesive friction, such as sole patterns as understood by those skilled in the art. For example, the sole structure 102 may include, for example, Figure 1A and Figure 1B The illustrated anti-slip studs are as seen in football (global football) boots. However, it should be understood that this disclosure can be applied to footwear without anti-slip studs.

[0033] The upper 104 defines a cavity within the footwear article 100 for receiving and securing the foot relative to the sole structure 102. An entrance to the cavity is provided through an ankle opening 125 located in at least the heel area 112. The upper 104 includes a throat area 126 disposed in the midfoot area 110 between the ankle opening 125 and the forefoot area 108. The throat area 126 can be configured to cover the top side of the wearer's foot, thus forming part of the top side (or suprafoot area) of the upper 104 between the outer side 114 and the inner side 116. The footwear article 100 may also include a closure system in the throat area 126 to adjust the foot-receiving cavity. Thus, the closure system can be used, for example, to secure the footwear article 100 to and / or release the footwear article 100 from the wearer's foot. An example closure system includes a lace 132 (e.g., Figure 1A and Figure 1B (As shown), strips, belts, cables, ropes, ratchet mechanisms, hook and loop connections, etc.

[0034] At least a portion of the upper 104 may include at least one knitted component 140, which is formed by a knitting process, such as weft knitting on a flat loom. In some aspects, the entire or substantially the entire upper 104 may be formed of the knitted component 140. Figure 2 The knitted part 140 is depicted in the form of Figure 1A and Figure 1B Another view of the shoe upper 104 shown.

[0035] The knitted component 140 can incorporate various types of yarn, each type imparting different properties to different areas of the upper 104. Specifically, one area of ​​the knitted component 140 can be formed by a first type of yarn imparting a first set of properties, while another area of ​​the knitted component 140 can be formed by a second type of yarn imparting a second set of properties. Using this configuration, these properties can be varied throughout the entire upper 104 by selecting specific yarns for different areas of the knitted component 140. The properties imparted to areas of the knitted component 140 by specific types of yarn depend in part on the materials forming the various filaments and fibers within the yarn. For example, cotton provides a soft hand feel, natural beauty, and biodegradability. Elastic fibers and stretched polyester each offer significant stretch and recovery, while stretched polyester also provides recyclability. Rayon provides high luster and moisture absorption. In addition to its insulating properties and biodegradability, wool offers high moisture absorption. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material and also provides relatively high durability. Besides the material, other aspects of the yarn selected for the knitted component 140 may affect the properties of the upper 104. For example, the yarn forming the knitted component 140 may be a monofilament yarn or a multifilament yarn. Therefore, unless otherwise stated, the term "yarn" as used herein does not necessarily refer to multiple filaments or fibers. The yarn may also comprise individual filaments each formed of different materials. Furthermore, the yarn may comprise filaments each formed of two or more different materials, such as bicomponent yarns with filaments having a sheath-core configuration or being two halves formed of different materials. Different degrees of twist and crimp, as well as different deniers, may also affect the properties of the upper 104. Therefore, the material forming the yarn and other aspects of the yarn can be selected to impart various properties to the separated areas of the upper 104. Additional properties of the yarns used in various aspects of this disclosure are further described in detail below.

[0036] Knitted components 140 can be formed as a single, integral element during a knitting process (e.g., weft knitting or another suitable knitting process). Additional elements, such as the foot portion and / or heel elements (including but not limited to heel stabilizers or other elements or components), can be integrally formed with the upper 104 as a single, integral structure, for example, in a single knitting process performed on a knitting machine. Alternatively, one or more such additional elements can be formed separately from the upper 104 and subsequently attached, secured, or otherwise assembled and / or integrated as needed. Forming the upper 104 with knitted components can provide the upper 104 with advantageous properties, including but not limited to specific degrees of elasticity, breathability, flexibility, strength, moisture absorption, weight, abrasion resistance, and / or combinations of such properties. Furthermore, forming the upper 104 from integrally knitted components can create a variety of features and structures for the upper 104 without requiring significant additional manufacturing steps or processes, thereby improving production efficiency.

[0037] See Figure 1A and Figure 1B as well as Figure 2 The knitting component 140 may include radially extending rows of loops. That is, the knitting component 140 may include loops extending from its outer periphery 124 (e.g., as shown in the image). Figure 2 (As shown) The rows of knitted loops extending to the common portion of the knitted component 140 (which may form or be adjacent to the stitch line 106 when the knitted component 140 is formed as the upper 104 and connected to the sole structure 102). The common portion can be an area of ​​the knitted component 140 towards which all rows of loops extend when the knitted component 140 is formed into the shape of the upper 104 or otherwise constructed. In some aspects, the common portion is positioned along the longitudinal axis of the upper 104 that separates the outer side 114 and the inner side 116. In some aspects, the common portion is adjacent to the longitudinal axis. For example, the common portion may include a throat region 126 that extends along the longitudinal axis between the inner side 116 and the outer side 114. As per [reference to...] Figure 3 Further described, radially extending rows of loops within a knitted component (such as knitted component 140) can produce rows of loops aligned with a number of different constraint lines, such that the knitted loop rows can provide constraint around the entire foot of the wearer.

[0038] Figure 3 The illustration shows a schematic diagram of a knitted section 340 with radially extending rows of loops. Unless otherwise indicated, Figure 3 The knitted component 340 is intended to generally depict radially extending rows of loops, and the details disclosed regarding the knitted component 340 can be applied to any other knitted component disclosed herein (including knitted components 140, 440, 640, 840, 940, and 1040). The knitted component 340 has radially extending rows of loops, such as loops 342a-342e, which can be collectively referred to as "loops 342". Loops 342 are depicted in a simplified form as each having a single knitted loop, and it should be understood that these loops do not necessarily represent the stitch sequence used. For example, loops 342 may include other types of stitches, such as float stitches, tuck stitches, transfer stitches, etc. Similarly, as a representation of the various directions in which loops 342 may extend, only a few loops are depicted throughout the knitted component 340; however, it should be understood that... Figure 3 Additional coil rows may exist between the coil rows 342 depicted herein, which extend radially from the common portion of the knitted part 340 in a manner similar to that described below (as are many other aspects described herein).

[0039] The coil rows 342 extend from the outer perimeter 324 to the common area or region. Figure 3In the example shown, the common portion is the throat region 326, which may include a tongue component, an opening for the tongue component, and / or an inner periphery 334 of a knitted component 340 that defines a space through which the tongue component can extend. In some aspects, the throat region 326 is continuously knitted from the outer side 314 to the inner side 316, making it possible that there is no opening or space for the tongue component.

[0040] Each of the forefoot region 308, midfoot region 310, and heel region 312 may include radially extending coil rows extending in different directions, such that at least some of the coil rows are not parallel to each other, for example, at an angle. For example, at least one forefoot coil row in the forefoot region 308 (such as coil row 342c) extends in a direction not parallel to the midfoot coil row in the midfoot region 310 (such as coil row 342b). In other words, at least some of the coil rows, including forefoot coil row 342c and midfoot coil row 342b, may be at an angle relative to each other, wherein the angle is greater than 0 degrees and less than 180 degrees.

[0041] Conversely, once the knitted component 340 is worn in footwear (such as...) Figure 1A and Figure 1B In the footwear 100 shown, the loop rows 342 can extend in different directions, which can represent different constraint lines or constraint angles. Constraint lines can be represented by a loop row extending toward a common portion of the knitted part, while another loop row extends toward the common portion from the opposite direction, but at the same or substantially the same angle as the first loop row. In a conventionally knitted part where all or most of the loop rows extend horizontally across the upper, such constraint lines can be constrained to the same angle. Conversely, in a radially knitted part, different loop rows can effectively extend 360 degrees around the length of the wearer's foot to form additional constraint lines. At least some constraint may be solely due to the radial direction of the knitted loop rows. In some aspects, greater constraint is achieved by using yarns with higher tensile strength, higher toughness, and / or higher stretch resistance for loop rows along certain constraint lines, utilizing certain knitting stitches (such as float stitches) to reduce stretching in loop rows along certain constraint lines, or combinations thereof. In at least some aspects, at least some of the knitted components described herein (such as knitted component 140) are described as including one or more constraint regions. These constraint regions may represent areas within the knitted component that include one or more features, such as a particular yarn type, fusion regions, and / or certain knitted stitches, which add constraints beyond those provided solely by the orientation and alignment of the radial knitted loop rows.

[0042] In an example, the knitted component 340 includes rows of loops parallel to a first constraint diagonal (shown by a first axis 321) and rows of loops parallel to a second constraint diagonal (shown by a second axis 323), the second constraint diagonal intersecting the first constraint diagonal in a common portion of the knitted component 340. The first axis 321 extends from a portion of the knitted component 340 configured to cover the wearer's first metatarsal to the heel area 312 on the outer side 314, and the second axis 323 extends from a portion of the knitted component 340 configured to cover the wearer's fifth metatarsal to the heel area 312 on the inner side 316. These axes 321 and 323 may collectively form an X-shape and may represent constraint lines that can improve the stability of the wearer's foot within the upper for various types of movement, including rotation or change of direction, lateral movement, forward movement, and backward movement. Accordingly, the performance of footwear articles (such as footwear article 100) can be enhanced by restricting the wearer’s foot within the upper (such as upper 104) by limiting the coil rows that extend or otherwise provide support along these axes 321 and 323.

[0043] A knitted component 340 with radially extending loop rows 342 can be achieved through a radial knitting process, wherein the outer side 314 and the inner side 316 of the knitted component 340 are formed sequentially, rather than simultaneously. For example... Figure 3 As shown, the knitted part 340 is formed by a knitting machine 362 (e.g., having a front needle bed 361 and a back needle bed 363) by starting at the heel area 312 on the inner side 316 of the knitted part 340, knitting in a knitting direction 344 from the heel area 312 to the forefoot area 308, and then, as shown in the knitting direction 344, starting at the forefoot area 308 to knit the outer side 314 of the knitted part, and ending at the heel area 312 on the outer side 314. Thus, the knitted part 340 can be formed by knitting the inner side 316 (or at least a plurality of loop rows on the inner side 316), knitting the forefoot area 308 after knitting the loop rows on the inner side 316, and knitting the outer side 314 (or at least a plurality of loop rows on the outer side 314) after knitting the forefoot area 308.

[0044] In other respects, a similar but opposite knitting direction can be used to form the knitted part 340. For example, the knitted part 340 can be formed by knitting the outer side 314 (or at least a plurality of loop rows on the outer side 314), knitting the forefoot area 308 after knitting the loop rows on the outer side 314, and knitting the inner side 316 (or at least a plurality of loop rows on the inner side 316) after knitting the forefoot area 308.

[0045] The knitting process for manufacturing the knitted part 340 can be performed on a knitting machine 362, which may include an automatic knitting machine. Figure 3The knitting machine 362 in the text is intended for simplicity. In terms of examples, the knitting machine 362 can be a plain knitting machine, such as a flat V-bed knitting machine with a front needle bed and a back needle bed. The knitted part 340 can be formed by needles from a single needle bed or from two needle beds.

[0046] According to this knitting process that sequentially forms the outer side 314 and the inner side 316, at least some of the needles used to form the outer side 314 are also used to form the inner side 316. Thus, compared to conventional knitting processes where the outer side 314 and the inner side 316 are formed simultaneously in the heel and / or midfoot portion, fewer needles may be needed on the knitting bed of the knitting machine 362 to produce the knitted part 340. Additionally, the same yarn feeder can be used for both the outer side 314 and the inner side 316, instead of requiring a repeater for each side. Thus, the disclosed knitting process allows more needles and / or yarn feeders on the knitting machine 362 to be used for knitting separate items, such as another knitted part for another shoe upper, while the knitted part 340 is being knitted.

[0047] Furthermore, radially extending loops within the knitted part 340 can divide the knitted part 340 into wedge-shaped portions. For example, observed in the forefoot region 308, the wedge-shaped portion between axes 321 and 318 can have radially knitted loops, and the wedge-shaped portion between axes 318 and 323 can have additional radially knitted loops. In some aspects, the loops forming the wedge-shaped portion between axes 321 and 318 are knitted before the wedge-shaped portion between axes 318 and 323. The remainder of the knitted part 340 can similarly be divided into various wedge-shaped portions. These wedge-shaped portions can be formed by knitting full-length, radially extending loops and partial-length, radially extending loops. Full-length knitted loops (such as loop 342a) can extend from one edge of the knitted part 340 (e.g., at the outer periphery 324) to the other edge of the knitted part 340 (e.g., at the inner periphery 334 in the throat region 326). Partial length knitted loop rows (such as loop rows 342d and 342e) may not extend between the two edges of the knitted part 340. One or both ends of a partial length knitted loop row may end before the edge of the knitted part 340. However, partial length knitted loop rows (such as loop rows 342d and 342e) can still be considered to extend radially because they extend in a direction from the outer periphery 324 toward the common area (e.g., the throat area 326). Forming partial length knitted loop rows distributed between full-length knitted loop rows can create shape and size in the knitted part 340 while also allowing the loop rows to extend radially.

[0048] In one aspect, the forefoot region includes a set of wedges configured to form a curved structure with a high curvature (e.g., a small radius of curvature). For example, each of these wedges in the forefoot region may have a smaller surface area than a set of wedges in the midfoot region. Alternatively, the total number of wedges in the forefoot region may be increased. Thus, by incorporating multiple wedges in the forefoot region, a curved structure of the knitted component of the upper is generated in the forefoot region.

[0049] Thus, the knitted component may include a stack of wedges, such that when knitted from the inside to the outside, a first set of wedges is configured to form the inner side of the knitted component, a second set of wedges is configured to form the toe area of ​​the knitted component, and a third set of wedges is configured to form the outer side of the knitted component. In one aspect, additionally, a fourth set of wedges may be included to form the heel area of ​​the knitted component. In a second instance, which optionally includes the first example, among other possibilities, the number of wedges in the second set of wedges is greater than the number of wedges in the first set of wedges or the number of wedges in the third set of wedges.

[0050] Such as about Figure 3 The entire side (e.g., inner side 316) can be knitted before knitting the other side (e.g., outer side 314). However, in other respects, the areas where the knitting process begins and ends in the knitted part can vary. For example, some example knitted parts can have other shapes and configurations before being formed into an upper, such as where a portion of the inner side of the heel area of ​​the knitted part is knitted integrally with a portion of the outer side of the heel area in a seamless manner. In this way, a seam can be formed on either the inner or outer side of the heel area, rather than forming a central seam in the heel area. However, for these configurations, since the outer and inner sides of the knitted part are not knitted simultaneously, a certain distance can be maintained between the inner and outer sides of the knitted part. Figure 3 The order of the knitted parts is described as follows. Conversely, when the seam of the knitted part will be formed on the inside, the inside heel portion can be knitted first, followed by the outside (e.g., the heel, midfoot, and forefoot areas on the outside), and then the remaining inside (e.g., the forefoot and midfoot areas on the outside). When the seam of the knitted part will be formed on the outside, the outside heel portion can be knitted first, followed by the inside (e.g., the heel, midfoot, and forefoot areas on the inside), and then the remaining outside (e.g., the forefoot and midfoot areas on the outside).

[0051] Back Figures 1A to 1B and Figure 2 The example knitted component 140 shown includes, regarding Figure 3The knitted component 140 comprises radially extending rows of knitted loops. Additionally, the knitted component 140 includes radially extending tension elements 150. Similar to the rows of knitted loops of the knitted component 140, the tension elements 150 extend from the outer periphery 124 to common areas or regions, such as... Figure 1A and Figure 1B The throat region 126 may include a tongue, an opening for the tongue, and / or the inner periphery 134 of the knitted component 140.

[0052] Similar to rows of knitted loops, the tension element 150 can extend along the constraint line. Additionally, due to the material composition and / or integration of the tension element 150, it can provide additional strength and structure to the underlying knitted structure of the knitted component 140. Thus, the tension element 150 can be positioned in areas of the knitted component 140 corresponding to specific constraint lines desired or suitable for the footwear article 100. In the example knitted component 140, the tension elements 150 are arranged in groups that, when viewed from above, collectively have an X-shaped configuration. For example, Figure 2 The knitted component 140 prior to forming the upper 104 is shown, and the grouped X-shaped configuration is depicted more clearly, which may be referred to herein as constraint regions (or constraint vectors) 152a, 152b, 152c, and 152d. The first constraint region 152a includes a stretching element 150 and a row of knitted loops extending from a portion of the outer periphery 124 in the heel region 112 on the medial side 116 to a common portion or throat region 126 in the midfoot region 110 on the medial side 116. The second constraint region 152b includes a stretching element 150 and a row of knitted loops extending from a portion of the outer periphery 124 in the forefoot region 108 on the medial side 116 to a common portion or throat region 126 in the midfoot region 110 on the medial side 116. The third constraint region 152c includes a tension element 150 and a row of knitted loops extending from a portion of the outer periphery 124 of the heel region 112 on the outer side 114 to a common portion or throat region 126 of the midfoot region 110 on the outer side 114. The fourth constraint region 152d includes a tension element 150 and a row of knitted loops extending from a portion of the outer periphery 124 of the forefoot region 108 on the outer side 114 to a common portion or throat region 126 of the midfoot region 110 on the outer side 114. The distance between adjacent tension elements 150 within a single constraint region (e.g., constraint region 152a) (measured by the number of loop rows) is less than the distance between tension elements 150 in individual constraint regions.

[0053] The placement (including density) and orientation of the tension elements 150 within the knitted component 140 can vary based on the intended activities of the footwear article 100. Typically, the constraint provided by the tension elements 150 on one side (e.g., the outer side 114) can be improved by the constraint on the other side (e.g., the inner side 116) to serve as an anchor. Thus, a first constraint region 152a of the tension element 150 extending toward the heel area 112 on the inner side 116 can be anchored to a fourth constraint region 152d of the tension element 150 extending toward the forefoot area 108 on the outer side 114, while a second constraint region 152b of the tension element 150 extending toward the forefoot area 108 on the inner side 116 can be anchored to a third constraint region 152c extending toward the heel area 112 on the outer side 114.

[0054] The stretching element 150 may each have a configuration such as multifilament yarn, filament (e.g., monofilament yarn), thread, rope, webbing, cable, or chain. The stretching element 150 may include a material having properties that increase the strength of the knitted part 140 in the region where the stretching element 150 is located. For example, the stretching element 150 may include a yarn with high toughness (e.g., toughness greater than 5 g / denier). In some embodiments, the toughness of the stretching element 150 may be greater than that of the other yarns of the knitted part 140. In one example, the stretching element 150 is formed from a high-toughness polyester yarn, such as Gral manufactured by Coats Group PLC. In another example, the stretching element 150 is formed from a high-toughness nylon yarn. Furthermore, in some instances, the stretching element 150 may exhibit greater resistance to stretching than the rest of the knitted part 140 and may be formed from various engineered filaments for high tensile strength applications, including glass, aramids (e.g., para-aramids and meta-aramids), ultra-high molecular weight polyethylene, and liquid crystal polymers.

[0055] The stretching element 150 can be incorporated into the knitted structure of the knitted part 140 in various ways. For example, each stretching element 150 can be embedded in the structure of the knitted part 140. When the stretching element 150 is embedded, it can extend, in a non-looped state, along a row of loops formed by knitted loops of one or more other yarns. Embedding the stretching element 150 may include loops at each end of the stretching element 150 to anchor it to the knitted structure of the knitted part 140, but it can generally extend through the row of loops without interlacing with another yarn. For example, the stretching element 150 can alternate between being behind and in front of loops of another yarn within the row of loops, such that the stretching element 150 extends through the interlacing structure formed by another yarn of the knitted part. In some aspects, the knitted part 140 includes a double-knitted fabric construction formed by at least two ends of yarns that switch between needles on two needle beds of the knitted part. In this configuration, the stretching element 150 can be embedded such that it generally extends between the surfaces formed by loops produced on the two needle beds. In other instances, the knitted component 140 includes a first and a second layer that extend together and overlap each other to form a channel extending in the transverse direction of the loops, and the stretching element 150 may extend through the channel, respectively.

[0056] In other instances, a knitting sequence can be used to knit the stretch element 150 into a knitted structure of the knitted part 140 to simulate the embedded structure described above. For example, as the stretch element 150 extends from the outer periphery 124 to the inner periphery 134 of the knitted part 140, the loop rows of the stretch element 150 can be knitted using a repeating sequence of float stitches and knitted stitches. Regarding Figure 9 Further details of this knitting technique, referred to in this paper as imitation inlay, are discussed.

[0057] like Figures 1A to 1B and Figure 2 As shown, at least some of the tension elements 150 may form loops around the shoelace holes formed in the knitted component 140, which may reinforce the knitted component 140 to withstand additional tension applied to the knitted component 140 in those areas when the shoelace 132 is tensioned. In other instances, at least some of the tension elements 150 may extend out of the knitted component 140 and form loops for receiving the shoelace 132.

[0058] In some instances, the knitted component 140 may be at least partially formed of a fusible yarn. For example, the knitted component 140 may be formed of a first yarn knitted together with at least a second yarn, wherein the first yarn has a first melting temperature and the second yarn has a second temperature greater than the first melting temperature of the first yarn, wherein the second temperature is lower than the decomposition or melting temperature of the second yarn. Thus, when heat is applied, the first yarn, which may be referred to as a fusible yarn, may at least partially melt or soften, while the second yarn may retain its solid structure. Once fully melted, partially melted, or softened, the fusible yarn may fuse with other portions of the fusible yarn and / or the second yarn. Activation of the fusible yarn within the knitted component may result in certain properties of the upper 104. For example, the fused region formed by the fusible yarn may provide increased abrasion resistance and / or water resistance in selected areas and may limit the stretching of the knitted component 140, thereby imparting stretch resistance and restraint in selected areas. The example fusible yarn in the knitted component 140 may have one of the following structures: a multifilament yarn having some filaments formed of a low-melting-point material and some filaments formed of a high-melting-point material, a multifilament yarn made entirely of filaments having a low-melting-point material, a bicomponent yarn having a low-melting-point material and a high-melting-point material (arranged in a core / sheath configuration or a side-by-side configuration), or a monofilament yarn made entirely of a low-melting-point material.

[0059] As further described below with reference to specific examples, the fusible yarn in the knitted component 140 can be activated by heating to a temperature higher than the melting temperature of the fusible material (such as a thermoplastic polymer) in the fusible yarn, and the molten fusible material can bond to one or more other knitted strands or structures within the knitted component 140. For example, the fusible yarn can be a coated yarn (e.g., having a core-sheath configuration), wherein the coating is a first material (which may include a thermoplastic polymer) and has a melting temperature lower than that of a second material forming the core (which may exclude the thermoplastic polymer from the first material). This example fusible yarn can be activated by softening, partially melting, or completely melting the coating, while at least the core retains its substantially solid structure. In one example where the fusible yarn is a coated yarn, the coating can be softened such that portions of the coating can fuse with adjacent portions of the coated yarn (and any other yarn or stretching element) within the interlaced loop rows of the coated yarn. In another example where the fusible yarn is a coated yarn, the coating can be partially melted, such that the first material of the melted coating can flow back and solidify between adjacent structures within the knitted component. Thus, the partially melted coating can fuse adjacent portions of the coated yarn, including the core yarn and the remaining (unmelted) portion of the coating, together, as well as fuse to other yarns or stretching elements. In another example where the fusible yarn is a coated yarn, the coating can be completely melted, flowed back, and solidified, such that the re-solidified coating fuses the remaining core portion together with other yarns or stretching elements. In yet another example, the fusible yarn is a monofilament yarn made entirely of a thermoplastic polymer material that can be heated to partially melt and re-solidify to fuse the unmelted portion of the monofilament yarn to other unmelted portions of the monofilament yarn and / or to other yarns or stretching elements knitted together with the fusible yarn, or can be heated to completely melt and re-solidify to fuse other yarns knitted together with the fusible yarn.

[0060] The knitted component 140 may have an outward-facing surface 142 and an opposing inward-facing surface. Although in Figure 1A , Figure 1B and Figure 2The knitted component 140 is not visible in the view, but the inward-facing surface of the knitted component 140 should be understood as generally facing away from the outward-facing surface 142 and toward the foot to accommodate the opening when the knitted component 140 is formed as the upper 104. In some aspects, the outward-facing surface 142 is formed by a first layer of the knitted component 140, and the inward-facing surface is formed by a second layer knitted integrally with the first layer. For example, the knitted component may have a double-knitted structure (e.g., a double-knitted jacquard structure) such that the outward-facing surface 142 is formed by yarns on a first needle bed (e.g., a front needle bed), and the inward-facing surface is formed by yarns on a second needle bed (e.g., a back needle bed). Additionally, as described below, the knitting component 140 may have a jacquard double-knitting structure, such that yarns knitted on the first needle bed to form an outward-facing surface in some areas of the knitting component 140 may be selectively moved to the second needle bed to form an inward-facing surface in other areas of the knitting component 140, and yarns knitted on the second needle bed to form an inward-facing surface in some areas may be selectively moved to the first needle bed to form an outward-facing surface 142 in other areas.

[0061] At least the outer-facing surface 142 of the knitted component 140 is formed of fusible yarn in the region having tension elements 150 (e.g., constraint regions 152a-152d). The fusible yarn can be knitted on the outer-facing surface 142 to form a row of loops including the tension elements 150. Thus, once the fusible yarn is activated (e.g., by heat), it can at least partially melt to fuse to the tension elements 150. Additionally, aspects of this disclosure may include fusible yarn knitted on the outer-facing surface 142 to form rows of loops positioned between and separating adjacent tension elements 150 within the constraint regions (e.g., 152a-152d) of the tension elements 150. When fully or partially melted, the fusible material of the fusible yarn can flow to fill the spaces between the remaining knitted structures, as further described below. For example, the fusible yarn may be a yarn having a sheath surrounding a core, wherein the sheath is formed of a material with a melting temperature lower than that of the material forming the core. In this respect, the sheath of the fusible yarn can at least partially melt and fill the space between the knitted loops formed by the remaining core of the fusible yarn. Additionally or alternatively, the fusible material of the fusible yarn can at least partially melt to fill the space between other yarns or structures, such as the tension element 150 forming the knitted part 140 and / or the second yarn. Using fusible yarn to create a fusion zone along the rows of loops within the restraint areas 152a-152d can help increase the restraint or locking provided by the tension element 150, and provide other benefits such as increased abrasion resistance and water resistance, while minimizing or even eliminating the need for additional layers and post-knitting processes. Minimizing or eliminating the need for additional layers helps the upper 104 maintain a light weight. For example, aspects of the upper 104 can have a weight of about 50 grams or less in some aspects, about 40 grams or less in some aspects, or about 30 grams or less in some aspects.

[0062] In other regions of the knitted component 140, such as the region extending between the constraint regions 152a-152d of the tension element 150, the outward-facing surface 142 of the knitted component 140 does not include fusible yarn. Instead, the outward-facing surface 142 in these regions may be formed of a second yarn having a higher melting or decomposition temperature than the fusible yarn. Thus, when heat is applied, a fusion region on the outward-facing surface 142 can be created only in selected portions of the knitted component 140.

[0063] The fusible yarn may comprise a thermoplastic polymer material. Example materials for fusible yarns may include polyurethane, such as thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), low-melting-point polyamide (nylon) yarns (such as nylon-6, nylon-11, or nylon-12), low-melting-point polyesters, or combinations thereof. In some respects, the melting temperature of the fusible yarn is less than about 115 degrees Celsius, in some respects less than about 100 degrees Celsius, or in some respects less than about 100 degrees Celsius. Conversely, a second yarn knitted together with the fusible yarn and / or the material forming the stretch element 150 may have a melting or decomposition temperature greater than about 150 degrees Celsius in some respects, greater than about 185 degrees Celsius in some respects, or greater than about 100 degrees Celsius in some respects.

[0064] In an example, the fusible yarn also includes a "clamping" property, which, when knitted into the knitted part 140, creates a region with a larger coefficient of friction compared to areas with no or lower concentrations of clamping yarn. Creating a region with a larger coefficient of friction on the outward-facing surface 142 within the knitted part 140 can help the wearer of footwear 100 control a ball, such as a football, because the upper 104 with the knitted part 140 can grip the ball better. Differences in the coefficient of friction in different portions of the knitted part 140 or other knitted parts mentioned herein can be determined using the fabric-ball friction coefficient test disclosed herein.

[0065] In embodiments of this disclosure, a fusible yarn having clamping properties (referred to herein as a clamping yarn) may have a coating surrounding a core having a first polymer composition, the core having a second material composition different from the first polymer composition. The first polymer composition may include a thermoplastic elastomer not present in the second composition. The thermoplastic elastomer may include one or more of thermoplastic copolyester elastomers, thermoplastic polyether block amide elastomers, thermoplastic polyurethane elastomers, polyolefin-based copolymer elastomers, thermoplastic styrene copolymer elastomers, thermoplastic ionomer elastomers, or any combination thereof. In one aspect, the first polymer composition includes a thermoplastic elastomer styrene copolymer. In another aspect, the thermoplastic elastomer styrene copolymer may be a styrene-butadiene-styrene (SBS) block copolymer, styrene-ethylene / butene-styrene (SEBS) resin, styrene-acrylonitrile (SAN) resin, or any combination thereof. In one aspect, the polymer composition includes a thermoplastic elastomer polyester polyurethane, a thermoplastic polyether polyurethane, or any combination thereof. In some aspects, the thermoplastic elastomer polyester polyurethane may be an aromatic polyester, an aliphatic composition, or a combination thereof. It should be understood that other thermoplastic polymer materials not specifically described below are also envisioned for use in the clamping yarns as described herein. In one aspect, the coatings for clamping yarns described herein are produced from fibers or filaments consisting of only a single thermoplastic elastomer. In other aspects, the coatings consist of blends of two or more different thermoplastic elastomers.

[0066] In one aspect, the first polymer composition comprising a thermoplastic elastomer has a melting temperature greater than about 110 degrees Celsius and less than about 170 degrees Celsius. In another aspect, the first polymer composition comprises a thermoplastic elastomer having a melting temperature of about 110 degrees Celsius to about 170 degrees Celsius, about 115 degrees Celsius to about 160 degrees Celsius, about 120 degrees Celsius to about 150 degrees Celsius, about 125 degrees Celsius to about 140 degrees Celsius, about 110 degrees Celsius to about 150 degrees Celsius, or about 110 degrees Celsius to about 125 degrees Celsius.

[0067] Additionally, the second material composition of the core yarn can be a thermoplastic composition or a thermosetting composition. The core yarn can be any material that retains its strength at the temperature at which the first polymer material is extruded during the coating process. The core yarn can be a natural fiber or regenerated fiber or filament, or a synthetic fiber or filament, and can have a structure of staple yarn, multifilament yarn, or monofilament yarn. In one aspect, the core yarn can be composed of cotton, silk, wool, rayon, nylon, elastic fiber, polyester, polyamide, polyurethane, and / or polyolefin. In one aspect, the core yarn is composed of polyethylene terephthalate (PET). The second material composition of the core yarn can have a second melting or deformation temperature that is at least 20 degrees Celsius, at least 50 degrees Celsius, at least 75 degrees Celsius, or at least 100 degrees Celsius higher than the first melting temperature of the first polymer composition. Further details of various examples of clamped yarns are disclosed below.

[0068] In some embodiments, the clamping yarn is heated to partially or completely melt a thermoplastic elastomer forming a coating. Once the coating has partially or completely melted, it can flow into the space between the remaining interlacing structures (e.g., the interlacing portions of the remaining coating and core (where the coating is only partially melted), the interlacing portions of the remaining core (where the coating is completely melted), and / or the interlacing portions of another strand (such as the stretching element 150)). As the knitted part 140 cools, the return coating from the clamping yarn effectively fuses these various structures together, as described more generally above with respect to fusible yarns. The remaining structures may be referred to herein as a fused network of interlaced yarns, since interlaced yarns may remain within the fused region. In some aspects, the return coating and the remaining portions of the clamping yarn (the unmelted coating) can contribute to providing a greater coefficient of friction to the fused region, while also providing increased constraint due to fusing the coils together within and / or in adjacent coil rows. In some aspects, the clamping yarn can be heated by steam. In some respects, the clamped yarns can be heated using a thermoforming process, in which heat and pressure are applied to the knitted part 140 in a mold. In these respects, the remaining structure, once cooled, can be referred to herein as a thermoformed network of interlaced yarns.

[0069] In the examples described herein, a knitted part is formed such that it includes clamping yarns in one or more zones. During this process, one or more of the temperature, pressure, humidity, and post-treatment duration applied to the knitted part including the clamping yarns can be adjusted based on one or more of the desired coefficient of friction, desired level of restraint, and desired level of air permeability. Post-treatment may include processing the knitted part after knitting. In one example, post-treatment of the clamping yarns may include at least partially melting the clamping material of the clamping yarns. Furthermore, post-treatment of the clamping yarns may include at least partially refluxing the clamping material. Additionally, post-treatment of the clamping yarns may include solidifying the clamping material after melting and refluxing. In one example, the knitted part may be subjected to the same post-treatment conditions entirely. In another example, one or more zones of the knitted part may be selectively post-treated. For example, one or more constrained areas on the outward-facing surface of a knitted part that hold yarns can be selectively treated by applying heat and / or pressure to those constrained areas, while the remaining areas of the knitted part on the outward-facing surface that do not hold yarns can be shielded to avoid applying heat and / or pressure, or different amounts of heat and / or pressure can be applied.

[0070] As a non-limiting example, to process the clamped yarns (e.g., melt, reflow), and then at least partially resolidify them, the knitted part is placed in a steam chamber. Steam and / or heat are then applied at least at the melting temperature of the clamping material, but below the melting temperature of the remaining yarn forming the knitted part. This allows the clamping material of the yarn to melt and reflow as needed. In one case, the process can be carried out at 150 to 153 degrees Celsius for 10 to 15 seconds at 1 to 3 bar. Then, once the heating and steaming process has reached the desired completion level, e.g., the fusible material has at least partially melted, reflowed, and begun to solidify, the knitted part can be transferred to a cooling chamber and cooled at atmospheric pressure until the knitted part reaches 20 to 25 degrees Celsius.

[0071] In different aspects, fusible yarns can be treated, for example, by heating, melting, and / or reflowing to varying degrees. In some aspects, certain portions of a knitted part comprising fusible material (e.g., yarn) may be left untreated, for example, by heating, melting, and / or reflowing. In other aspects, some areas of a knitted part comprising fusible material (e.g., yarn) may be treated, for example, by heating, melting, and / or reflowing, while other areas may be left untreated. In yet another aspect, some areas of a knitted part comprising fusible material (e.g., yarn) may be treated more than other areas comprising fusible material, for example, by exposure to higher heat, exposure to longer steam durations, exposure to greater heat and / or steam durations, or otherwise treated to cause different material changes, for example, the amount of melting, reflowing, and resolidification of the fusible material, and / or the degree of formation of the thermoforming network of the interwoven yarns caused by the same material.

[0072] In some embodiments, clamping yarns are not included on at least the outward-facing surface of the rear portion of the knitted component 140. Thus, clamping yarns may not be included on the outward-facing surface 142 within the first constraint region 152a or the third constraint region 152c. Because the forefoot 100 is more likely to come into contact with the ball, it may be more advantageous to include clamping yarns on the outward-facing surface 142 of the front portion of the knitted component 140 (such as in the second constraint region 152b and the fourth constraint region 152d). Additionally, in some aspects, clamping yarns may be included in the outward-facing surface 142 of the central forefoot region 109 between the second constraint region 152b and the fourth constraint region 152d of the knitted component 140. In some aspects, portions of the outward-facing surface 142 having clamping yarns (such as the second constraint region 152b and the fourth constraint region 152d) include different fusible yarns on the inward-facing surface. In one example, the fusible yarn, in the form of a monofilament, may have a different polymer composition than the clamping yarn and, in at least some aspects, form a knitted area with a lower coefficient of friction than the area formed by the clamping yarn. Furthermore, in some aspects, monofilament yarns with different material compositions are knitted together with the fusible yarn on the inward-facing surface. In some aspects, the fusible yarn may be completely or at least partially melted after knitting to form a fused region on the inward-facing surface, which can provide additional abrasion resistance, water resistance, and structural support for the wearer's foot.

[0073] In some aspects, clamping yarns are not included at all within or above the rear portion of the knitted part 140 (on the outward-facing surface 142 or the opposing inward-facing surface). Conversely, in some aspects, high-tenacity yarns having a higher melting or decomposition temperature than the clamping yarns may form the outward-facing surface 142 and the inward-facing surface of the knitted part 140 in these rear portions, and the restraint regions 152a and 152c may also include tension elements 150 knitted or embedded together with the high-tenacity yarns.

[0074] In an alternative configuration, the knitted component 140 includes yarn clamping on the outward-facing surface 142 of each of the constraint regions 152a, 152b, 152c, and 152d of the tension element 150, but the outward-facing surface 142 of the knitted component 140 extending between the constraint regions 152a and 152d does not include yarn clamping. For example, the outward-facing surface 142 may not include yarn clamping in the central forefoot region 109 located between the second constraint region 152b and the fourth constraint region 152d, in the midfoot region 110 located on the inner side 116 between the first constraint region 152a and the second constraint region 152b, in the midfoot region 110 located on the outer side 114 between the third constraint region 152c and the fourth constraint region 152d, in the heel region 112 adjacent to the first constraint region 152a on the inner side 116, and in the heel region 112 adjacent to the third constraint region 152c on the outer side 114.

[0075] As previously described, one or more additional yarns may be knitted (interlaced) together with the clamping yarn, such that the clamping yarn and the one or more additional yarns form the same loop rows within the knitting member 140. In various examples, the clamping yarn may be knitted to form at least a portion of the outward-facing surface 142, while a high-tenacity yarn having a higher melting or decomposition temperature than the clamping yarn may be knitted to form at least a portion of the inward-facing surface. In loop rows including the stretching element 150, the stretching element 150 may also be knitted to form at least a portion of the outward-facing surface 142 with the clamping yarn, or embedded between loop rows forming the outward-facing surface 142 and the inward-facing surface. In some aspects, the stretching element 150 is a high-tenacity yarn, which may have a different material composition than the second yarn, which may also be a high-tenacity yarn; however, it is conceivable that the high-tenacity yarn knitted on the inward-facing surface may have the same material composition as the stretching element 150.

[0076] In the portions of the midfoot region 110 on the inner side 116 between the first constraint region 152a and the second constraint region 152b, and on the outer side 114 between the third constraint region 152c and the fourth constraint region 152d, the knitting component 140 may not include clamping yarn. Instead, these portions may be formed of monofilaments knitted on both the first and second needle beds, wherein the monofilaments have a melting or decomposition temperature higher than the melting temperature of the clamping yarn. The monofilaments knitted on the first and second needle beds may have the same or different material compositions. Additionally, in some aspects, high-tenacity yarns are knitted between the first and second needle beds within these portions of the midfoot region 110. High-tenacity yarns can be knitted between the two needle beds by intermittently switching between knitting with a first monofilament on the first needle bed and knitting with a second monofilament on the second needle bed.

[0077] Figures 4A to 4D Various views of a footwear article 400 and its features according to another embodiment of this disclosure are depicted. The footwear article 400 includes a sole structure 402 coupled to an upper 404. The sole structure 402 may have the same features described with respect to the sole structure 102 of footwear article 100 and may be coupled to the upper 404 in a similar manner. Additionally, the upper 404 may have the same or similar features as the upper 104, unless otherwise indicated below.

[0078] For example, the upper 404 includes a knitted component 440. In various instances, the knitted component 440 forms the entire or substantially the entire upper 404 and may be incorporating various types of yarn to impart different properties to separate areas of the upper 404. Any type of yarn described as being incorporated into the knitted component 140 may be incorporated into the knitted component 440, and specific examples will be discussed further below. The knitted component 440 may be formed by any of the processes described for the knitted component 140 and may similarly have an integral knitted structure, wherein various structures are integrally knitted to provide different properties to the upper 404. Additionally, in some aspects, the knitted component 440 is radially knitted in a manner similar to that described with respect to knitted components 140 and 340, such that the knitted component 440 includes radially knitted rows of loops extending from the outer periphery of the knitted component 440 (which may extend at the bite line 406 or partially under the foot) to common areas (such as the throat area 426, which may be adjacent to the inner periphery 434 of the knitted component 440).

[0079] Furthermore, similar to the example of knitted component 140, knitted component 440 may include radially extending tension elements 450 extending from the outer periphery 424 to a common portion as described above. Due to the material composition of the tension elements 450 and / or the manner in which the tension elements 450 are integrated into the knitted component 440, these tension elements 450 can provide additional strength and structure to the underlying knitted structure of the knitted component 440. Such materials and / or manner of integrating the tension elements 450 can be any instance described with respect to the tension element 150 of knitted component 140. Additionally, the tension elements 450 may be arranged in groups (referred to herein as constraint regions) such that the distance between adjacent tension elements 450 within a single constraint region is less than the distance between tension elements 450 within different constraint regions. Examples of knitted component 440 include at least two constraint regions comprising tension elements. In one example, the knitted component 440 includes four constraint regions: a first constraint region 452a having a tension element 450 extending from a portion of the outer periphery 424 of the heel region 412 on the inner side 416 to a common portion or throat region 426 of the midfoot region 410 on the inner side 416; a second constraint region 452b having a tension element 450 extending from a portion of the outer periphery 424 of the forefoot region 408 on the inner side 416 to a common portion or throat region 426 of the midfoot region 410 on the inner side 416. The first constraint region 452a-452d has a stretching element 450 extending from a portion of the outer periphery 424 of the heel region 412 on the outer side 414 to a common portion of the midfoot region 410 on the outer side 414 or a throat region 426; and a fourth constraint region 452d has a stretching element 450 extending from a portion of the outer periphery 424 of the forefoot region 408 on the outer side 414 to a common portion of the midfoot region 410 on the outer side 414 or a throat region 426. The first constraint region, second constraint region, third constraint region, and fourth constraint regions 452a-452d can typically form an X-shaped configuration on the upper 404, such as... Figure 4C The top-down view depicting footwear product 400 is shown.

[0080] Additionally, in some aspects, additional tension elements 450 may be located in the forefoot region 408. These tension elements 450 may extend from the outer periphery 424 in the forefoot region 408 to the common portion or throat region 426 in the forefoot region 408. Figures 4A to 4CThe depicted example includes three such additional tension elements 450 extending in the forefoot zone 408 between the second restraint region 452b and the fourth restraint region 452d. These tension elements 450 in the forefoot zone 408 can provide additional restraint to the forefoot region of the wearer's foot, which may be particularly advantageous during activities requiring agility and / or forward movements with sudden or rapid stops. Furthermore, for Figures 4A to 4D The knitted component 440 shown, and any other aspect described herein, may include additional stretching elements in the forefoot region 408, such as stretching elements having a higher density (e.g., smaller spacing), wherein these additional stretching elements extend radially about a common portion (e.g., throat region 426). Additionally, and similarly, multiple stretching elements may be included on the inner side 416 between restraint regions 452a and 452b and / or on the outer side 414 between restraint regions 452c and 452d, wherein these additional stretching elements extend, for example, in a linear or radial manner about a common portion between the outer perimeter 424 and the inner perimeter 434 for additional reinforcement and / or restraint in these directions.

[0081] In another example, the knitted component 440 is partially formed of fusible yarn in the same or similar manner as described with respect to the knitted component 140. For example, the fusible yarn may be incorporated into the outward-facing surface 442 in selected areas of the knitted component 440, and may not be present on the outward-facing surface 442 in other areas of the knitted component 440. The fusible yarn may have a melting temperature lower than that of the second yarn, where the temperature of the second yarn is a lower of the decomposition temperature or the melting temperature. The second yarn may be knitted together with the fusible yarn on the outward-facing surface, or knitted to form an inward-facing surface. The fusible yarn in the knitted component 440 can be activated by heat such that the outward-facing surface 442 of the knitted component 440 includes fused regions (corresponding to areas formed by the fusible yarn on the outward-facing surface 442) and unfused regions (corresponding to areas on the outward-facing surface 442 that do not contain the fusible yarn).

[0082] The example materials and structures of the fusible yarns described for the knitted part 140 can be similarly used for the fusible yarns in the knitted part 440. Additionally, examples of fusible yarns in the knitted part 440 can be clamping yarns as described with respect to the knitted part 140, such that the portion of the knitted part 440 formed by the clamping yarns can have a greater coefficient of friction or a lower concentration of clamping yarns than the portion of the knitted part 440 without clamping yarns.

[0083] Fusible yarns, or in some respects clamping yarns, can be knitted on the outward-facing surfaces 442 within the constrained regions 452a-452d. The fusible yarns can be knitted to form rows of loops including tension elements 450 within these constrained regions 452a-452d. Thus, once the fusible yarns are activated (e.g., by heat), they can fuse to the tension elements 450. For example, the fusible yarns can be clamping yarns with a core having a thermoplastic elastomer coating as described herein, and once heated, the core of the clamping yarn fuses to the tension elements 450 by melting the thermoplastic elastomer coating. Additionally, aspects of this disclosure can include fusible yarns knitted on the outward-facing surfaces 442 to form rows of loops positioned between adjacent tension elements 450 within the constrained regions (e.g., 452a-452d or any one thereof). When fully or partially melted, the fusible material of the fusible yarns can flow to fill the spaces between the remaining knitted structures. Using fusible yarns to create fusion zones along the coil rows within restraint areas 452a-452d can help increase the restraint or locking provided by the tension element 450, and provide other benefits such as increased abrasion resistance and water resistance, while minimizing or even eliminating the need for additional layers and post-knitting processes. Minimizing or eliminating the need for additional layers helps the upper 104 maintain a light weight. For example, aspects of the upper 104 may have a weight of about 50 grams or less in some aspects, about 40 grams or less in some aspects, and about 30 grams or less in some aspects. Additionally, where the fusible yarns are aspects of clamping yarns as disclosed herein, the areas of the upper 404 with clamping yarns can allow the wearer to better feel and grip a ball (such as a football) to provide the wearer with better ball control.

[0084] Examples of knitted components 440 may include fusible yarns, and in some respects, may include clamping yarns in portions of knitted components 440 other than the constraint regions 452a-452d. For example, knitted components 440 may include clamping yarns in the outward-facing surface 442 in the midfoot region 410 in the region adjacent to the engagement line 406 between the upper 404 and the sole structure 402 (e.g., on the inner side 416 between the first constraint region 452a and the second constraint region 452b, and on the outer side 414 between the third constraint region 452c and the fourth constraint region 452d). Similarly, knitted components 440 may include knitted clamping yarns to form an outward-facing surface 442 in the forefoot region 408 between the second constraint region 452b and the third constraint region 452c in the region adjacent to the engagement line 406. These additional regions on the outward-facing surface 442, outside the restraint regions 452a-452d, that can hold the fusible or clamping yarn may extend only partially upwards to the upper 404. For example, as Figures 4A to 4CAs depicted in the dotted lines, the fusible or clamping yarns on the outward-facing surface 442 outside the constraint region 452a can extend from the interlocking line 406, but discontinuously to the inner periphery 434 at the throat region 426. Thus, although the fusible or clamping yarns can be knitted within the loop rows having the additional stretching elements 450 in the forefoot region 408, the fusible or clamping yarns do not extend the length of these additional stretching elements 450 in the same way that the fusible or clamping yarns can extend the length of the stretching elements 450 within the constraint regions 452a-452d.

[0085] Some examples of the knitted component 440 may also include fusible or clamping yarns knitted along the inner periphery 434 in the throat region 426 on the outward-facing surface 442. Additionally, as... Figure 4D As shown, fusible yarns or clamping yarns can be knitted along the central region of the heel area 412. For example, the upper 404 may include a heel seam, wherein the outer side 414 is secured to the inner side 416 in the heel area 412, and fusible yarns or clamping yarns can be knitted along the seam, from the interlocking line 406 to the ankle opening 425 of the knitted member 440 in the outward-facing surface 442.

[0086] As previously described, one or more additional yarns can be knitted (interlaced) together with the clamping yarn, such that the clamping yarn and the one or more additional yarns form the same loop rows within the knitting section 440. In various instances, the clamping yarn can be knitted on a first needle bed (e.g., the front needle bed), while a high-tenacity yarn with a higher melting or decomposition temperature than the clamping yarn is knitted on a second needle bed (e.g., the back needle bed). In a loop row with a stretching element 450, in some aspects, the stretching element 450 can be knitted with the clamping yarn on the first needle bed, or in other aspects, the stretching element 450 can be embedded between the first and second needle beds. In some aspects, the high-tenacity yarn knitted on the second needle bed has a different material composition than the stretching element 450, but it is conceivable that the high-tenacity yarn knitted on the second needle bed can have the same material composition as the stretching element 450. In the portion of the knitting member 440 where there is no yarn clamping on the outward-facing surface 442, the clamping yarn can be knitted on the second needle bed to be included on the inward-facing surface of the knitting member 440, while the high-tenacity yarn can be knitted on the first needle bed to be included on the outward-facing surface 442.

[0087] Some aspects of footwear described herein may include a polymer layer applied to at least a portion of the outward-facing surface of the knitted component after knitting. Figure 5 An example polymer layer 500 is depicted, and Figure 6 Depicting with Figure 5Example footwear article 600 with polymer layer 500. Various structures can be used for polymer layer 500, including, for example, polymer films, polymer webs, polymer powders, and nonwoven fabrics. For any of these structures, various polymer materials can be used for polymer layer 500, including polyurethane, polyester, polyester polyurethane, and / or nylon. While polymer layer 500 can be formed from thermosetting polymer materials, many configurations of polymer layer 500 are formed from thermoplastic polymer materials (such as thermoplastic polyurethane), such that polymer layer 500 can melt upon heating and return to a solid state upon cooling. Thus, polymer layer 500 formed from thermoplastic polymer materials can be melted, molded, cooled, remelted, remolded, and cooled again through multiple cycles. Polymer layer 500 formed from thermoplastic polymer materials can also be welded or thermally bonded to fabrics, such as knitted parts described further below.

[0088] Figure 6 A polymer layer 500 is depicted applied to a footwear article 600, which includes a sole structure 602 attached to an upper 604. The polymer layer 500 is positioned adjacent to at least a portion of the outward-facing surface 642 of a knitted component 640 and is attached to the knitted component 640 to form a portion of the outer surface of the upper 604. The knitted component 640 can be any form of knitted component disclosed herein, including any of knitted components 140, 340, 440, 840, and 1040. The polymer layer 500 can extend continuously from the forefoot region 608, midfoot region 610, and heel region 612 of the footwear article 600, for example, covering any portion of each or all of these regions in different aspects. Furthermore, in different aspects, the polymer layer 500 can extend continuously from the interlocking line 606 between the upper 604 and the sole structure 602 to the throat region 626, or can extend a portion of that distance.

[0089] like Figure 5 and Figure 6As depicted, the polymer layer 500 may include holes 510 extending through the polymer layer 500 to expose the underlying portion of the knitted component 640 when the polymer layer 500 is applied to the upper 604. Thus, when the polymer layer 500 is applied, the holes 510 allow the utilization of certain properties of the knitted component 640. For example, the outward-facing surface 642 of the knitted component 640 may be formed at least partially by the clamping yarns described with respect to knitted components 140 and 440, and the area of ​​the outward-facing surface 642 formed by the clamping yarns may have a higher coefficient of friction compared to the area of ​​the outward-facing surface 642 without clamping yarns. The holes 510 in the polymer layer 500 may be positioned to expose those areas with a higher coefficient of friction due to the clamping yarns, allowing the wearer of the footwear 600 to utilize the clamping yarns in the knitted component 640 to better grip the ball and have improved ball control. The holes 510 in the polymer layer 500 may also increase the breathability and flexibility of the upper 604.

[0090] In terms of attachment, the polymer layer (e.g., similar to 500) may cover different percentages of the knitted component forming a portion of the upper, for example, at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the surface of the knitted component, for example, across the entire knitted component, or across each zone (e.g., forefoot, heel, medial, and / or lateral). Furthermore, although in Figure 5 Holes 510 are depicted on the polymer layer 500 shown, but in any aspect of the polymer layer herein, holes may be present, but may also be partially or completely omitted, leaving the clamping yarn exposed in the area surrounding the polymer layer. Furthermore, in various aspects, the polymer layer may overlap with the edge of the area formed by, for example, heat-treated clamping yarn.

[0091] See also Figure 5 The polymer layer 500 can have pores 510 with different distributions in its regions. For example, such as Figure 5 and Figure 6 As shown, the holes 510 may be distributed only in the anterior portions of the forefoot region 608 and the midfoot region 610, while the holes may not be present in the posterior portions of the heel region 612 and the midfoot region 610. In other words, a first region of the knitted component 640 located in the forefoot region 608 may have a first surface area covered by the polymer layer 500, while a second region of the knitted component 640 located in the midfoot region 610 and / or the heel region 612 may have a surface area covered by the polymer layer 500 that is larger than the first surface area.

[0092] Integrating the perforation 510 into the foreground of the upper 604 allows access to the area of ​​the clamping yarn most likely to come into contact with the ball, while maintaining increased abrasion resistance, water resistance, and stability in other areas. Further aspects of the polymer layer 500 may include graphic designs, and omitting the perforations in areas of the polymer layer 500 that do not particularly benefit from exposed fusible clamping material allows for greater flexibility in graphic designs on the polymer layer 500.

[0093] Furthermore, the holes 510 in the polymer layer 500 can have different sizes (e.g., different diameters). For example, the polymer layer 500 includes larger holes (such as hole 510a) located closer to the forefoot region 618 of the upper 604 and smaller holes (such as hole 510b) located closer to the midfoot region 610 and / or the throat region 626. Thus, a larger surface area of ​​the knitted component 640 can be exposed in the forefoot region 608 and / or near the forefoot region 618 of the upper 604 through the holes 510 of the polymer layer 500, compared to the more rearward side of the knitted component 640, to expose the outward-facing surface 642 knitted by the clamping yarn. Besides changing the size of the holes 510, or as an alternative to changing the size of the holes 510, the density of the holes 510 in the polymer layer 500 can be varied in different areas to expose a more fusible clamping material in some areas of the knitted component 640 compared to other areas.

[0094] Similarly, the shape of the polymer layer 500 (e.g., the shape of the periphery of the polymer layer 500) may also be advantageous based on the exposure of areas knitted by knitted yarns, with the clamping yarns providing tactile properties (such as a greater coefficient of friction). For example, some aspects of the polymer layer 500 may not extend continuously from the bite line 606 to the throat region 626 in one or more areas of the upper 604. Figure 6 The polymer layer 500 extends from the occlusal line 606 in the forefoot region 608, but does not extend completely to the front end 628 of the throat region 626. Instead, the portion of the polymer layer 500 located in front of or in front of the throat region 626 extends only partially upward from the occlusal line 606 to the upper 604. In some respects, the polymer layer 500 may terminate at approximately one-third, one-half, or two-thirds of the distance from the occlusal line 606 to the front end 628 of the throat region 626. In the respect where the polymer layer 500 extends only partially upward from the occlusal line 606 to the upper 604 in the forefoot region 608, an additional surface area of ​​the knitted component 640 is exposed, and thus the area knitted by the clamping yarn can be exposed to maintain touch characteristics.

[0095] Various aspects of this disclosure may include methods for manufacturing uppers having polymer layers (such as...) Figure 6The method of the upper 604. This may include knitting a knitted component 640, which may include knitting clamping yarns on at least one needle bed to form the knitted component 640, wherein the clamping yarns form at least a portion of the outer-facing surface 642 of the knitted component 640. After the knitted component 640 is knitted, the clamping yarns at least on the outer-facing surface 642 may be activated by heat and / or pressure, such that the clamping yarns at least partially melt and fuse with the clamping yarns, the second yarns, and / or the infusible portions of the stretching elements as described with respect to knitted components 140 and 440. In one example, a heat source applied throughout the steaming process may heat the knitted component 640 to a temperature greater than the melting temperature of the clamping yarns and less than the melting or decomposition temperature of the second yarns in the knitted component 640. After the clamping yarns have at least partially melted, the knitted component 640 may be cooled, such that the molten fusible material of the clamping yarns may solidify. Additionally, the knitted part 640 may be held on a clamp, which may be used to apply tension to the knitted part 640 during heating and cooling, for example, from spaced pins extending through holes in the knitted part 640.

[0096] After the clamping yarns in the knitted part 640 are activated, the polymer layer 500 can be fixed to the knitted part 640. This process can be performed by covering the knitted part 640 with the polymer layer 500 between the portion where the knitted part 640 and the polymer layer 500 are compressed and heated in a hot press to bond them together. In the example of footwear article 600, the polymer layer 500 may have a polymer composition (formed from one or more polymer materials) with a melting temperature lower than the melting temperature of the fusible material in the clamping yarns of the knitted part 640. Additionally, the polymer layer 500 covering the knitted part 640 can be heated to a temperature greater than the melting temperature of the polymer layer 500 but less than the melting temperature of the clamping yarns. In this way, when the polymer layer 500 is bonded to the knitted part 640, the fusible polymer composition from the clamping yarns in the knitted part 640 will not be reactivated (e.g., remelted). After the polymer layer 500 is bonded to the knitted component 640, the polymer layer 500 and the knitted component 640 can be shaped into the upper 604 and fixed to the sole structure 602.

[0097] Additional aspects of this disclosure include processes for manufacturing knitted components of shoe uppers and / or shoe uppers. In particular, some aspects include steps for reducing fan-shaped notches on the edges of the knitted components during manufacturing without adding additional components to produce straight edges. For example, Figure 7 The illustration depicts a flowchart of an example method 700 for manufacturing an upper for a footwear article, which may include upper 104, upper 404, or upper 604. The steps provided in method 700 are merely illustrative, and method 700 may include additional steps not shown. Figure 8 An example knitted part 840 is depicted during method 700 and can be referenced. Figure 8 Let me explain the steps of method 700.

[0098] In step 710, the knitted part is knitted on a knitting machine. Step 710 can be performed by an automatic knitting machine, and thus, can be performed and / or controlled using a control unit having a processor or computer communicatively coupled to or integrated into the knitting machine. In an example aspect, the knitting machine used for knitting the knitted part is a V-bed plain knitting machine with two needle beds (a front needle bed and a back needle bed) angled relative to each other to form a V-shaped bed. The front and back needle beds may each include a plurality of independent needles extending across a common plane. A carriage can move yarn feeders, such as standard and / or combined yarn feeders, along the front and back needle beds to supply yarn to the needles. Typically, both standard and combined yarn feeders supply yarn to the needles for knitting, tucking, and / or floating, while combined yarn feeders can also supply yarn to pass through or embed between knitted structures. While a plain knitting V-bed knitting machine has been described herein, it should be understood that this is an example and other knitting machines can be used to form a knitted part or a portion thereof.

[0099] Furthermore, step 710 may include radially knitting a knitting component on a knitting machine. Radial knitting may be as described above. Figure 3 The knitted part 340 is performed as described.

[0100] Additionally, step 710 may include incorporating a stretching element, similar to stretching element 150 and / or stretching element 450, into the knitted structure of the knitted part. In some examples, the stretching element is embedded without loops via a combined yarn feeder of the knitting machine and is embedded between loops formed on the front and / or back beds of the knitting machine. In other instances, the stretching element can be incorporated along... Figure 9 The further described loop rows are combined with the stretching elements to form a repeating sequence of loop stitches and float stitches. Additionally, embodiments of step 710 may include knitting the knitted part with any yarn type described with respect to knitted parts 140, 440, or 640, and have any configuration of knitted parts 140, 540, or 640.

[0101] The knitted component formed in step 710 may include a first inner peripheral edge and a second inner peripheral edge. The first and second inner peripheral edges may be located in the throat region. For example, the first inner peripheral edge may be the inner edge of the knitted component in the throat region, while the second inner peripheral edge may be the outer edge of the knitted component in the throat region. Accordingly, the first and second inner peripheral edges may extend substantially parallel to each other.

[0102] In step 712, the first inner peripheral edge and the second inner peripheral edge are secured together. In one example, the first inner peripheral edge and the second inner peripheral edge are secured together by stitching. For example, Figure 8 A knitted component 840 on the clamp 810 is depicted, which has a first inner peripheral edge 832 and a second inner peripheral edge 834 sewn together to form a seam 850. Note that because the knitted component 840 is on top of the clamp 810, therefore... Figure 8 The outline of the clamp 810 is only visible through the knitting part 840.

[0103] In step 714, the knitted component is secured to the clamp using pins along a portion of its periphery. For example, the pins may be placed along the outer periphery of the knitted component. Additionally, in some aspects, the pins may be placed along the fourth and fifth inner periphery edges, which are not secured to each other and, once the upper is formed by the knitted component, the fourth and fifth inner periphery edges may together form the ankle opening of the upper. The first inner periphery edge 832 and the second inner periphery edge 834 are not directly pinned to the clamp. For example, in Figure 8 In the middle, the knitting component 840 is fixed to the clamp 810 by pin 812 along the outer periphery 824 of the knitting component 840 and along the third inner periphery edge 836 and the fourth inner periphery edge 838.

[0104] In step 716, one or more post-knitting processes can be performed on the knitted part while it is being secured to the fixture. For example, heat (e.g., by steam) can be applied to at least partially melt or soften the fusible material knitted into the knitted part, as described with respect to knitted parts 140, 440, and / or 640. Additionally or alternatively, while the knitted part is on the fixture, a separate polymer layer, such as polymer layer 500 or another similar polymer layer of some size, can be secured (e.g., thermally bonded) to the knitted part. Furthermore, the knitted part can be cooled to solidify the thermally bonded portion while still being secured to the fixture.

[0105] In step 718, after the post-knitting process of securing the knitted component to the clamp, the first inner peripheral edge 832 and the second inner peripheral edge 834 are separated. For example, the seam between the first inner peripheral edge 832 and the second inner peripheral edge 834 can be removed. Step 718 can be performed by die-cutting the knitted component to cut the seam formed between the first inner peripheral edge 832 and the second inner peripheral edge 834, and in some respects, also to cut the eyelets of the shoelaces into the knitted component. This step can be performed while the knitted component is still on the clamp or after the knitted component has been removed from the clamp.

[0106] Furthermore, aspects of method 700 may also include shaping the knitted component into the shape of the shoe upper, which can be done using a shoe last. Additionally, the shoe upper may be attached to one or more sole structures, such as a midsole fabric, midsole, and / or outsole.

[0107] Forming the upper from knitted components according to method 700 helps ensure a smooth, straight line along the throat region. Specifically, before securing the knitted components to the jig, the first and second inner peripheral edges are sewn together in the throat region, and a post-knitting heat treatment is applied to remove fan-shaped notches or curves that may naturally form along the first and second inner peripheral edges during the knitting process. When the fan-shaped notches are not removed before heating the knitted components, the heating process can maintain the fan-shaped or curved shape of the edges by melting and cooling the fusible yarn and / or applying a polymer (surface) layer. Although fan-shaped notches can be removed from the edges when the knitted components are pinned to the jig, a number of pins along the first and second inner peripheral edges are typically required to effectively remove the fan-shaped notches, and the use of additional pins increases manufacturing time. In particular, the time required to pin the first and second peripheral edges together sufficient to remove the fan-shaped notches is greater than the time required to stitch the first and second peripheral edges together.

[0108] Further embodiments of this disclosure relate to knitted structures and knitting methods that simulate embedded stretch elements. Specifically, stretch elements, such as stretch elements 150 and 450 described herein, can be embedded in the knitted structure such that the stretch elements float and / or woven between loops formed of other yarns, while the stretch elements themselves are not interwoven within the loop rows. Alternative structures can be knitted into the stretch elements in a manner that simulates the strength provided by the embedded stretch elements.

[0109] In some aspects of the knitted components, uppers, and footwear articles discussed herein, the knitted component or portions thereof may include an extended lining (e.g., a floating extended lining) to impart extended properties. In one aspect, the extended lining may be positioned and / or floating along the inward-facing surface of the knitted component.

[0110] Furthermore, in some aspects of the knitted components, uppers, and footwear articles discussed herein, the clamping yarns may be located in different areas of the inward-facing and / or outward-facing surfaces of the knitted component, for example, along the forefoot area (e.g., in the toe area) and / or along the vamp.

[0111] Furthermore, in some aspects of the knitted components, uppers, and footwear discussed herein, the forefoot area (e.g., the toe box and / or the forefoot panel) may include yarns and / or fabrics (e.g., polyester, nylon) having limited or virtually no stretch properties for greater reinforcement, durability, and abrasion resistance and / or durability. This may be used in combination with other aspects described herein.

[0112] Figure 9 A close-up view of a portion of an example knitted part 940 with a stretching element 950 having a simulated or analogous embedded structure is shown. Specifically, each loop row of the stretching element 950 includes a sequence of knitted stitches 952 (e.g., knitted loops) and float stitches 954, wherein the sequence repeats along the length of the loop row. In the example, the sequence includes a knitted stitch and a float stitch extending across multiple loop rows. The number of loop rows the float stitch extends across can correspond to the number of needles along the needle bed, with the stretching element floating between two knitted stitches. The number of loop rows each float stitch extends across can range from 3 to 8, from 4 to 7, and from 5 to 6. In one example, each float stitch of the stretching element extends across 5 loop rows. Thus, the stretching element can be knitted using a knitted sequence of a knitted stitch formed on one needle and a float stitch extending across five needles.

[0113] By incorporating numerous float stitches along the loop rows with a stretching element, it is possible to simulate the strength and stretch resistance imparted when the stretching element is embedded in a knitted structure. However, knitting the stretching element with temporary stitches (loops) can help maintain the stretching element along the loop rows in a straighter or flatter line. Furthermore, the stretching element can be combined with knitted stitches and floats rather than inserts on a knitting machine using a combination feeder or a regular feeder. This provides greater flexibility in which knitting machines can be used to form the knitted part 940 and / or how a particular knitting machine can be used.

[0114] In some respects, the positions of the knitted stitches in adjacent loop rows of the tension element 950 can be offset so that they appear at different needle positions. For example, if the knitted stitches in the loop row of tension element 950a are at needle positions 2, 8, and 14, the knitted stitches in the loop row of the adjacent tension element 950b can be at positions 3, 9, and 15.

[0115] For the sake of simplicity, in Figure 9The drawing element 950 following the simulated embedded structure is only schematically depicted; however, it should be understood that the loop rows in the knitted component may include additional yarns knitted together with the drawing element 950. For example, the drawing element 950 may be knitted on a first needle bed, where another yarn is knitted using a different stitch sequence. The other yarn on the first needle bed (referred to herein as the first yarn) may be a fusible yarn (including clamping yarn), a high-tenacity yarn, a monofilament yarn, or a yarn having a combination of these characteristics as described in this disclosure. The first yarn may be knitted using a knitted stitch or a combination of knitted stitches and tuck stitches. In some aspects, the first yarn loops on multiple consecutive needles on the first needle bed, then tucks on needles on a second needle bed, and continues looping on needles on the first needle bed. The tuck stitch of the first yarn to the second needle bed helps to hold the floating yarn of the drawing element 950 in place. In some loop rows, the first yarn may be knitted only on the first needle bed without tucking on the second needle bed.

[0116] In some aspects, the knitted component 940 is also formed of a second yarn knitted on a second needle bed. This second yarn can be knitted using knitting stitches and / or tuck stitches. In some aspects, the second yarn is knitted on the second needle bed at the needle position where the first yarn is knitted on the first needle bed, and the second yarn switches to knitting on the first needle bed when the first yarn switches to knitting on the second needle bed. Examples of the second yarn may include fusible yarns (including clamping yarns), high-tenacity yarns, monofilament yarns, or yarns having combinations of these characteristics as described in this disclosure. In one embodiment, the first yarn is a clamping yarn, and the second yarn is a high-tenacity yarn whose melting or decomposition temperature is at least higher than that of the fusible material on the first yarn.

[0117] Figure 9 The knitted part 940 is radially knitted, such that the stretching element 950 extends radially from the outer periphery 924 along the loop rows to a common portion, such as the throat region 926. However, it should be understood that the same knitting sequence of the stretching element 950 can be applied to non-radially knitted parts, such as those in which the loop rows of the stretching elements extend parallel to each other (e.g., parallel along an inside-to-outside axis) without converging toward a common portion.

[0118] Figure 10 Another example of a knitted component 1040 having a stretching element 1050 according to various aspects of the invention is depicted. The knitted component 1040 can be used to form the upper of footwear articles (such as footwear 100 or footwear 400). The knitted component 1040 may have any of the features described with respect to other knitted components disclosed herein (including knitted components 140, 340, 440, 640, 840, and 940), except as indicated below with respect to the stretching element 1050.

[0119] The tension element 1050 in the knitted component 1040 can be formed from a cable such as a braided cable, or from a strand of yarn with a cross-sectional diameter much larger than the cross-sectional diameter of the other strands forming the knitted component 1040. Additionally, the tension element 1050 with this structure can be incorporated into the knitted structure by knitting (e.g., interlacing the tension element 150 with the loops of adjacent loop rows), rather than being embedded between interlaced loop rows of other yarns without forming loops. For example, it can be based on... Figure 9 The knitting sequence of the stretching element 950 is used to knit the stretching element 1050. Therefore, when the knitted part 1040 is formed into the upper, the stretching element 1050 can form a raised structure extending away from the foot-accommodating gap. When the knitted part 1040 is worn on the upper, the raised stretching element 1050 can generate more spin when it comes into contact with a ball (such as a soccer ball). In some aspects, this may include... Figure 5 and Figure 6 Polymer layers (e.g., surface layers) of various aspects of the described polymer layer 500 may be applied to the knitted part 1040 and to at least a portion of the raised stretching element 1050.

[0120] Additional example features of clamping yarn

[0121] As described above, the knitted components disclosed herein may include selectively combined yarns (hereinafter referred to as clamping yarns) as described alone or in combination with other materials (e.g., second yarns or stretching elements not falling under the fibers, filaments, and yarns described herein as clamping yarns). In some aspects, the yarns and / or fibers described herein may be used to provide specific functions. For example, in some aspects, fibers or yarns as described herein may be fused to form a surface or at least a recirculation area having waterproof or water-resistant properties, restraining properties, specific adhesion frictional properties, "ball contact" properties, and providing a higher coefficient of friction. In addition to the materials and properties of the clamping yarns disclosed above, the following properties can be found in examples of clamping yarns.

[0122] In one aspect, the clamping yarn described herein has a breaking strength of an applied force of about 0.6 to about 0.9 kg, or an applied force of about 0.7 to about 0.9 kg, or an applied force of about 0.8 to about 0.9 kg, or an applied force greater than 0.9 kg.

[0123] Clamping yarns include or are substantially composed of clamping materials. The clamping materials are elastic thermoplastic materials because they comprise or are substantially composed of one or more thermoplastic elastomers. In some aspects, the clamping materials have a melting temperature of less than 115 degrees Celsius, less than 110 degrees Celsius, or less than 100 degrees Celsius.

[0124] Clamping yarns comprising or substantially consisting of clamping material should be understood to include a coating of clamping material, or to include one or more clamping fibers, wherein each of the individual clamping fibers includes clamping material, or includes both a clamping material coating and clamping fibers. The clamping fibers of a clamping yarn may include a variety of short clamping fibers, or may include a variety of long clamping filaments, or may include a single long clamping filament (i.e., a monofilament), or may include a combination of short clamping fibers and one or more filaments. Similarly, clamping yarns may include a single clamping filament, or may include a variety of clamping fibers or clamping filaments, or may include one or more core yarns. When a clamping yarn includes one or more core yarns, each of the one or more core yarns may be individually at least partially coated with clamping material. Alternatively, when a clamping yarn includes one or more core yarns, the one or more core yarns may form a twisted yarn, and the twisted yarn may be at least partially coated with clamping material.

[0125] In one aspect, when the clamping yarn consists essentially of clamping fibers, 95% or more of the fibers present in the clamping yarn are clamping fibers. In other aspects, when the clamping yarn comprises two or more types of fibers, at least one of the two or more types of fibers is a clamping fiber. When the clamping yarn comprises two or more types of fibers, the clamping fibers may account for at least 10% by weight, or at least 25% by weight, or at least 50% by weight, or at least 75% by weight of the fibers present in the clamping yarn.

[0126] In one aspect, the clamping yarn includes a core coated with a clamping material. The clamping yarn core includes a core material, wherein the core material comprises different types of polymers and / or has properties different from those of the clamping yarn material. The core material can be a polymeric material comprising one or more polymers, or it can include a non-polymeric material. When the core material is a polymer, the polymer present in the core material can be a polymer of a different type than the polymer present in the clamping material. For example, the core material can include one or more polyester homopolymers or polyamide homopolymers, while the clamping material can be substantially free of polyester homopolymers or polyamide homopolymers. When the core material is a thermoplastic material, the core material can have a higher flexural or melting temperature than the clamping material. When the core material is a non-polymeric or thermosetting material, the core material can have a higher degradation temperature than the melting temperature of the clamping material. The core material can be inelastic or less elastic than the clamping material (e.g., having a lower percentage of elongation).

[0127] In one aspect, the core of the clamping yarn comprises one or more fibers. In this aspect, the clamping material may completely or partially coat the core. The one or more core fibers may be a variety of short fibers, such as a variety of short fiber lengths spun into a single yarn, or a variety of short fiber lengths spun into two or more yarns, wherein the two or more yarns are twisted together. The one or more core fibers may be a variety of filaments. The multiple filaments may be aligned, or may be aligned and entangled. The one or more core fibers may be a single long monofilament.

[0128] In one aspect, the clamping yarn is a coated yarn, wherein the core yarn comprises a second polymer composition as a core material and a coating disposed on the core yarn, the coating comprising a first polymer composition as a clamping material, wherein the first polymer composition has a clamping material melting temperature. In another aspect, the core material is thermoplastic and has a deformation temperature at least 20 degrees Celsius, at least 50 degrees Celsius, at least 75 degrees Celsius, or at least 100 degrees Celsius higher than the clamping melting temperature of the first polymer composition. The clamping material comprises one or more thermoplastic elastomers, or is substantially composed of one or more thermoplastic elastomers. Optionally, in addition to comprising one or more thermoplastic elastomers, the clamping material may also comprise one or more additional polymers, or one or more additional non-polymer additives, or may comprise both. The one or more thermoplastic elastomers of the clamping material may comprise one or more thermoplastic polyurethane (TPU) elastomers, or one or more thermoplastic styrene elastomers, or a combination of both. In one respect, one or more thermoplastic elastomers are two or more thermoplastic elastomers, such as two or more TPU elastomers, or two or more styrene elastomers, or a combination of two TPU elastomers and styrene elastomers, or a combination of two styrene elastomers and TPU elastomers.

[0129] As used herein, a polymer composition (such as a clamping composition or a core composition) should be understood to include a polymer component consisting of all polymers present in the polymer composition. The polymer component may consist of a single polymer or may consist of two or more polymers. In one aspect, the polymer component consists of one or more polymers of a single type. For example, the polymer component of a core material may consist of one or more polyesters, or one or more polyethers, or one or more polyamides, or one or more polyurethanes, or one or more polyolefins. The polymer component of a core material may consist of one or more polyesters. The polymer component of a core material may consist of polyethylene terephthalate (PET). The polymer component of a clamping material may consist of one or more TPU elastomers, or one or more styrene elastomers. The polymer component of a clamping material may consist of one or more polyester-polyurethane elastomers. The polymer component of a clamping material may consist of one or more styrene-butadiene-styrene (SBS) elastomers.

[0130] The core material of the core fiber or core yarn can be any material that retains its strength at the temperature when the clamping material is applied to the core fiber or core yarn. The core fiber coated with the clamping material, and / or the fiber used to form the core yarn, can be a natural fiber or a regenerated fiber or filament, or a synthetic fiber or filament. In one aspect, the core fiber or core yarn comprises natural or regenerated materials (such as cotton, silk, wool, or rayon) or is substantially composed of natural or regenerated materials (such as cotton, silk, wool, or rayon), which are not thermoplastic and therefore have a degradation temperature but not a melting or deformation temperature. In another aspect, the core material of the core fiber or core yarn comprises one or more synthetic thermosetting materials (such as thermosetting polyurethane or thermosetting polyurea) or is substantially composed of one or more synthetic thermosetting materials (such as thermosetting polyurethane or thermosetting polyurea), which also have a degradation temperature but not a melting or deformation temperature. In another aspect, the core material of the core fiber or core yarn comprises or is substantially composed of one or more synthetic thermoplastics, such as polyesters, polyamides, polyurethanes, polyolefins, copolymers thereof, and mixtures thereof. In one aspect, the core material comprises or is substantially composed of one or more polyesters or one or more polyamides. In one example, the one or more polyesters comprises or is substantially composed of polyethylene terephthalate (PET). In one aspect, the core material is a thermoplastic material and has a deformation temperature greater than 200 degrees Celsius, or greater than 220 degrees Celsius, or greater than 240 degrees Celsius, or from about 200 degrees Celsius to about 300 degrees Celsius.

[0131] In one aspect, the core yarn has a linear density of about 100 denier to about 300 denier, or about 100 denier to about 250 denier, or about 100 denier to about 200 denier, or about 100 denier to 150 denier, or about 150 denier to 300 denier, or about 200 denier to 300 denier, or about 250 denier to 300 denier. In one aspect, the core yarn has a thickness of about 60 micrometers to 200 micrometers, about 60 to 160 micrometers, about 60 to 120 micrometers, about 60 to 100 micrometers, about 100 to 200 micrometers, or about 140 to 200 micrometers. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material containing one or more synthetic polymers or is substantially composed of a core material containing one or more synthetic polymers. The one or more synthetic polymers may include polyamides, polyesters, polyethers, polyurethanes, polyolefins, and combinations thereof. One or more polyurethanes may include polyurethane terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature at least 20°C, at least 50°C, at least 75°C, or at least 100°C higher than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0132] In one aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier. In one aspect, the core yarn has an elongation of about 20% to about 30%, about 22% to about 30%, about 24% to about 30%, about 20% to about 28%, or about 20% to about 26%. In one aspect, the core yarn has a toughness of about 1 g / denier to about 10 g / denier, about 3 g / denier to about 10 g / denier, about 5 g / denier to about 10 g / denier, about 1 g / denier to about 7 g / denier, or about 1 g / denier to about 5 g / denier. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material containing one or more synthetic polymers or is substantially composed of a core material containing one or more synthetic polymers. One or more synthetic polymers may include polyamides, polyesters, polyethers, polyurethanes, polyolefins, and combinations thereof. One or more polyurethanes may include polyurethane terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature at least 20°C, at least 50°C, at least 75°C, or at least 100°C higher than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0133] In one aspect, a clamping yarn can be created by extruding a coating (e.g., a first polymer composition as a coating material) onto a core yarn through an annular die or orifice, such that the coating surrounds the core yarn and is axially centered. The thickness of the coating applied to the core yarn can vary depending on the application of the yarn. In one aspect, the clamping yarn has a nominal average outer diameter of up to 1.00 mm, or up to about 0.75 mm, or up to about 0.5 mm, or up to about 0.25 mm, or up to about 0.2 mm, or up to about 0.1 mm. In another aspect, the coating has a nominal average outer diameter of about 0.1 mm to about 1.00 mm, or about 0.1 mm to about 0.80 mm, or about 0.1 mm to about 0.60 mm. In yet another aspect, the coating on the yarn has an average radial coating thickness of about 50 micrometers to about 200 micrometers, or about 50 micrometers to about 150 micrometers, or about 50 micrometers to about 125 micrometers. The core yarn may comprise one or more natural or regenerated fibers or be substantially composed of one or more natural or regenerated fibers. The core yarn may include a core material containing one or more synthetic polymers or be substantially composed of a core material containing one or more synthetic polymers. The one or more synthetic polymers may include polyamides, polyesters, polyethers, polyurethanes, polyolefins, or any combination thereof. The one or more polyurethanes may include polyurethane terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature at least 20°C, at least 50°C, at least 75°C, or at least 100°C higher than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0134] In one aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier, and the coating has a nominal average outer diameter of about 0.10 mm to about 0.50 mm, or about 0.10 mm to about 0.25 mm, or about 0.10 mm to about 0.20 mm. In another aspect, the core yarn has a thickness of about 100 denier to about 200 denier, about 125 denier to about 175 denier, or about 150 denier to about 160 denier, and the coating has a nominal average outer diameter of about 0.10 mm to about 0.50 mm, or about 0.10 mm to about 0.25 mm, or about 0.10 mm to about 0.20 mm. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material containing one or more synthetic polymers or is substantially composed of a core material containing one or more synthetic polymers. One or more synthetic polymers may include polyamides, polyesters, polyethers, polyurethanes, polyolefins, and combinations thereof. One or more polyurethanes may include polyurethane terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature at least 20°C, at least 50°C, at least 75°C, or at least 100°C higher than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200°C, greater than 220°C, greater than 240°C, or between about 200°C and about 300°C.

[0135] In another aspect, the clamping yarn has a net total diameter of from about 0.2 to about 0.6 mm, or from about 0.3 to about 0.5 mm, or from about 0.4 to about 0.6 mm. In some aspects, a lubricant, including but not limited to mineral oil or silicone oil, is present on the yarn in an amount from about 0.5 wt% to about 2 wt%, or from about 0.5 wt% to about 1.5 wt%, or from about 0.5 wt% to about 1 wt%. In some aspects, the lubricating composition is applied to the surface of the fusible clamping yarn prior to or during the fabric forming process. In some aspects, the thermoplastic composition and the lubricating composition are miscible when the thermoplastic composition is reflowed and re-solidified in the presence of the lubricating composition. After reflow and re-solidification, the reflowed and cured composition may include the lubricating composition.

[0136] In another aspect, the clamping yarn has a net total diameter of 0.2 to 0.6 mm, or 0.3 to 0.5 mm, or 0.4 to 0.6 mm.

[0137] In some aspects, the lubricant, including but not limited to mineral oil or silicone oil, is present in the yarn at a concentration of from about 0.5 wt% to about 2 wt%, or from about 0.5 wt% to about 1.5 wt%, or from about 0.5 wt% to about 1 wt%. In some aspects, the lubricating composition is applied to the surface holding the yarn before or during the fabric forming process. In some aspects, the thermoplastic composition and the lubricating composition are miscible when the thermoplastic composition is reflowed and re-solidified in the presence of the lubricating composition. After reflow and re-solidification, the reflowed and solidified composition may include the lubricating composition.

[0138] In one aspect, the core yarn has an elongation of about 8% to about 30%, about 10% to about 30%, about 15% to about 30%, about 20% to about 30%, about 10% to about 25%, or about 10% to about 20%. In another aspect, the core yarn has a toughness of about 1 g / denier to about 10 g / denier, about 2 g / denier to about 8 g / denier, about 4 g / denier to about 8 g / denier, or about 2 g / denier to about 6 g / denier. The core yarn may comprise one or more natural or regenerated fibers or is substantially composed of one or more natural or regenerated fibers. The core yarn may comprise a core material containing one or more synthetic polymers or is substantially composed of a core material containing one or more synthetic polymers. The one or more synthetic polymers may comprise polyamide, polyester, polyether, polyurethane, polyolefin, or any combination thereof. The one or more polyurethanes may comprise polyurethane terephthalate (PET) or be substantially composed of PET. The core yarn or core material, or both, may have a degradation or deformation temperature that is at least 20 degrees Celsius, at least 50 degrees Celsius, at least 75 degrees Celsius, or at least 100 degrees Celsius higher than the melting temperature of the clamping material. The core yarn or core yarn material, or both, may have a degradation or deformation temperature greater than 200 degrees Celsius, greater than 220 degrees Celsius, greater than 240 degrees Celsius, or between about 200 degrees Celsius and about 300 degrees Celsius.

[0139] In one aspect, the clamping material has a melting temperature from about 100 degrees Celsius to about 210 degrees Celsius, optionally from about 110 degrees Celsius to about 195 degrees Celsius, from about 120 degrees Celsius to about 180 degrees Celsius, or from about 120 degrees Celsius to about 170 degrees Celsius. In another aspect, the clamping material has a melting temperature greater than about 120 degrees Celsius and less than about 170 degrees Celsius, and optionally greater than about 130 degrees Celsius and less than about 160 degrees Celsius.

[0140] On the other hand, when the melting temperature of the clamping material is greater than 100 degrees Celsius, the integrity of the article formed or incorporated with the coating material is protected if the article is briefly subjected to relatively high temperatures, for example, during transportation or storage. On the other hand, when the melting temperature of the clamping material is greater than 100 degrees Celsius or greater than 120 degrees Celsius, the article formed or incorporated with the first polymer composition as the clamping material can be steamed without melting or unintentionally fusing any higher melting temperature (e.g., polyester) component incorporated in the article for purposes such as filling, striped surfaces, or comfort features, as well as yarns for wearing comfort and fit characteristics.

[0141] In one aspect, when the melting temperature of the clamping material is greater than 120 degrees Celsius, articles incorporating materials with higher deformation or melting temperatures (e.g., the first polymer composition or the second polymer composition) are unlikely to soften and / or become sticky during use on hot paved surfaces, stadium surfaces, artificial or natural football fields, or similar sports surfaces, tracks, or fields. In another aspect, the higher the melting temperature and the greater the enthalpy of fusion of the first polymer composition or the second polymer composition, the greater the ability of footwear articles or sports equipment incorporating or composed of the first polymer composition or the second polymer composition to withstand contact heating offset, frictional surface heating events, or environmental heating offset. In another aspect, such thermal offset can occur when the article comes into contact with a hot ground, stadium, or turf surface, or when the article comes into contact with another surface such as the ground, another shoe, a ball, etc., such thermal offset arises from frictional heating as a result of friction or wear.

[0142] On the other hand, when the melting temperature of the clamping material is less than about 210 degrees Celsius, or less than 200 degrees Celsius, or less than 190 degrees Celsius, or less than 180 degrees Celsius, or less than 175 degrees Celsius but greater than 120 degrees Celsius, or greater than 110 degrees Celsius, or greater than 103 degrees Celsius, the yarn coated with the clamping material can be melted in order to mold and / or thermoform a given area of ​​a fabric knitted by the clamping material in order to impart the desired design and aesthetic features in a short time.

[0143] On one hand, the melting temperature of the clamping material below 140 degrees Celsius prevents or mitigates the risk of dye migration from packaged dyed yarns (such as packaged dyed polyester yarns incorporated into footwear or other articles). On the other hand, dye migration from packaged dyed yarns or fibers is a diffusion-limiting process, and short-term exposure to temperatures above 140 degrees Celsius (such as during thermoforming) will not severely damage the appearance of footwear or other articles, discolor them, or otherwise render their appearance unacceptable. However, on the other hand, if the melting temperature of the clamping material is above approximately 210 degrees Celsius, heat damage and dye migration may occur.

[0144] On the one hand, a high enthalpy of melting indicates that a longer heating time is required to ensure that the polymer or polymer material melts completely and flows well. On the other hand, a low enthalpy of melting requires less heating time to ensure complete melting and good flow.

[0145] On the other hand, high exothermic cooling indicates a rapid transition from melt to solid. Higher recrystallization temperatures indicate that the polymer or polymer material can solidify at higher temperatures. In one respect, high-temperature solidification is beneficial for thermoforming. In another respect, recrystallization above 95 degrees Celsius promotes rapid solidification after thermoforming, reduces cycle time, reduces cooling requirements, and improves the stability of shoe components during assembly and use.

[0146] In one aspect, the viscosity effects of the clamping materials disclosed herein include the properties and processing of the articles of clamping materials. In another aspect, high viscosity at low shear rates (e.g., less than the reciprocal of 1 second) indicates resistance to flow, displacement, and more solid-like behavior. In yet another aspect, low viscosity at higher shear rates (e.g., greater than the reciprocal of 10 seconds) favors high-speed extrusion. In one aspect, as viscosity increases, the ability to flow and deform sufficiently to coat core yarns or fabric regions incorporating coated yarns becomes challenging. In yet another aspect, materials exhibiting a high shear thinning index (e.g., viscosity at the reciprocal of 10 or 100 seconds is lower than that at the reciprocal of 1 second) may be difficult to extrude, and melt fracture may occur if coated or extruded at excessively high speeds.

[0147] In some aspects, the clamping yarn exhibits a toughness greater than 1 g / denier. In one aspect, the clamping yarn exhibits a toughness from about 1 g / denier to about 5 g / denier. In one or more aspects, the clamping yarn exhibits a toughness from about 1.5 g / denier to about 4.5 g / denier. In one aspect, the clamping yarn exhibits a toughness from about 2 g / denier to about 4.5 g / denier.

[0148] As used in this article, " tenacity"Toughness" refers to the properties of fibers or yarns, and is determined using the corresponding test methods and sampling procedures described below. Specifically, the toughness and elongation of yarn samples are determined according to the test methods detailed in EN ISO 2062, where the preload is set to 5 grams. Elongation is recorded at the maximum tensile force applied before breakage. Toughness can be calculated as the ratio of the load required to break the sample to the linear density of the sample.

[0149] In some respects, it may be desirable to utilize clamping yarns suitable for use on commercial knitting equipment. The independent shrinkage of yarn at 50 degrees Celsius is a characteristic that can predict the suitability of yarns for use on commercial knitting machines. In some respects, clamping yarns may exhibit less than 15% independent shrinkage when heated from 20 degrees Celsius to 70 degrees Celsius. In various respects, clamping yarns may exhibit approximately 0% to approximately 60%, approximately 0% to approximately 30%, or approximately 0% to approximately 15% independent shrinkage when heated from 20 degrees Celsius to 70 degrees Celsius. As used herein, the term "independent shrinkage" refers to a characteristic of the yarn, and the corresponding test methods are described below:

[0150] yarn shrinkage test Independent shrinkage of yarn can be determined by the following method. Prepare a yarn sample according to the yarn sampling procedure described below, and cut it into lengths of approximately 30 mm with minimal tension at approximately room temperature (e.g., 20 degrees Celsius). Place the cut sample in an oven at 50 degrees Celsius or 70 degrees Celsius for 90 seconds. Remove the sample from the oven and measure it. Using the measurements of the sample before and after the oven, calculate the percentage shrinkage by dividing the post-oven measurement by the pre-oven measurement and multiplying by 100.

[0151] Yarn sampling procedure Before testing, store the yarn to be tested at room temperature (20°C to 24°C) for 24 hours. Discard the first 3 meters of material. Cut the sample yarn into lengths of approximately 30 mm at approximately room temperature (e.g., 20°C) with minimal tension.

[0152] In one or more aspects, the independent shrinkage of a yarn at 70 degrees Celsius can be a useful indicator of the yarn's ability to be exposed to certain environmental conditions without any significant change in its physical structure. In some aspects, when heated from 20 degrees Celsius to 70 degrees Celsius, the clamped yarn exhibits an independent shrinkage from about 0% to about 60%. In one or more aspects, when heated from 20 degrees Celsius to 70 degrees Celsius, the clamped yarn exhibits an independent shrinkage from about 0% to about 30%. In one aspect, when heated from 20 degrees Celsius to 70 degrees Celsius, the clamped yarn exhibits an independent shrinkage from about 0% to about 20%.

[0153] As discussed above, in some respects, the clamping material (e.g., the first polymer composition) and the core material (e.g., the second polymer composition) have different properties. In various respects, these different properties allow the clamping fibers and yarns, as described herein, to melt and flow during the thermoforming process, and subsequently cool and solidify into a structure different from their structure prior to the thermoforming process (e.g., thermoforming from clamping yarns into reflowing clamping material), whereas when the thermoforming process is carried out at a temperature below the melting or deformation temperature of the uncoated fibers or yarns, the uncoated fibers or yarns do not deform or melt during such a process and can maintain their structure (e.g., as fibers or yarns). In such respects, the reflowing clamping material formed from the clamping fibers or yarns during thermoforming can be integrally connected to an unaltered structure (e.g., yarns or fibers) that can provide a three-dimensional structure and / or other properties for specific areas on footwear articles.

[0154] The clamping materials for clamping yarns described herein include one or more thermoplastic elastomers. In one aspect, an "elastomer" is defined as a material having an elongation at break greater than 400% as measured using ASTM D-412-98 at 25 degrees Celsius. In another aspect, the elastomer is formed into a sheet having a tensile strength of 10 to 35 kgf, or from about 10 to about 25 kgf, or from about 10 to about 20 kgf, or from about 15 to about 35 kgf, or from about 20 to about 30 kgf. In another aspect, if adjusted for cross-sectional area, the tensile strength at break or ultimate tensile strength is greater than 70 kgf / cm², or greater than 80 kgf / cm². In another aspect, the elastomer sheet has a tensile strain of 450% to 800%, or from 500% to 800%, or from 500% to 750%, or from 600% to 750%, or from 450% to 700%. On the other hand, the elastomer plate has a load of 3 to 8 kgf / mm at 100% strain, or about 3 to about 7 kgf / mm, about 3.5 to about 6.5 kgf / mm, or about 4 to about 5 kgf / mm.

[0155] In one aspect, the elastomeric plate has a toughness from 850 kg-mm to 2200 kg-mm, or from about 850 kg-mm to about 2000 kg-mm, or from about 900 kg-mm to about 1750 kg-mm, or from about 1000 kg-mm to about 1500 kg-mm, or from about 1500 kg-mm to about 2000 kg-mm. In another aspect, the elastomeric plate has a stiffness from about 35 to about 155, or from about 50 to about 150, or from about 50 to about 100, or from about 50 to about 75, or from about 60 to about 155, or from about 80 to about 150. In yet another aspect, the elastomeric plate has a tear strength from about 35 to about 80, or from about 35 to about 75, or from about 40 to about 60, or from about 45 to about 50.

[0156] In various aspects, exemplary thermoplastic elastomers include homopolymers and copolymers. The term "polymer" refers to a polymeric molecule having one or more monomeric species, and includes homopolymers and copolymers. The term "copolymer" refers to a polymer having two or more monomeric species, and includes terpolymers (i.e., copolymers having three monomeric species). In some aspects, thermoplastic elastomers are random copolymers. In one aspect, thermoplastic elastomers are block copolymers. For example, a thermoplastic elastomer may be a block copolymer having repeating blocks (segments) of polymeric units with the same relatively stiff (hard segment) chemical structure and repeating blocks of polymeric segments with relatively soft (soft segment). In various aspects, in block copolymers (including block copolymers having repeating hard and soft segments), physical crosslinking may be present within blocks or between blocks or both within and between blocks. Specific examples of hard segments include isocyanate segments and polyamide segments. Specific examples of soft segments include polyether segments and polyester segments. As used herein, polymer segments can be specific types of polymer segments, such as isocyanate segments, polyamide segments, polyether segments, polyester segments, etc. It should be understood that the chemical structure of a segment is derived from the described chemical structure. For example, an isocyanate segment is a polymeric unit comprising an isocyanate functional group. When referring to a block of a polymer segment with a specific chemical structure, the block may contain up to 10 mol% of segments with other chemical structures. For example, as used herein, a polyether segment should be understood to include up to 10 mol% of non-polyether segments.

[0157] In one aspect, the clamping material (e.g., a first polymer composition) comprises a polymer component consisting of all the polymers present in the clamping material. Optionally, the polymer component may include two or more polymers.

[0158] When two or more polymers share individual segments with chemical structures falling within the same general polymer structure (e.g., polyester, polyamide, polyolefin, polyurethane, polystyrene, etc.), they can be considered polymers of the same "type". In one aspect, the shared individual segments can be polyester, polyamide, polyolefin, polyurethane, polystyrene, etc. According to this aspect, the polymer composition can be described as consisting of polyester, polyamide, polyolefin, polyurethane, polystyrene, etc. When no polymers share segments with chemical structures falling within the same general polymer structure, the two or more polymers can be considered distinct from each other.

[0159] On the other hand, two or more polymers may share a common chemical structure because they all comprise segments with the same chemical structure, but each polymer may include a different number of segments, thus resulting in different molecular weights. For example, they may all be in the form of polyethylene terephthalate (PET), or they may all be in the form of nylon 6,6, or they may all be in the form of polyester-polyurethane copolymers, or they may all be in the form of ethylene styrene / butene styrene (SEBS) copolymers, etc. According to this aspect, the polymer composition can be described as consisting of PET, or nylon 6,6, or polyester-polyurethane, or SEBS copolymers, etc.

[0160] In various aspects, thermoplastic elastomers may include one or more of thermoplastic copolyester elastomers, thermoplastic polyether block amide elastomers, thermoplastic polyurethane elastomers, polyolefin-based copolymer elastomers, thermoplastic styrene copolymer elastomers, thermoplastic ionomer elastomers, or any combination thereof. In one aspect, the first polymer composition comprises a thermoplastic elastomer styrene copolymer. In another aspect, the thermoplastic elastomer styrene copolymer may be a styrene-butadiene-styrene (SBS) block copolymer, a styrene-ethylene / butene-styrene (SEBS) copolymer, a styrene-acrylonitrile (SAN) copolymer, or any combination thereof. In one aspect, the clamping material comprises a thermoplastic elastomer polyester polyurethane, a thermoplastic polyether polyurethane, or any combination thereof. In some aspects, the thermoplastic elastomer polyester polyurethane may be an aromatic polyester, an aliphatic composition, or a combination thereof. It should be understood that other thermoplastic polymer materials not specifically described below are also contemplated for use in clamping yarns and / or core materials as described herein. In one aspect, the clamping material comprising the thermoplastic elastomer has a melting temperature greater than about 110 degrees Celsius and less than about 170 degrees Celsius. In another aspect, the clamping material comprising the thermoplastic elastomer has a melting temperature of about 110 degrees Celsius to about 170 degrees Celsius, about 115 degrees Celsius to about 160 degrees Celsius, about 120 degrees Celsius to about 150 degrees Celsius, about 125 degrees Celsius to about 140 degrees Celsius, about 110 degrees Celsius to about 150 degrees Celsius, or about 110 degrees Celsius to about 125 degrees Celsius.

[0161] In various aspects, the thermoplastic elastomer has a glass transition temperature (Tg) of less than 50 degrees Celsius when measured according to ASTM D3418-97 as described below. In some aspects, the thermoplastic elastomer has a glass transition temperature (Tg) of about -60 degrees Celsius to about 50 degrees Celsius, about -25 degrees Celsius to about 40 degrees Celsius, about -20 degrees Celsius to about 30 degrees Celsius, about -20 degrees Celsius to about 20 degrees Celsius, or about -10 degrees Celsius to about 10 degrees Celsius when measured according to ASTM D3418-97 as described below. In one aspect, the glass transition temperature of the thermoplastic elastomer is selected such that articles incorporating the clamping materials disclosed herein, when incorporated into footwear articles, have a glass transition temperature above their glass transition temperature during normal wear (i.e., the thermoplastic elastomer is in its more rubbery and less brittle state).

[0162] In one aspect, the thermoplastic elastomer includes: (a) a plurality of first segments; (b) a plurality of second segments; and optionally (c) a plurality of third segments. In various aspects, the thermoplastic elastomer is a block copolymer. In some aspects, the thermoplastic elastomer is a multiblock copolymer. In other aspects, the thermoplastic elastomer is a random copolymer. In yet another aspect, the thermoplastic elastomer is a condensation copolymer.

[0163] In another aspect, the thermoplastic elastomer has a weight-average molecular weight of about 50,000 Daltons to about 1,000,000 Daltons; about 50,000 Daltons to about 500,000 Daltons; about 75,000 Daltons to about 300,000 Daltons; and about 100,000 Daltons to about 200,000 Daltons.

[0164] In another aspect, the ratio of the first segment to the second segment of the thermoplastic elastomer is from about 1:1 to about 1:2 based on the weight of each of the first segment and the second segment, or from about 1:1 to about 1:1.5 based on the weight of each of the first segment and the second segment.

[0165] In another aspect, the ratio of the first segment to the third segment of the thermoplastic elastomer is from about 1:1 to about 1:5 based on the weight of each of the first and third segments; from about 1:1 to about 1:3 based on the weight of each of the first and third segments; from about to about 1:2 based on the weight of each of the first and third segments; and from about to about 1:3 based on the weight of each of the first and third segments.

[0166] In another aspect, the thermoplastic elastomer has a first segment derived from a first component having a number average molecular weight of about 250 Daltons to about 6 Daltons, about 400 Daltons to about 6,000 Daltons, about 350 Daltons to about 5,000 Daltons, or about 500 Daltons to about 3,000 Daltons.

[0167] In some aspects, the thermoplastic elastomer includes phase-separated structural domains. For example, a plurality of first segments can be phase-separated into structural domains primarily comprising the first segments. Furthermore, a plurality of second segments derived from segments with different chemical structures can be phase-separated into structural domains primarily comprising the second segments. In some aspects, the first segments may include hard segments, and the second segments may include soft segments. In other aspects, the thermoplastic elastomer may include phase-separated structural domains containing a plurality of first copolyester units.

[0168] In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a glass transition temperature from about 20 degrees Celsius to about -60 degrees Celsius. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a Tiber abrasion resistance from about 10 mg to about 40 mg, as determined by ASTM D3389. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a hardness (Shore A) from about 60 to about 90, as determined by ASTM D2240. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a hardness from about 0.80 g / cm³, as determined by ASTM D792. 3 Approximately 1.30 g / cm³ 3 The specific gravity. In one aspect, prior to thermoforming, using a test weight of 2.16 kg, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a melt flow index of about 2 g / 10 min to about 50 g / 10 min at 160°C. In one aspect, prior to thermoforming, when using a test weight of 10 kg, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a melt flow rate greater than about 2 g / 10 min at 190°C or 200°C. In one aspect, prior to thermoforming, the clamping material or one or more thermoplastic elastomers of the clamping material, or both, has a modulus of about 1 MPa to about 500 MPa.

[0169] Example thermoplastic polyurethane elastomer

[0170] In some aspects, one or more thermoplastic elastomers in the clamping material used to clamp yarns include one or more thermoplastic polyurethane (TPU) elastomers or are substantially composed of one or more TPU elastomers. The thermoplastic polyurethane elastomer may be a thermoplastic polyurethane copolymer comprising hard segments and soft segments, including hard segment blocks and soft segment blocks. Hard segments may include segments derived from isocyanates or consist of segments derived from isocyanates. In the same or alternative aspects, soft segments may include segments derived from polyols or consist of segments derived from polyols, such as polyether segments or polyester segments, or a combination of polyether segments and polyester segments. In one aspect, one or more thermoplastic elastomers include elastomeric thermoplastic polyurethane or are substantially composed of elastomeric thermoplastic polyurethane (which includes hard segments and soft segments), such as elastomeric thermoplastic polyurethane having repeating blocks of hard segments and repeating blocks of soft segments.

[0171] In various respects, one or more thermoplastic polyurethane elastomers are produced by polymerizing one or more isocyanates with one or more polyols to generate polymer chains having urethane bonds (—N(CO)O—), wherein each isocyanate-derived segment preferably comprises two or more isocyanate (—NCO) groups, such as 2, 3, or 4 isocyanate groups per segment (optionally including monofunctional isocyanates, for example, as chain termination units). Additionally, the isocyanate-derived segments may also be extended with one or more chain extenders to bridge two or more isocyanate functional groups.

[0172] The term "aliphatic" refers to saturated or unsaturated organic molecules that do not include cyclic conjugated ring systems with delocalized π electrons. Examples of suitable aliphatic diisocyanates for producing thermoplastic polyurethane elastomers include hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), succinate diisocyanate (BDI), dicyclohexylmethane diisocyanate (HMDI), 2,2,4-trimethylhexamethylene diisocyanate (TMDI), bis(methyl)cyclohexane, bis(methyl)tricyclodecane, norbornane diisocyanate (NBDI), cyclohexane diisocyanate (CHDI), 4,4'-dicyclohexylmethane diisocyanate (H12MDI), dodecane diisocyanate, lysine diisocyanate, and combinations thereof.

[0173] The term "aromatic" refers to a cyclic conjugated ring system with delocalized π electrons, which exhibits greater stability than a hypothetical ring system with localized π electrons. Examples of suitable aromatic diisocyanates for producing thermoplastic polyurethane elastomers include toluene diisocyanate (TDI), adducts of TDI and trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylphenyl dimethylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some aspects, thermoplastic polyurethane elastomers are substantially free of aromatic groups.

[0174] In certain aspects, thermoplastic polyurethane elastomers are made from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. For example, clamping materials may include one or more diisocyanates (including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof). 12 Thermoplastic polyurethane elastomers prepared from aliphatic compounds and combinations thereof.

[0175] In some respects, crosslinked thermoplastic polyurethane elastomers (e.g., partially crosslinked polyurethane elastomers that retain thermoplastic properties) or crosslinkable thermoplastic polyurethane elastomers may be used according to this disclosure. Crosslinked or crosslinkable polyurethane elastomers may be prepared using polyfunctional isocyanates. Examples of suitable triisocyanates for producing polyurethane elastomers include adducts of TDI, HDI, and IPDI with trimethylolpropane (TMP), urea diketone (i.e., dimer isocyanates), polymeric MDI, and combinations thereof.

[0176] When chain extenders are used to form thermoplastic polyurethane elastomers, the specific chain extender polyols used can be, for example, aliphatic, aromatic, or polyether. Examples of suitable chain extender polyols for producing one or more thermoplastic polyurethane elastomers include ethylene glycol, lower oligomers of ethylene glycol (e.g., diethylene glycol, triethylene glycol, and tetraethylene glycol), 1,2-propanediol, 1,3-propanediol, lower oligomers of propylene glycol (e.g., dipropylene glycol, tripropylene glycol, and tetrapropylene glycol), 1,4-butanediol, 2,3-butanediol, 1,6-hexanediol, 1,8-octanediol, neopentyl glycol, 1,4-cyclohexanediol, 2-ethyl-1,6-hexanediol, 1-methyl-1,3-propanediol, 2-methyl-1,3-propanediol, and dihydroxyalkylated aromatic compounds (e.g., bis(2-hydroxyethyl) ethers of hydroquinone and resorcinol, xylene-α,α-diol, bis(2-hydroxyethyl) ethers of xylene-α,α-diol, and combinations thereof).

[0177] Optionally, in some instances, one or more thermoplastic polyurethane elastomers include thermoplastic polyurethane elastomers with a relatively high degree of hydrophilicity. For example, the thermoplastic polyurethane elastomer may be a thermoplastic polyether polyurethane comprising segments containing polyether groups, polyester groups, polycarbonate groups, aliphatic groups, or aromatic groups, wherein the aliphatic or aromatic groups are replaced by one or more side chain groups (i.e., relatively "hydrophilic" groups) with a relatively high degree of hydrophilicity. The relatively "hydrophilic" groups may be selected from the group consisting of: hydroxyl groups, polyethers, polyesters, polylactones (e.g., polyvinylpyrrolidone (PVP)), amino groups, carboxyl groups, sulfonate groups, phosphate groups, ammonium groups (e.g., tertiary and quaternary ammonium), zwitterionic groups (e.g., betaine, such as poly(carboxybetaine) (pCB), and ammonium phosphate, such as phosphatidylcholine), and combinations thereof. In such instances, the relatively hydrophilic group or segment may form part of the main chain of the thermoplastic polyurethane elastomer or may be grafted onto the main chain as a side chain group. In some instances, the hydrophilic side chain groups or segments can be bonded to aliphatic or aromatic groups via linking groups.

[0178] In some instances, at least one segment of the thermoplastic polyurethane elastomer comprises a polyether segment (i.e., a segment having one or more ether groups). Suitable polyethers include, but are not limited to, polyethylene oxide (PEO), polypropylene oxide (PPO), polytetrahydrofuran (PTHF), polytetramethylene oxide (PTMO), and combinations thereof. As used herein, the term "alkyl" refers to a straight-chain and branched saturated hydrocarbon group containing 1 to 30 carbon atoms, for example, 1 to 20 carbon atoms or 1 to 10 carbon atoms. Term C n This refers to an alkyl group having "n" carbon atoms. For example, C4 alkyl means an alkyl group with 4 carbon atoms. 1-7 Alkyl refers to an alkyl group having a number of carbon atoms covering the entire range (i.e., 1 to 7 carbon atoms) and all subgroups (e.g., 1 to 6, 2 to 7, 1 to 5, 3 to 6, 1, 2, 3, 4, 5, 6, and 7 carbon atoms). Non-limiting examples of alkyl groups include methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl (2-methylpropyl), tert-butyl (1,1-dimethylethyl), 3,3-dimethylpentyl, and 2-ethylhexyl. Unless otherwise indicated, an alkyl group may be an unsubstituted alkyl group or a substituted alkyl group.

[0179] In some aspects, one or more thermoplastic polyurethane elastomers include one or more polyester segments. One or more polyester segments may be derived from the polyesterification of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol-1,5, diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanediol, and combinations thereof) with one or more dicarboxylic acids (e.g., adipic acid, succinic acid, sebacic acid, octanoic acid, methyl adipic acid, glutaric acid, pimelic acid, azelaic acid, thiodipropionic acid, and citralic acid, and combinations thereof). The polyester segments may also be derived from polycarbonate prepolymers such as poly(hexamethylene carbonate) glycol, poly(propylene carbonate) glycol, poly(tetramethylene carbonate) glycol, and poly(nonamethylene carbonate) glycol. Suitable polyesters may include, for example, polyethylene adipate (PEA), poly(1,4-butylene adipate), poly(tetramethylene adipate), poly(hexamethylene adipate), polycaprolactone, polyhexamethylene carbonate, poly(propylene carbonate), poly(tetramethylene carbonate), poly(nonamethylene carbonate), and combinations thereof.

[0180] In all respects, thermoplastic polyurethane elastomers include one or more polycarbonate segments. These polycarbonate segments may be derived from the reaction of one or more diols (e.g., ethylene glycol, 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 1,3-butanediol, 2-methylpentanediol-1,5, diethylene glycol, 1,5-pentanediol, 1,5-hexanediol, 1,2-dodecanediol, cyclohexanediol, and combinations thereof) with ethylene carbonate.

[0181] As described herein, thermoplastic polyurethane elastomers can be physically crosslinked, for example, through nonpolar or polar interactions between urethane or urethane groups on the polymer. In these respects, soft segments can be covalently bonded to hard segments. In some respects, thermoplastic polyurethane elastomers having physically crosslinked hard and soft segments can be hydrophilic thermoplastic polyurethane elastomers (i.e., thermoplastic polyurethane elastomers comprising hydrophilic groups as disclosed herein).

[0182] In one respect, prior to thermoforming, the thermoplastic polyurethane elastomer is an aromatic polyester thermoplastic elastomer polyurethane or an aliphatic polyester thermoplastic elastomer polyurethane having the following properties: (1) a glass transition temperature from about 20 degrees Celsius to about -60 degrees Celsius; (2) a Tiber abrasion resistance from about 10 mg to about 40 mg as determined by ASTM D3389; (3) a hardness (Shore A) from about 60 to about 90 as determined by ASTM D2240; and (4) a hardness from about 0.80 g / cm³ as determined by ASTM D792. 3 Approximately 1.30 g / cm³ 3 (5) Specific gravity; (6) Melt flow index of about 2 g / 10 min to about 50 g / 10 min at 160 degrees Celsius using a test weight of 2.16 kg; (7) Melt flow rate of more than about 2 g / 10 min at 190 degrees Celsius or 200 degrees Celsius when using a test weight of 10 kg; and (8) Modulus of about 1 MPa to about 500 MPa.

[0183] Commercially available thermoplastic polyurethane elastomers suitable for use in this invention include, but are not limited to, those with trade names such as “TECOPHILIC” (e.g., TG-500, TG-2000, SP-80A-150, SP-93A-100, SP-60D60 (Lubrizol, Countryside, IL, Cook, Illinois)), “ESTANE” (e.g., 58238, T470A; Lubrizol, Cook, Illinois), and “ELASTOLLAN” (e.g., 9339, 1370A; BASF).

[0184] Example thermoplastic styrene copolymer elastomer

[0185] In some aspects, one or more thermoplastic elastomers comprise or are substantially composed of one or more thermoplastic elastomers of styrene-based polymers, including one or more thermoplastic styrene-based copolymers. Examples of such copolymers include, but are not limited to, styrene-butadiene-styrene (SBS) block copolymers, styrene-ethylene / butene-styrene (SEBS) copolymers, polyacetal (POM) copolymers, styrene-acrylonitrile (SAN) copolymers, and combinations thereof. Exemplary commercially available thermoplastic elastomers of styrene-based copolymers include MONOPRENE IN5074, SP066070, and SP16975 (Teknor Apex, Pawtucket, RI, USA), which are styrene-ethylene / butene-styrene (SEBS) resins. In some aspects, blends, alloys, and mixtures of one or more thermoplastic elastomers are melt-compatible or can be compatible with additives, oils, or grafted chemical moieties to achieve miscibility.

[0186] On the other hand, one or more thermoplastic elastomer styrene copolymers may include or consist essentially of SBS block copolymers, the SBS block copolymers including a first polystyrene block, a polybutadiene block, and a second polystyrene block.

[0187] On the other hand, one or more thermoplastic elastomers may include SEBS block copolymers or consist substantially of SEBS block copolymers, wherein the SEBS block copolymers include a first polystyrene block, a polyolefin block, and a second polystyrene block, wherein the polyolefin block includes alternating polyethylene blocks and polybutene blocks.

[0188] In one aspect, one or more SEBS copolymers have a density from about 0.88 g / cm³ to about 0.92 g / cm³. In another aspect, the density of one or more SEBS copolymers can be as low as 15 to 25% lower than that of crosslinked rubber, crosslinked polyurethane, and thermoplastic polyurethane materials. In aspects where the polymer component of the clamping material comprises or is substantially composed of one or more SEBS copolymers, the density of the clamping material is lower than that when using other thermoplastic elastomers (such as TPU elastomers). Lower density clamping materials provide weight savings and cost savings per unit volume for the same volume of material used, while achieving similar performance.

[0189] The term "chemical compound" refers to one or more molecules of a chemical compound, not just a single molecule. Furthermore, these molecules can be the same or different, as long as they belong to the category of chemical compounds. Thus, for example, "polyamide" is interpreted as including one or more polymer molecules of polyamide, where the polymer molecules can be the same or different (e.g., different molecular weights and / or isomers).

[0190] The terms “at least one” and “one or more” are used interchangeably and have the same meaning, including both single and multiple elements, and can also be indicated by the suffix “(s)” at the end of the element. For example, “at least one polyamide,” “one or more polyamides,” and “polyamide” are used interchangeably and have the same meaning.

[0191] Unless otherwise stated, the temperatures mentioned in this article are measured at standard atmospheric pressure (i.e., 1 ATM).

[0192] Characterization and feature analysis procedures

[0193] The various properties and features described herein were evaluated through the various test procedures described below.

[0194] Sample friction coefficient The static or dynamic coefficient of friction (COF) of a fabric or board sample can be determined using test method ASTM D1894. In this method, the sample is cut to size and mounted on a sled, with a 100-gram board placed on the sled. During the test, the weighted sled is pulled across the test surface of the material being tested. For example, static and dynamic, or wet and dry COF, can be determined by pulling the sled across a concrete surface to determine the COF of the sample and the concrete. The coefficient of friction of the sample against the surface is captured by recording the normal force (100 grams plus the sled weight) and measuring the force required to pull the sled across the test surface. The coefficient of friction (COF) is then calculated based on the ratio of the two forces. Dry COF is determined by testing a dry sample against a dry test surface, and wet COF is determined by testing a water-wetted sample against a test surface wetted with room temperature water (by immersing it in room temperature water for 10 minutes).

[0195] Fabric-ball friction coefficient testThe static and dynamic coefficients of friction (COF) of samples prepared using the component sampling procedure or fabric sampling procedure described below relative to a sample from the panel of a “MERLIN” soccer ball (NIKE Inc., Beaverton, OR, USA) can be determined using a modified version of the test method ASTM D1894 as described regarding the coefficient of friction of samples. In this method, the sample is cut to size and mounted on an acrylic substrate, and the ball material is cut to size and mounted on a sled. Once the ball material is mounted on the sled, the sled has a contact footprint of 3.9 inches by 1 inch and a weight of approximately 0.402 kg. During testing, the sample and ball material are positioned such that the outward-facing surface of the ball material contacts the outward-facing surface of the sample intended to form the footwear article, and the sled is pulled across the sample. Dry sample and dry ball material are used to determine the static or dynamic dry COF. To determine the static or dynamic wet COF, both the sample and ball material are immediately immersed in room temperature water for 10 minutes prior to testing. Each measurement should be repeated at least 3 times, and the results should be averaged.

[0196] Melting and glass transition temperature tests. The melting temperature and / or glass transition temperature of samples prepared according to the material sampling procedure described below are determined using a commercially available differential scanning calorimeter (“DSC”) in accordance with ASTM D3418-97. Briefly, 10 to 60 mg of sample is placed in an aluminum DSC pan, and the cap is sealed using a coil press. The DSC is configured to scan from -100°C to 225°C at a heating rate of 20°C / min, held at 225°C for 2 minutes, and then cooled to 25°C at a rate of -20°C / min. The DSC curves generated by this scan are then analyzed using standard techniques to determine the glass transition temperature and melting temperature. The enthalpy of melting is calculated by integrating the endothermic reaction of melting and normalizing the sample mass. The enthalpy of crystallization upon cooling is calculated by integrating the endothermic reaction of cooling and normalizing the sample mass.

[0197] Deformation temperature testThe Vicat softening temperature of a sample prepared according to the material sampling or component sampling procedure described below is determined using the test method detailed in ASTM Tm D1525-09, "Standard Test Method for Vicat Softening Temperature of Plastics," preferably with load A and rate A. In short, the Vicat softening temperature is the temperature at which a flat-ended needle penetrates the sample to a depth of 1 mm under a specific load. This temperature reflects the expected softening point when the material is used in high-temperature applications. This temperature is considered to be the temperature at which the sample is penetrated to a depth of 1 mm by a flat-ended needle with a circular or square cross-section of 1 square millimeter. For the Vicat A test, a load of 10 Newtons (N) is used, while for the Vicat B test, the load is 50 Newtons. The test involves placing the test sample in the test apparatus such that the penetrating needle rests on its surface at least 1 mm from the edge. The load is applied to the sample according to the requirements of the Vicat A or Vicat B test. The sample is then lowered into an oil bath at 23°C. The bath is heated at a rate of 50 or 120 degrees Celsius per hour until the needle penetrates 1 mm. The test sample must be 3 to 6.5 mm thick and at least 10 mm wide and long. No more than three layers can be stacked to achieve the minimum thickness.

[0198] Melt flow index test The melt flow index is determined using procedure A described therein, according to the test method detailed in ASTM D1238-13, "Standard Test Method for Measuring Melt Flow Rate of Thermoplastic Plastics by Extrusion Plasticity Tester," by sampling the sample according to the material sampling procedure described below. In short, the melt flow index measures the extrusion rate of a thermoplastic plastic through an orifice at a specified temperature and load. In this test method, approximately 7 grams of material is loaded into the barrel of a melt flow apparatus, which has been heated to a temperature specified for the material. A specified weight of material is applied to the plunger, forcing the molten material through the die. The extrudate is collected at a time and weighed. For a given applied load and applied temperature, the melt flow index value is calculated in g / 10 minutes. As described in ASTM D1238-13, the melt flow index can be determined using a weight of 2.16 kg at 160°C or a weight of 10 kg at 200°C.

[0199] Melt polymer viscosity testTests were performed using 2 mm plates or films prepared according to the plate or film sampling procedure described below. A 50 mm sample disk was cut from the plate or film using a circular die. The test sample was mounted on a 50 mm diameter aluminum parallel plate on an ARES-G2 (displacement-controlled) rheometer. The top plate was lowered so that the test sample was in contact with the surfaces of both disks under a defined normal force load, and the platform was heated to 210°C. The sample was equilibrated until melted, for a defined residence time (minutes), and an oscillating shear frequency scan was applied at a low strain amplitude to acquire rate-related data. The ratio of the applied shear stress required to generate oscillating motion at a given shear frequency produces the measured viscosity value. Shear rate-related viscosity data can be acquired from countdowns of 0.1 seconds to 1000 seconds.

[0200] Plate modulus test The modulus of the sample prepared according to the plate or film sampling procedure described below is determined according to the test method detailed in ASTM D412-98 "Standard Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers - Tension", with the following modifications: The sample size is ASTM D412-98 die C, and the sample thickness used is 2.0 mm plus or minus 0.5 mm. The type of clamp used is a pneumatic clamp with metal toothed clamping surfaces. The clamping distance used is 75 mm. The loading rate used is 500 mm / min. The modulus (initial) is calculated by taking the slope of the stress (MPa) relative to the strain in the initial linear region. This test can also be used to determine other tensile properties, such as breaking strength, breaking strain, load at 100% strain, toughness, stiffness, tear strength, etc.

[0201] Yarn fineness and thickness testing To determine the fineness, a yarn sample was prepared according to the following yarn sampling procedure. The known length of the yarn sample and its corresponding weight were measured. This was converted to grams per 9000 meters of yarn. To determine the thickness of the coated yarn, the yarn was first cut with a razor and observed under a microscope, where the coating thickness was measured proportionally to the diameter of the core yarn.

[0202] Yarn modulus, toughness and elongation testingThe yarn modulus of the samples prepared according to the above yarn sampling procedure was determined, and the test was performed according to the test method detailed in EN ISO 2062 (Fabrics—Nails—Determination of breaking strength and elongation at break of single yarn using a constant speed tensile (CRE) tester). The following modifications to the test method were used: Five specimens were prepared, each 600 mm in length. The equipment used was an Instron Universal Testing System. An Instron pneumatic cord clamp or similar pneumatic clamp was installed at a clamping distance of 250 mm. When using an Instron pneumatic cord clamp, the clamping distance was set to 145 ± 1 mm, and the gauge length was set to 250 ± 2 mm. The preload was set to 5 g, and the loading rate used was 250 mm / min. The modulus (initial) was calculated by taking the slope of the stress (MPa) relative to the strain in the initial linear region. The maximum tensile force value was recorded. The toughness and elongation of the yarn samples were determined according to the test methods detailed in EN ISO 2062, where the preload was set to 5 grams. Elongation was recorded at the maximum tensile force applied before fracture. In some respects, toughness was calculated as the ratio of the load required to break the sample to the linear density of the sample.

[0203] Specific gravity test. Specific gravity (SG) is determined using volume displacement according to the test method detailed in ASTM D792. The SG of samples obtained using a plate sampling procedure or component sampling procedure is measured using a digital balance or a Densicom tester (Qualitest Plantation, Florida, USA). Each sample is weighed (g) and then immersed in a distilled water bath (22°C ± 2°C). To avoid error, air bubbles are removed from the sample surface, for example by wiping the sample with isopropanol before immersion in water, or by using a brush to remove air bubbles after immersion. The weight of the sample in distilled water is recorded. Specific gravity is calculated using the following formula:

[0204]

[0205] Hardness tester The hardness of the material can be determined using the Shore A scale according to the test method detailed in ASTM D-2240 Hardness Tester.

[0206] yarn shrinkage testIndependent shrinkage of yarn can be determined by the following method. Prepare a yarn sample according to the yarn sampling procedure described below, and cut it into lengths of approximately 30 mm with minimal tension at approximately room temperature (e.g., 20 degrees Celsius). Place the cut sample in an oven at 50 degrees Celsius or 70 degrees Celsius for 90 seconds. Remove the sample from the oven and measure it. Using the measurements of the sample before and after the oven, calculate the percentage shrinkage by dividing the post-oven measurement by the pre-oven measurement and multiplying by 100.

[0207] Stoll wear test Abrasion resistance (including resistance to abrasion simulating footwear upper scratches) can be measured using a Stroll abrasion test with samples prepared according to the component sampling procedure, plate or film sampling procedure, or fabric sampling procedure described below. The minimum number of samples used for the Stroll abrasion test is 3. The samples used herein are hand-cut or die-cut into circles with a diameter of 112 mm. The Stroll abrasion test is described more fully in ASTM D3886 and can be performed on the Atlas Universal Wear Tester. In the Stroll abrasion test, an abrasive medium moves across a fixedly mounted test sample, and the visual appearance of the sample is monitored. The Stroll abrasion test is performed under pressure to simulate wear under normal use.

[0208] DIN wear test Samples were prepared according to the component sampling procedure, plate or film sampling procedure, or fabric sampling procedure described below. Wear loss was tested on cylindrical samples with a diameter of 16 ± 0.2 mm and a minimum thickness of 6 mm using an ASTM standard hole drill. Wear loss was measured on a Gotech GT-7012-D wear testing machine using ASTM D5963-97a Method B. The test was performed at 22 degrees Celsius over a 40-meter wear path. The standard rubber #1 used in the test had a strength of 1.336 g / cm³. 3 The density of the material. The smaller the wear loss, the better the wear resistance.

[0209] Permeability testThe permeability of a sample is determined as follows, using a sample prepared according to the component sampling procedure, plate or membrane sampling procedure, or fabric sampling procedure described below. The sample to be tested is mounted on a support base at a 45-degree angle to the horizontal plane. The support base includes an inner ring of the sample stage with a diameter of 152 mm. The sample is equilibrated in a laboratory environment for at least 2 hours before testing. The test sample is cut into a circle with a diameter of 220 mm. Thicker or stiffer materials (such as leather or hard synthetic leather) will have three cuts at the outer edge of the sample. The sample can be hand-cut or die-cut. For softer materials, test samples are cut to the same size, and the length direction is marked on the test sample. The backing paper is prepared from white or off-white paper towels, coffee filters, or similar thin absorbent paper. The backing paper is also cut into a circle with a diameter of 220 mm. One backing paper is prepared for each test sample, and the backing paper is not reused. The backing paper and sample are placed in a sample holder, which in turn is placed in a spray test apparatus. The length direction of the sample should be parallel to the direction of water flow. Adjust the funnel to a height of 6 inches (152.4 mm) between the spray nozzle and the test sample. The spray nozzle must be above the center of the test sample. Add 250 ± 2 mL of distilled water to the funnel, allowing the water to spray onto the test sample. Within 10 seconds of the spray ending, assess the water repellency of the top surface. After assessing the top surface, remove the sample holder from the support base and assess the backing paper to determine if water has permeated through the sample. Report the water permeability after visual assessment and rate the sample as "pass" or "fail" based on the degree of wetting. The sample is considered to have passed if no adhesion or wetting is observed on the top surface, if slight random adhesion or wetting is observed on the top surface, or if wetting of the top surface is observed at the spray point. Additional wetting outside the spray point and / or including the back surface indicates that the sample has failed the water permeability test.

[0210] Fabric-ball impact test Prepare a fabric test sample according to the component sampling procedure or fabric sampling procedure described below. Mount a 10-inch × 8-inch fabric test sample onto the outer surface of a metal cylinder with a 10-inch circumference. Mount the test sample and cylinder onto a robot arm that swings at a speed of 50 mph and impacts the equator of a stationary ball. The ball used is a Nike "MERLIN" soccer ball of specified size, inflated to 0.80 bar. A high-speed camera is used to record the ball's position immediately after impact. Using the ball's position in space and its rotation across multiple frames of images recorded by the high-speed camera, software is then used to calculate the ball's velocity and rotation rate immediately after impact. Each measurement is repeated at least three times, and the test results are averaged.

[0211] Upper-ball impact testThe entire upper of a men's size 10.5 soccer boot is mounted on a robot's swing arm and positioned such that the ball impacts the boot on the inside of the forefoot, on or near the laces (if the boot includes a lacing system), and the upper strikes the ball's equator as the robot's swing arm swings at a speed of 50 mph. The ball used is a Nike "MERLIN" soccer ball of a specified size, inflated to 0.80 bar. A high-speed camera is used to record the ball's position immediately after impact. Using the ball's position in space and its rotation across multiple frames of images recorded by the high-speed camera, software is then used to calculate the ball's velocity and spin rate immediately after impact. Each measurement is repeated at least three times, and the results are averaged.

[0212] Sampling procedure

[0213] Using the above tests, various properties of the materials disclosed herein and articles formed therefrom can be characterized using samples prepared with the following sampling procedure:

[0214] Material Sampling Procedure Material sampling procedures can be used to obtain pure samples of polymer compositions or polymers, or in some cases, samples of materials used to form polymer compositions or polymers. The material is provided in the form of a medium, such as flakes, granules, powders, pellets, etc. If the source of the polymer material or polymer is not available in pure form, a sample can be cut from a part or component containing the polymer material or polymer (such as a composite element or shoe sole structure) to isolate the material sample.

[0215] Plate or membrane sampling procedurePrepare a sample of the polymer composition or polymer. Then, a portion of the polymer or polymer composition is molded into a film or plate sized to fit the testing equipment. For example, when using a Ross flexural tester, the plate or film sample is sized to fit inside the Ross flexural tester by thermoforming the polymer composition or polymer in a mold, resulting in a sample with dimensions of approximately 15 cm × 2.5 cm and a thickness of approximately 1 mm to approximately 4 mm. For a plate sample of the polymer, the sample can be prepared by melting the polymer, loading the molten polymer into a mold, re-solidifying the polymer into the shape of the mold, and removing the solidified molded sample from the mold. Alternatively, the polymer sample can be melted and then extruded into a film, which is then cut to a specific size. For a sample of the polymer composition, the sample can be prepared by blending the components of the polymer composition together, melting the thermoplastic component of the polymer composition, loading the molten polymer composition into a mold, re-solidifying the polymer composition into the shape of the mold, and removing the solidified molded sample from the mold. Alternatively, a sample of the polymer material can be prepared by mixing and melting the components of a polymer composition, and then the molten polymer composition can be extruded into a film, which is then cut to a specific size. For the film sample of the polymer or polymer composition, the film is extruded into a roll or sheet having a substantially constant film thickness (within ±10% of the average film thickness) and cooled to solidify the resulting roll or sheet. A sample with a lower surface area of ​​4 square centimeters is then cut from the resulting roll or sheet. Alternatively, if a source of the film material cannot be obtained in its pure form, the film can be cut from a substrate of a footwear component or from a backing substrate of a co-extruded sheet or roll, thereby isolating the film. In either case, a sample with a lower surface area of ​​4 square centimeters is then cut from the resulting isolating film.

[0216] Component Sampling Procedure This procedure can be used to obtain samples of material from components of footwear, apparel, sports equipment, or other footwear products, including samples of polymer compositions or fabrics, or portions of fabrics such as thermoformed meshes. A sample of the material in a non-wet state (e.g., at 25 degrees Celsius and 20% relative humidity) is cut from the product or component using a blade. If the material is bonded to one or more additional materials, the procedure may include separating the additional materials from the material to be tested. For example, to test material on the ground-facing surface of a shoe sole structure, the opposing surface may be abraded, rubbed, scratched, or otherwise cleaned to remove any adhesives, yarns, fibers, foams, etc., attached to the material to be tested. The resulting sample includes the material and may include any additional materials bonded to it.

[0217] Samples are taken at locations along the article or component where a substantially constant thickness of material present on the article or component is provided (within plus or minus 10% of the average material thickness), such as in footwear, in the forefoot, midfoot, or heel areas of the ground-facing surface. For many of the above test protocols, samples with a surface area of ​​4 square centimeters (cm²) are used. The samples are cut to a size and shape suitable for the testing equipment (e.g., dog bone-shaped samples). Where the material is not present in any section of the article or component with a surface area of ​​4 square centimeters, and / or where the material thickness in sections with a surface area of ​​4 square centimeters is not substantially constant, a sample size with a smaller cross-sectional surface area may be taken, and the area-specific measurements adjusted accordingly.

[0218] Yarn sampling procedure Before testing, store the yarn to be tested at room temperature (20°C to 24°C) for 24 hours. Discard the first 3 meters of material. Cut the sample yarn into lengths of approximately 30 mm at approximately room temperature (e.g., 20°C) with minimal tension.

[0219] Fabric Sampling Procedure Before testing, store the fabric to be tested at room temperature (20 to 24 degrees Celsius) for 24 hours. Depending on the test method to be used, cut the fabric sample to a certain size at approximately room temperature (e.g., 20 degrees Celsius) with minimal tension.

[0220] Example Terms

[0221] Clause 1 A shoe upper includes: a knitted component having a plurality of interlaced loop rows defining a plurality of wedge-shaped portions of the knitted component, each of the plurality of wedge-shaped portions being defined by a portion of an outer periphery of the knitted component, a portion of an inner periphery of the knitted component, a first knitted loop row extending from the outer periphery to the inner periphery, and a second knitted loop row extending from the outer periphery to the inner periphery.

[0222] Clause 2 The upper according to Clause 1, wherein the portion defining the inner periphery of the wedge-shaped portion has a shorter length than the portion defining the outer periphery of the wedge-shaped portion.

[0223] Clause 3 The upper according to any one of Clauses 1 to 2, wherein each wedge portion includes a full-length coil row positioned between the first coil row and the second coil row and extending from the outer periphery to the inner periphery, and includes a partial-length coil row positioned between the first coil row and the second coil row and extending from the outer periphery and terminating before the inner periphery.

[0224] Clause 4 The upper according to any one of clauses 1 to 3, wherein at least some of the wedge-shaped portions of the knitted component form the forefoot area of ​​the upper.

[0225] Clause 5 The upper according to any one of clauses 1 to 4, wherein at least some of the wedge-shaped portions of the knitted component form the midfoot area of ​​the upper.

[0226] Clause 6 The upper according to any one of Clauses 1 to 3, wherein at least some of the wedge-shaped portions of the knitted component form the heel area of ​​the upper.

[0227] Clause 7 The upper according to any one of clauses 1 to 6, wherein the knitted component includes a constraint region containing a first material, the first material being at least partially fused to one or more interlaced yarns of the knitted component, wherein the first material comprises a thermoplastic elastomer.

[0228] Clause 8 The upper as described in Clause 7, wherein the first material is at least partially fused with one or more interlaced yarns of the knitted component on the outward-facing surface of the upper.

[0229] Clause 9 The shoe upper according to any one of clauses 7 to 8, wherein the portion of the knitted component having the first material has a different coefficient of friction relative to the portion of the knitted component not having the first material.

[0230] Clause 10 According to Clause 9, the upper of the shoe has a greater coefficient of friction in the portion of the knitted component having the first material than in the portion of the knitted component not having the first material.

[0231] Clause 11 The upper according to any one of Clauses 7 to 10, wherein the constrained area includes at least one tension element, the at least one tension element forming at least one yarn at least partially fused to one or more yarns of the first material.

[0232] Clause 12 The upper according to any one of Clauses 7 to 11, wherein the restraining region is a first restraining region located on the outer side of the upper and at least partially in the forefoot area, wherein the upper further includes a second restraining region extending on the inner side of the upper and at least partially in the forefoot area.

[0233] Clause 13 The upper according to Clause 12, wherein the first material is at least partially fused to one or more interwoven yarns in the first constraint region, the second constraint region, and a portion of the forefoot region between the first constraint region and the second constraint region.

[0234] Clause 14 The upper according to any one of clauses 7 to 13, wherein the first material forms a coating comprising the thermoplastic elastomer, the coating surrounding a core yarn having a second material, the second material not comprising the thermoplastic elastomer and having a higher melting temperature than the first material.

[0235] Clause 15 The upper according to any one of Clauses 7 to 14, wherein the thermoplastic elastomer is thermoplastic polyurethane.

[0236] Clause 16: The upper according to any one of Clauses 7 to 14, wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

[0237] Clause 17 A shoe upper includes: a knitted component forming at least a forefoot region and a midfoot region of the upper and having an outer periphery, the forefoot region and the midfoot region being integrally knitted, the knitted component having an outward-facing surface and an inward-facing surface opposite to the outward-facing surface, each row of loops in the forefoot region and the midfoot region extending in a direction from the outer periphery of the knitted component toward a common portion of the knitted component, such that the rows of loops in the forefoot region extend diagonally relative to the rows of loops in the midfoot region; the knitted component having a constrained region extending from the outer periphery toward the common portion, the constrained region including a first material at least partially fused to one or more interlaced yarns of the knitted component, the first material including a thermoplastic elastomer.

[0238] Clause 18 The upper as described in Clause 17, wherein the first material is located on the outward-facing surface of the knitted component.

[0239] Clause 19 The upper according to any one of Clauses 17 to 18, wherein the constrained area has a different coefficient of friction than the portion of the knitted component without the first material.

[0240] Clause 20 The upper according to any one of clauses 17 to 19, wherein the constrained area has a greater coefficient of friction than the portion of the knitted component without the first material.

[0241] Clause 21 The upper according to any one of Clauses 17 to 20, wherein the thermoplastic elastomer is thermoplastic polyurethane.

[0242] Clause 22 The upper according to any one of Clauses 17 to 20, wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

[0243] Clause 23 The upper of the shoe according to any one of Clauses 17 to 22, wherein the common part is the throat area.

[0244] Clause 24 The upper according to any one of Clauses 17 to 23, wherein the knitted component forms the heel area of ​​the upper, and each row of loops within the heel area extends in a direction toward the common portion.

[0245] Clause 25 The upper according to any one of clauses 17 to 24, wherein the restraint area comprises a plurality of adjacent rows of coils and extends from the outer periphery in the forefoot area to the common portion in the midfoot area.

[0246] Clause 26 The upper according to any one of clauses 17 to 25, wherein the restraint region is a first restraint region located on the outer side of the upper, wherein the upper further includes a second restraint region extending from the outer periphery of the forefoot region on the inner side of the upper to the common portion of the midfoot region on the inner side of the upper, wherein the first restraint region and the second restraint region each have a greater coefficient of friction than the portion of the knitted component without the first material.

[0247] Clause 27 The upper according to Clause 26 further includes a third constraint region and a fourth constraint region, the third constraint region extending from the outer periphery of the heel area on the outer side of the upper to the common portion of the midfoot area on the outer side of the upper, and the fourth constraint region extending from the outer periphery of the heel area on the inner side of the upper to the common portion of the midfoot area on the inner side, the third constraint region and the fourth constraint region each having a greater coefficient of friction than the portion of the knitted component without thermoplastic elastomer material.

[0248] Clause 28According to Clause 27, the first constraint region, the second constraint region, the third constraint region, and the fourth constraint region are each separated from each other by a portion of the knitted component on the outward-facing surface where the thermoplastic elastomer material is not present.

[0249] Clause 29 According to Clause 27, the outward-facing surface of the knitted component includes one or more regions along the outer periphery of the knitted component, the knitted component including the thermoplastic elastomer material at least partially fused to one or more interlaced yarns, wherein the one or more regions along the outer periphery are located between the first constraint region and the third constraint region, between the first constraint region and the second constraint region, and between the second constraint region and the fourth constraint region, wherein the one or more regions along the outer periphery extend from the outer periphery and terminate below the common portion.

[0250] Clause 30 The upper according to any one of clauses 17 to 29, wherein the yarn at least partially fused to the first material includes a core yarn having a second material, the second material not including the thermoplastic elastomer and having a higher melting temperature than the first material.

[0251] Clause 31 The upper according to any one of clauses 17 to 29, wherein the one or more yarns fused at least partially to the first material include coated yarns having a core having a coating comprising the first material.

[0252] Clause 32 The upper according to any one of clauses 17 to 31, wherein the one or more yarns at least partially fused to the first material include at least one stretching element extending from the outer periphery toward the common portion.

[0253] Clause 33 The upper according to Clause 32, wherein the one or more yarns comprise a core yarn and a second yarn, each having a higher melting temperature than the first material, and the at least one stretching element comprises strands embedded along a row of coils formed by the coils of the core yarn and the second yarn.

[0254] Clause 34 According to Clause 33, the upper of the shoe includes at least one tensioning element comprising strands that form a repeating sequence of knitted stitches and float stitches along the loops in the constrained area.

[0255] Clause 35The upper according to any one of Clauses 17 to 34, wherein the one or more yarns comprise a high-tenacity yarn and a core yarn, the high-tenacity yarn and the core yarn each having a higher melting temperature than the first material, and the high-tenacity yarn having a tenacity of at least 5 g / denier.

[0256] Clause 36 The upper as described in Clause 35, wherein the portion of the outer-facing surface of the knitted component adjacent to the constrained area does not include the first material and includes the high-tenacity yarn.

[0257] Clause 37 The upper according to any one of clauses 17 to 36, wherein the upper has a weight of 30 grams or less.

[0258] Clause 38 The upper according to any one of clauses 17 to 37 further includes a polymer layer extending over at least a portion of the outer surface of the knitted component, the polymer layer comprising a polymer material with a melting temperature lower than that of the first material.

[0259] Clause 39 The upper according to Clause 38, wherein the polymer layer extends over at least a portion of the restraint area and includes a plurality of holes exposing portions of the restraint area.

[0260] Clause 40 A footwear article comprising an upper according to any one of clauses 17 to 39, wherein the upper is attached to a sole structure.

[0261] Clause 41 A shoe upper includes: a knitted component forming at least a forefoot region and a midfoot region of the upper and having an outer periphery, the forefoot region and the midfoot region being knitted integrally, each row of loops in the forefoot region and the midfoot region extending in a direction from the outer periphery of the knitted component toward a common portion of the knitted component, such that the rows of loops in the forefoot region extend diagonally relative to the rows of loops in the midfoot region; the knitted component having a first region and a second region, each having rows of loops extending from the outer periphery toward the common portion, the first region including a first yarn having a first material having a first melting temperature, and the second region including a second yarn having a second material having a second melting temperature greater than the first melting temperature, the first material not being present in the second region.

[0262] Clause 42 The upper as described in Clause 41, wherein the common portion is the throat area.

[0263] Clause 43 The upper according to any one of clauses 41 to 42, wherein the first yarn includes a core having a coating formed of the first material, the coating forming at least partially fused surfaces in the first region.

[0264] Clause 44 The upper according to any one of clauses 41 to 43, wherein the first region has a greater coefficient of friction than the second region.

[0265] Clause 45 The upper according to any one of clauses 41 to 44, wherein the first material comprises a thermoplastic elastomer.

[0266] Clause 46 The upper as described in Clause 45, wherein the thermoplastic elastomer is thermoplastic polyurethane.

[0267] Clause 47 The upper as described in Clause 45, wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

[0268] Clause 47 The upper according to any one of clauses 41 to 47, wherein the first region extends from the forefoot region to the midfoot region on the outer side of the upper.

[0269] Clause 49 The upper according to Clause 48 further includes a third region on the inner side extending from the forefoot region to the midfoot region, the third region including the first yarn, wherein the first region and the third region are separated by the second region.

[0270] Clause 50 According to Clause 49, the upper, wherein the first region and the third region each include at least one stretching element extending from the outer periphery toward the common portion.

[0271] Clause 51 The upper according to Clause 50, wherein the at least one stretching element comprises strands embedded along the loops of the interlaced yarn.

[0272] Clause 52 The upper according to Clause 50, wherein the at least one stretching element comprises strands that form a repeating sequence of knitted stitches and float stitches along the loops of the interlaced yarns.

[0273] Clause 53The upper according to any one of clauses 49 to 52, wherein the upper further comprises a fourth region and a fifth region, the fourth region being on the outer side and extending from the heel region to the midfoot region, the fifth region being on the inner side and extending from the heel region to the midfoot region, the fourth region and the fifth region each comprising the first yarn.

[0274] Clause 54 A footwear article comprising an upper according to any one of clauses 41 to 53, wherein the upper is attached to a sole structure.

[0275] Clause 55 A shoe upper includes: a knitted component comprising an outward-facing surface and an inward-facing surface, a first region of the outward-facing surface of the knitted component including a first material not present in a second region of the outward-facing surface of the knitted component, the first region having a greater coefficient of friction than the second region; and a polymer layer extending over a portion of the outward-facing surface of the knitted component, the polymer layer including pores, and wherein a portion of the first material in the first region is exposed through at least some of the pores.

[0276] Clause 56 The upper as described in Clause 55, wherein the first region comprises a thermoformed network of interwoven yarns formed of core yarns and a coating, the coating comprising the first material fused within the thermoformed network of interwoven yarns.

[0277] Clause 57 The upper according to any one of clauses 55 to 56, wherein the first material comprises a thermoplastic elastomer.

[0278] Clause 58 The upper according to any one of clauses 55 to 57, wherein the polymer layer comprises a second material having a lower melting temperature than the first material.

[0279] Clause 59 The upper according to any one of clauses 55 to 58, wherein the polymer layer extends over the forefoot area, midfoot area and heel area of ​​the upper.

[0280] Clause 60 The upper as described in Clause 59, wherein the polymer layer extends over a portion of the heel area that is larger than the forefoot area.

[0281] Clause 61 The upper according to any one of clauses 55 to 60, wherein the polymer layer extends over the portion of the midfoot area that is larger than the forefoot area.

[0282] Clause 62 The upper according to any one of clauses 55 to 61, wherein the polymer layer extends in the forefoot area from the bite line at the junction of the upper and the sole structure and terminates before the front end of the throat area of ​​the upper.

[0283] Clause 63: The upper according to any one of Clauses 55 to 62, wherein the pores in the polymer layer are located at least in the forefoot area.

[0284] Clause 64 The upper according to any one of clauses 55 to 63, wherein the pores in the polymer layer are located at least in the midfoot area.

[0285] Clause 65 The shoe upper according to any one of clauses 55 to 64, wherein the perforation is excluded from the heel area.

[0286] Clause 66 The upper according to any one of clauses 55 to 65, wherein the pores in the polymer layer include pores of different sizes.

[0287] Clause 67 The upper as described in Clause 66, wherein the polymer layer includes pores in the forefoot region of the upper, the pores being larger than the pores in the polymer layer in the midfoot region of the upper.

[0288] Clause 68 The upper according to any one of clauses 55 to 67, wherein the density of the pores varies within the polymer layer.

[0289] Clause 69 The upper according to any one of clauses 55 to 68, wherein the first region has a first percentage of surface area covered by the polymer layer, and the second region has a second percentage of surface area covered by the polymer layer, the second percentage being greater than the first percentage.

[0290] Clause 70 The upper according to any one of clauses 55 to 69, wherein the polymer layer includes a graphic design.

[0291] Clause 71 A footwear article comprising an upper according to any one of clauses 55 to 70, wherein the upper is attached to a sole structure.

[0292] Clause 72An upper comprising: a knitted component forming at least a midfoot region and a throat region of the upper, the knitted component having a first row of loops extending continuously from an outer periphery to the throat region, the first row of loops including a first yarn and a stretching element, the stretching element being knitted with a sequence of one or more knitted stitches and float stitches extending a plurality of loop warps, wherein the sequence is repeated multiple times between the outer periphery and the throat region, the number of loop warps in the plurality of loop warps being greater than the number of knitted stitches in the sequence.

[0293] Clause 73 The upper according to Clause 72, wherein the stretching element has at least one of a larger diameter, greater tensile strength, or greater toughness compared to the first yarn.

[0294] Clause 74 The upper according to any one of clauses 72 to 73, wherein the knitted component comprises groups of stretching elements that each form the sequence.

[0295] Clause 75 The upper as described in Clause 74, wherein the coil rows of the stretching elements within each group are separated from each other by coil rows without float stitches.

[0296] Clause 76 The upper according to any one of clauses 72 to 75, wherein the first yarn and the second yarn are included in the outward-facing surface of the knitted component.

[0297] Clause 77 The upper as described in Clause 76, wherein the first loop row is knitted with a third yarn forming the inward-facing surface of the knitted component.

[0298] Clause 78 The upper according to any one of clauses 72 to 77, wherein at least a portion of the stretching element within the first coil row is at least partially fused to the polymer material of the first yarn.

[0299] Clause 79 According to any one of Clauses 72 to 78, the upper, wherein the knitted component further forms the forefoot region of the upper, wherein each row of loops in the forefoot region and the midfoot region extends in a direction from the outer periphery of the knitted component toward the throat region, such that the rows of loops in the forefoot region extend diagonally relative to the rows of loops in the midfoot region.

[0300] Clause 80 A footwear article comprising an upper according to any one of clauses 75 to 79, wherein the upper is attached to a sole structure.

[0301] Clause 81 A shoe upper includes: a knitted component forming at least a forefoot region and a midfoot region of the upper and having an outer periphery, the forefoot region and the midfoot region being knitted integrally, each row of loops in the forefoot region and the midfoot region extending in a direction from the outer periphery of the knitted component toward a common portion of the knitted component, such that the rows of loops in the forefoot region are angled relative to the rows of loops in the midfoot region; the knitted component includes a first material at least partially fused to one or more interwoven yarns, the first material comprising a thermoplastic elastomer.

[0302] Clause 82 According to Clause 81, the upper, wherein the knitted component has an outward-facing surface and an inward-facing surface opposite the outward-facing surface, and wherein the knitted component includes a constrained region on the outward-facing surface having a different coefficient of friction than the remaining area of ​​the upper.

[0303] Clause 83 The upper according to Clause 82, wherein the one or more interwoven yarns include partially melted coated yarns having a partially melted coating around a core, wherein the first material forms the partially melted coating.

[0304] Clause 84: The upper according to Clause 83, wherein the one or more interwoven yarns include a restraint region, the restraint region including a stretching element knitted together with the partially melted coated yarn.

[0305] Clause 85: The upper according to Clause 84, wherein the knitted component includes at least one constrained region without a stretching element, the constrained region having the stretching element having a different coefficient of friction on the outward-facing surface of the knitted component than the constrained region without the stretching element.

[0306] Clause 86. An upper comprising: a knitted component having a plurality of interlaced loop rows defining a plurality of wedge-shaped portions of the knitted component, each of the plurality of wedge-shaped portions being defined by a portion of an outer periphery of the knitted component, a portion of an inner periphery of the knitted component, a first knitted loop row extending between the outer periphery and the inner periphery, and a second knitted loop row extending between the outer periphery and the inner periphery.

[0307] Clause 87. The upper as described in Clause 86, wherein the portion defining the inner periphery of the wedge-shaped portion has a shorter length than the portion defining the outer periphery of the wedge-shaped portion.

[0308] Clause 88. The upper according to Clause 86 or Clause 87, wherein each of the plurality of wedge-shaped portions includes a full-length coil row positioned between the first coil row and the second coil row and extending from the outer periphery to the inner periphery, and includes a partial-length coil row positioned between the first coil row and the second coil row and extending from the outer periphery and terminating before the inner periphery.

[0309] Clause 89. The upper according to any one of claims 86 to 88, wherein at least some of the wedge-shaped portions of the knitted component form the forefoot area of ​​the upper.

[0310] Clause 90. The upper according to any one of claims 86 to 89, wherein at least some of the wedge-shaped portions of the knitted component form the midfoot area of ​​the upper.

[0311] Clause 91. The upper according to any one of claims 86 to 90, wherein at least some of the wedge-shaped portions of the knitted component form the heel area of ​​the upper.

[0312] Clause 92. The upper according to any one of claims 86 to 91, wherein the knitted component includes a constraint region containing a first material, the first material being at least partially fused to one or more interlaced yarns of the knitted component, wherein the first material comprises a thermoplastic elastomer.

[0313] Clause 93. The upper of claim 92, wherein the first material is at least partially fused with one or more interlaced yarns of the knitted component on the outward-facing surface of the upper.

[0314] Clause 94. The upper according to any one of claims 92 to 93, wherein the portion of the knitted component having the first material has a different coefficient of friction relative to the portion of the knitted component not having the first material.

[0315] Clause 95. The upper of claim 94, wherein the portion of the knitted component having the first material has a greater coefficient of friction than the portion of the knitted component not having the first material.

[0316] Clause 96. The upper according to any one of claims 92 to 95, wherein the constrained region includes at least one tension element, the at least one tension element forming at least one yarn at least partially fused to the first material of the one or more yarns.

[0317] Clause 97. The upper according to any one of claims 92 to 96, wherein the restraining region is a first restraining region extending on the outer side of the upper and at least partially located in the forefoot area, and wherein the upper further comprises a second restraining region extending on the inner side of the upper and at least partially located in the forefoot area.

[0318] Clause 98. The upper of claim 97, wherein the restraint area is located on the central forefoot area of ​​the upper.

[0319] Clause 99. The upper of claim 97, wherein the restraint region is further located on one or more of the inner side of the forefoot area and the outer side of the forefoot area of ​​the upper.

[0320] Clause 100. The upper of claim 99, wherein the constraint region on one or more of the inner and outer sides comprises one or more tension elements positioned along the loops of the interlaced yarns.

[0321] Clause 101. The upper of claim 100, wherein each of the one or more stretching elements comprises strands of yarn forming a repeating sequence of knitted stitches and float stitches along the loop rows of the interlaced yarns.

[0322] Clause 102. The upper according to any one of claims 100 to 101, wherein the one or more stretching elements extend between the outer periphery and the inner periphery of the upper.

[0323] Clause 103. The upper of claim 97 further comprises one or more of the following: a first set of tension elements positioned on the inner side of the forefoot area of ​​the upper; a second set of tension elements positioned on the outer side of the forefoot area of ​​the upper; a third set of tension elements positioned on the inner side of the heel area of ​​the upper; and a fourth set of tension elements positioned on the outer side of the heel area of ​​the upper.

[0324] Clause 104. The upper of claim 103, wherein the first set of tension elements and the second set of tension elements are interwoven with one or more yarns comprising a first material, the first material comprising a thermoplastic elastomer.

[0325] Clause 105. The upper of claim 104, wherein one or more of the first set of tension elements, the second set of tension elements, the third set of tension elements, and the fourth set of tension elements extend between the outer periphery and the inner periphery.

[0326] Clause 106. The upper according to any one of claims 104 to 105, wherein the first material is at least partially fused to one or more interwoven yarns in the first constraint region, in the second constraint region, and in a portion of the forefoot region between the first constraint region and the second constraint region.

[0327] Clause 107. The upper according to any one of claims 92 to 106, wherein the first material forms a coating comprising the thermoplastic elastomer, the coating surrounding a core yarn having a second material, the second material not comprising the thermoplastic elastomer and having a higher melting temperature than the first material.

[0328] Clause 108. The upper according to any one of claims 92 to 107, wherein the thermoplastic elastomer is thermoplastic polyurethane, or wherein the thermoplastic elastomer is ethylene styrene / butene styrene (SEBS).

[0329] As used herein, the phrase “and / or” relating to two or more elements should be interpreted as referring to only one element or a combination of elements. For example, “element A, element B, and / or element C” can include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or element A, B, and C. Additionally, “at least one of element A or element B” can include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Furthermore, “at least one of element A and element B” can include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

[0330] Detailed description is provided to satisfy legal requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways and in combination with other current or future techniques to include different steps, different combinations of steps, different elements and / or different combinations of elements, similar to or equivalent to those described in this disclosure. The examples herein are intended to be illustrative in all respects and not restrictive. In this sense, alternative examples or implementations may become apparent to those skilled in the art to which this subject matter pertains without departing from the scope of the subject matter.

Claims

1. A shoe upper, comprising: A knitted component, forming at least the forefoot, midfoot, and throat regions of the shoe upper, has a first row of loops extending continuously from the outer periphery to the throat region. The first row of loops includes a first yarn and a stretching element, the stretching element being knitted with a sequence of one or more knitted stitches and float stitches extending into multiple loop warps, wherein the sequence is repeated multiple times between the outer periphery and the throat region, and the number of loop warps in the multiple loop warps is greater than the number of knitted stitches within the sequence. The forefoot region has a plurality of coil rows forming a wedge-shaped portion, the wedge-shaped portion being at least partially located on the outer side and at least partially located on the inner side of the upper, each coil row within the wedge-shaped portion extending in a direction from the outer periphery toward the throat region.

2. The upper according to claim 1, wherein the stretching element has at least one of a larger diameter, greater tensile strength, or greater toughness compared to the first yarn.

3. The upper of claim 1, wherein the knitted component comprises groups of stretching elements each forming the sequence.

4. The upper according to claim 3, wherein the coil rows of the stretching elements within each group are separated from each other by coil rows without float stitches.

5. The upper according to claim 1, wherein the first yarn and the second yarn are included in the outward-facing surface of the knitted component.

6. The upper according to claim 1, wherein the first loop row is knitted with a third yarn forming the inward-facing surface of the knitted component.

7. The upper of claim 1, wherein at least a portion of the stretching element within the first coil row is at least partially fused to the polymer material of the first yarn.

8. The upper of claim 1, wherein each row of loops in the forefoot region and the midfoot region of the knitted component extends in a direction from the outer periphery of the knitted component toward the throat region of the knitted component, such that the rows of loops in the forefoot region extend diagonally relative to the rows of loops in the midfoot region.

9. The upper according to claim 1, wherein the knitted component is a single, integrally knitted element.

10. The upper according to claim 1, wherein the number of coil rows is in the range of 3 to 8.

11. The upper according to claim 10, wherein the number of longitudinal rows of coils is 5.

12. The upper of claim 10, wherein the sequence is a knitted stitch and a float stitch extending across five loops.

13. The upper of claim 1, wherein the plurality of loop rows comprise stretching elements knitted with a stitch sequence, wherein the positions of the float stitches in adjacent stretching elements are offset from each other.

14. The upper of claim 1, wherein the first yarn is knitted using knitting stitches and tuck stitches.

15. A footwear article comprising an upper according to claim 1, wherein the upper is fixed to a sole structure.

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