Article of footwear with integral knitted upper and grip yarn sole and method of manufacture

Abstract

An article of footwear includes an integrally knitted footwear upper and a sole that includes a reflow polymeric material of grip yarns. The ground-contacting surface of the sole may include a reflow polymeric material. The vamp and the sole of the shoe are of a single-piece and integral knitted structure. A method of manufacturing an article of footwear includes integrally knitting a footwear upper and a sole of the article of footwear, the sole including grip yarns. The method further includes thermoforming the grip yarn such that the sole includes the reflow polymeric material of the grip yarn.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 429,211, filed on December 1, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to a footwear article that includes an integrally knit footwear upper and a sole that includes traction yarns, and to a method of manufacturing the footwear article. Background Art

[0004] Footwear generally includes a sole configured to be located under a wearer's foot and an upper attached to the sole. The upper typically surrounds the sides and top of the foot. The sole is generally several layers, including an insole, a midsole, and an outsole, and generally serves to provide cushioning and impact protection. Putting on footwear can be difficult for some wearers, such as those with limited dexterity and young children. Brief Description of the Drawings

[0005] The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary and not limiting of the scope of the present disclosure.

[0006] Figure 1 is an outer side view of a footwear article within the scope of the present disclosure.

[0007] Figure 2 is Figure 1 an inner side view of the footwear article.

[0008] Figure 3 is Figure 1 a top perspective view of the footwear article, where the strip of the knit outer quarter portion is shown in an unfixed position.

[0009] Figure 4 is Figure 3 a top perspective view of the footwear article, where the tongue and the inner quarter portion are moved inward to facilitate foot entry.

[0010] Figure 5 is Figure 1 a side view of the footwear article turned inside - out from the inner side, where the inner side of the knit inner quarter portion is exposed.

[0011] Figure 6 is Figure 1 a side view of the footwear article turned inside - out from the inner side, where the inner side of the knit outer quarter portion and the strip are exposed.

[0012] Figure 7is taken at Figure 1 at line 7-7 in Figure 1 a cross-sectional view of a footwear article.

[0013] Figure 8 is Figure 1 a bottom view of a footwear article, showing the sole before heat treatment of the traction yarn.

[0014] Figure 9 is Figure 1 a bottom view of a footwear article, showing the sole with heat-treated traction yarn.

[0015] Figure 10 a schematic illustration of the yarn of a knitted sole, including the traction yarn before heat treatment.

[0016] Figure 11 is Figure 10 a schematic cross-sectional view of a traction yarn before heat treatment.

[0017] Figure 12 a schematic illustration of the yarn of a knitted sole after heat treatment of the traction yarn.

[0018] Figure 13 a schematic illustration of the yarn of a knitted inner quarter, knitted tongue, and knitted heel portion.

[0019] Figure 14 a schematic illustration of the yarn of a knitted outer quarter portion.

[0020] Figure 15 is taken at Figure 3 at line 15-15 in

[0021] Figure 16 a front perspective view of an alternative embodiment of a footwear article within the scope of the present disclosure, showing a strip of the knitted outer quarter portion in an unfixed position and wherein the tongue and inner quarter portion are moved inwardly to facilitate foot entry.

[0022] Figure 17 a perspective illustration of a shoe last for a footwear article.

[0023] Figure 18 is Figure 17 a perspective illustration of a footwear article on a shoe last, wherein a hand shown in dashed lines adjusts the position of the footwear article on the shoe last using a toe adjustment block.

[0024] Figure 19 is Figure 18 a perspective view of a toe adjustment block, showing a side configured to conform to a footwear article.

[0025] Figure 20 is Figure 17 A perspective view of a footwear article on a shoe last, wherein a laser system projects a laser mark onto the footwear article to assist in positioning the footwear article on the shoe last.

[0026] Figure 21 is a perspective view of a mold of a first hot press for heat - treating the sole of a footwear article.

[0027] Figure 22 is a perspective view of a first hot press, wherein the footwear article is on Figure 17 a shoe last and a mold of Figure 21 is mounted on the base of the first hot press to heat - treat the sole during a hot - pressing operation.

[0028] Figure 23 is a perspective view of the base of a footwear article, on which the forefoot region rests during a toe - heat - treating operation.

[0029] Figure 24 is a perspective view of a mold for heat - treating the toe of a footwear article.

[0030] Figure 25 is a lateral view of a footwear article, showing a second hot press using Figures 23 to 24 the base and the mold during heat - treatment of the toe.

[0031] Figure 26 is a flowchart of a method for manufacturing Figure 1 a footwear article.

[0032] Figure 27 is a lateral view of an alternative embodiment of a footwear article;

[0033] Figure 28 is at Figure 27 section line 28 - 28 of Figure 27 a cross - sectional view of a footwear article. Detailed Description

[0034] The footwear article disclosed herein provides a simplified construction having an integrally knitted upper and sole (i.e., a knitted upper and a knitted sole knitted together). Compared to traditional sole structures that include, for example, a foam midsole, the sole is relatively thin to enable the wearer's foot to more substantially sense the ground beneath the sole. Integrating traction yarns beneath the foot enables the sole to provide the attachment friction and durability functions of an insole and an outsole while eliminating the need for a typical midsole and insole. Although the footwear article can be implemented in various sizes, this can assist in the early development and walking of toddlers. Additionally, due to minimal waste and post-processing, the knitted structure can further the sustainability initiative. The footwear article can be particularly suitable for toddlers, young children, and those with limited dexterity as it can enable them to independently put on and take off their footwear.

[0035] The present disclosure generally relates to a footwear article that includes an integrally knitted footwear upper and sole, the sole including a reflow polymer material of traction yarns. For example, the ground contact surface of the sole can include the reflow polymer material. In one aspect, the footwear upper and sole are a single-piece, integral knitted construction.

[0036] In one example, the traction yarn can include a core and a sheath, and the sheath can include a thermoplastic material that reflows (e.g., undergoes heat treatment to at least partially melt and then subsequently cools and re-solidifies) to form a polymer material that can form at least a portion of the ground contact surface. In some embodiments, the sole can include more than one traction yarn, such as traction yarns of different materials, and the reflow polymer material can be a polymer composition of the different traction yarns.

[0037] In one example, the reflow polymer material of the sole can be at an outer layer of the sole, and the sole can further include an inner layer knitted integrally with the outer layer. The inner layer can be a yarn different from the traction yarn and can form an insole having a foot contact surface. For example, the yarn of the inner layer can include chenille yarn.

[0038] In one aspect, the footwear upper can include a knitted medial quarter portion at the medial side of the footwear article, a knitted lateral quarter portion at the lateral side of the footwear article, a knitted tongue fixed to the knitted medial quarter portion, and a knitted heel portion extending between the knitted medial quarter portion and the knitted lateral quarter portion at the rear of the footwear article. The sole and the footwear upper can together define a foot receiving cavity, and the knitted medial quarter portion, the knitted lateral quarter portion, the knitted tongue, and the knitted heel portion can together define an ankle opening at the foot receiving cavity. The knitted lateral quarter portion can extend to form a strap configured to span the knitted tongue and be fixed at the knitted medial quarter portion to secure the foot within the foot receiving cavity.

[0039] In one example, an article of footwear disclosed herein includes an integrally knit footwear upper that includes a sole portion and defines a foot receiving cavity above the sole portion. The footwear upper includes a knit medial quarter portion at an inner side of the article of footwear, a knit lateral quarter portion at an outer side of the article of footwear, a knit tongue secured to the knit medial quarter portion, and a knit heel portion extending between the knit medial quarter portion and the knit lateral quarter portion at a rear of the article of footwear. The article of footwear also includes a sole secured to an outer surface of the sole portion. The knit medial quarter portion, the knit lateral quarter portion, the knit tongue, and the knit heel portion together define an ankle opening at the foot receiving cavity. The knit lateral quarter portion extends to form a strap that is configured to span the knit tongue and secure at the knit medial quarter portion to secure a foot within the foot receiving cavity.

[0040] In one embodiment, an article of footwear may include a knit component that forms one or more of an upper portion of the footwear and a sole portion of the footwear. The sole portion includes an outer-facing layer that forms a ground-contacting portion and an inner-facing layer that forms a foot-contacting portion. The outer-facing layer includes a first material that includes a thermoplastic material, and the inner-facing layer includes a second material that is different from the first material. One or more portions of the outer-facing layer that include the first material have a different coefficient of friction relative to the inner-facing layer that includes the second material.

[0041] In one aspect, one or more portions of the outer-facing layer have a greater coefficient of friction relative to the inner-facing layer that includes the second material.

[0042] In one example, the sole portion may include one or more intersecting portions at or near a junction of the outer-facing layer and the inner-facing layer that include the first material.

[0043] In another example, the outer-facing layer may include one or more raised attachment friction elements that include the first material. The one or more raised attachment friction elements may include a reflowed first material.

[0044] The outer-facing layer may include one or more interwoven yarns. Each of the one or more interwoven yarns may have a coating of the first material around a core yarn. The core yarn may have a second material that does not include a thermoplastic material and has a melting temperature higher than the first material. In one aspect, the first material may be at least partially fused to one or more core yarns. The inner-facing layer may include one or more second interwoven yarns that include the second material. The first material may be at least partially fused to a portion of the one or more second interwoven yarns.

[0045] Footwear articles can include an integrally knitted footwear upper and a sole. The sole can include one or more interwoven yarns including a first material. The first material can include a thermoplastic material.

[0046] In one aspect, the sole can include a reflow polymer material of the thermoplastic material. For example, the ground contact surface of the sole can include the reflow polymer material.

[0047] In some embodiments, at least one of the one or more interwoven yarns includes a core and a sheath, and the sheath includes a thermoplastic material.

[0048] In one example, the one or more interwoven yarns including the first material are a first yarn, the one or more interwoven yarns include a second yarn, the second yarn includes a second thermoplastic material, and the ground contact surface of the sole is a polymer composition of the reflow polymer material of the first yarn and the reflow polymer material of the second yarn.

[0049] In another example, the one or more interwoven yarns including the first material can be in an outer layer of the sole, and the sole can further include an inner layer integrally knitted with the outer layer. The inner layer can include yarns that include a material different from the first material and can form a shoe bed having a foot contact surface. For example, the ground contact surface of the sole can include a reflow polymer material of the thermoplastic material, and one or more portions of the ground contact surface including the reflow polymer material can have a different coefficient of friction relative to the foot contact surface of the yarns including the inner layer. In the same example or in different examples, the yarns of the inner layer forming the shoe bed can include two or more plied core yarns with cut pile yarns therebetween.

[0050] A method of manufacturing a footwear article disclosed herein includes integrally knitting a footwear upper and a sole of the footwear article, the sole including traction yarns. The method further includes thermoforming the traction yarns such that the sole includes a reflow polymer material of the traction yarns. As used herein, "thermoforming" is a thermal process involving heating and shaping a thermoplastic material.

[0051] The above-described features and advantages of the present teachings, as well as other features and advantages, are apparent from the following detailed description of the manner of implementing the present teachings when considered in conjunction with the accompanying drawings. It should be understood that although embodiments may be described separately in the following drawings, their individual features can be combined into additional embodiments.

[0052] Referring to the drawings, wherein like reference numerals denote like parts throughout the views, Figure 1 and Figure 2FIG. 0 shows a footwear article 10 including an integrally knit footwear upper 12 and a sole 14. The integrally knit footwear upper 12 and sole 14 may be referred to, respectively, as the upper portion and the sole portion of a single-piece footwear article 10, or as the on-foot portion and the under-foot portion, as they are continuous and knitted together as a single-piece component. In other words, the footwear upper 12 is a knitted structure, the sole 14 is also a knitted structure, and the footwear upper 12 and sole 14 are knitted together into a single, integral knitted structure. The footwear upper 12 and sole 14 may be formed as an integral single-piece element during a single knitting process, such as a weft knitting process (e.g., using a flat knitting machine or a circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on a knitting machine may substantially form the knitted structures of the footwear upper 12 and sole 14 without the need for additional knitting steps. Alternatively, in other embodiments, two or more portions of the footwear upper 12 and sole 14 may be formed as separate integral single-piece elements and then attached to the corresponding elements. Thus, as used herein, a footwear article is defined as being formed of and having an "integral knitted construction" when formed as a single-piece element by a knitting process. The portions of the knitted footwear article 10 may be joined to each other after the knitting process (e.g., the edges of the knitted footwear upper 12 may be joined to each other as at a seam). In various aspects, other elements (e.g., logos, trademarks, placards) may be added after the knitting process.

[0053] In addition, the knitted sole 14 described herein includes the entire sole structure of the footwear article 10, as the footwear article 10 may be characterized as not having any additional shoe sole layer or sole component, such as no midsole, insole, midsole board, etc. Accordingly, the knitted sole 14 may include both a ground contact surface 16 (e.g., an outer, exposed ground engaging surface, also referred to as the ground contact portion) and a foot contact surface 18 (e.g., an inner foot receiving surface on which the foot rests, also referred to as the foot contact portion, best shown in Figure 4 and Figure 7 . Thus, the knitted sole 14 is versatile while maintaining a light weight and a thin structure, which is particularly advantageous for a developing toddler. As discussed herein, the knitted sole 14 achieves this versatility in part by utilizing Figures 10 to 11 the traction yarn 104 best shown in Figure 12 and having a ground contact surface 16 with a polymer composition 112 that includes

[0054] Reference Figure 1, the footwear article 10, as well as the upper 12 and the sole 14, can be divided into a forefoot region 20, a midfoot region 22, and a heel region 24. The forefoot region 20 generally includes the portion of the footwear article 10 corresponding to the toes and the metatarsophalangeal joint (which can be referred to as the MPT or MPJ joint), which connects the metatarsal bones of the foot to the proximal phalanges of the toes. Thus, the front portion of the forefoot region 20 can be referred to as the toe region 25. The midfoot region 22 generally includes the portions of the footwear article 10 corresponding to the arch region and the dorsal side of the foot, and the heel region 24 corresponds to the posterior portion of the foot, including the calcaneus. The forefoot region 20, the midfoot region 22, and the heel region 24 are not intended to demarcate the exact regions of the footwear article 10, but rather are intended to represent the general regions of the footwear article 10 to assist in the following discussion.

[0055] The footwear article 10 has a lateral side 26 (as Figure 1 indicated) and a medial side 28 (as Figure 2 indicated). The lateral side 26 and the medial side 28 extend through each of the forefoot region 20, the midfoot region 22, and the heel region 24, and correspond to the opposite sides of the footwear article 10, each falling on the opposite sides of the longitudinal midline (LM) of the footwear article 10, as Figure 3 indicated. Thus, the lateral side 26 is considered opposite to the medial side 28. The illustrated footwear article 10 is configured for a right foot. A footwear article configured for a left foot can be a mirror image of the footwear article 10.

[0056] The footwear upper 12 includes various parts or regions, which include a knitted medial quarter portion 30 at the medial side 28 of the footwear article 10, a knitted lateral quarter portion 32 at the lateral side 26 of the footwear article 10, a knitted tongue 34 fixed to the knitted medial quarter portion 30, a knitted heel portion 35 extending between the knitted medial quarter portion 30 and the knitted lateral quarter portion 32 at the rear portion 36 of the footwear article 10, a knitted toe 38 at the front portion 40 of the footwear article 10, a knitted collar 42, and a knitted heel tab 44. The knitted heel tab 44 extends integrally from the knitted collar 42. In the illustrated embodiment, the knitted heel tab 44 is configured as a strip having end portions 45, such as fixed to the knitted collar 42 by stitching to form a loop. In other embodiments, the knitted heel tab 44 can simply be a tab rather than a loop, or there can be no heel tab. When inserting the foot into the foot receiving cavity 46, the knitted heel tab 44 can be gripped to assist in pulling the footwear article 10 over the foot.

[0057] The various regions or partial regions of the footwear upper 12 and the sole 14 can be knitted from different yarns or different combinations of yarns as discussed herein. In Figure 1 and Figure 2In [the figure], the boundaries between the various parts of the footwear article 10 that include yarns or combinations of yarns that are different from one or more of the border portions are indicated by dashed lines. The boundary B1 is indicated between the sole 14 and the upper 12. The boundary B2 is indicated as adjacent to the top or rear edge of the toe 38, such as between the tongue 34 and the toe 38. The boundary B3 is indicated between the yarns in the front portion of the outer quarter portion 32 adjacent to the toe 38 and the yarns of the remaining portion of the outer quarter portion 32. The yarns of the front portion of the outer quarter portion 32 defined by the boundary B3 are near the lower edge of the front portion of the outer quarter portion 32 and are adjacent to and may be the same as the yarns of the toe 38, as discussed herein. The boundary B4 is indicated between the knitted collar 42 and the heel portion 35. The boundary B5 is indicated between the knitted collar 42 and the heel tab 44. The boundary B6 is indicated between the peripheral region of the outer quarter portion 32 and the strip 60 and the remaining portion of the outer quarter portion 32 and the strip 60, since the peripheral region may be another yarn different from the remaining portion discussed herein. The boundary B7 is indicated between the peripheral region at the top of the tongue 34 and the remaining portion of the tongue 34, since the peripheral region at the top of the tongue 34 may be one or more yarns different from the remaining portion of the tongue 34, as discussed herein. The boundary B8 is indicated between the heel region 35 and the outer quarter portion 32. The boundary B9 is indicated between the heel region 35 and the inner quarter portion 30.

[0058] As used herein, the term "yarn" shall be understood to mean a strand of long or substantially continuous fibers or filaments in a form suitable for knitting. Types of yarns include continuous filament yarns, examples of which include monofilament yarns (composed of a single type of continuous filament) and multifilament yarns (composed of multiple flat or textured filaments, which are typically twisted or air entangled with each other). Textile yarns are another type of yarn, which are composed of multiple short fibers (such as cotton or wool fibers) or staple fibers or filaments that are entangled with each other in a spinning process. Composite yarns are yet another type of yarn, which may be composed of cords or cables, or which may be composed of two or more single yarn strands combined into a ply yarn. Natural fibers or filaments may be used, including naturally occurring cellulosic fibers (such as cotton or linen), naturally occurring protein-based fibers or filaments (such as wool or silk), and naturally occurring mineral-based materials (such as asbestos). Man-made fibers or filaments may be used, including man-made fibers or filaments made from inorganic materials (such as glass or metal); and fibers or filaments made from regenerated natural polymers including cellulose-based polymers and protein-based polymers; man-made carbon fibers or filaments; and man-made fibers or filaments made from synthetic polymers. In many cases, the synthetic polymer is a thermoplastic, including thermoplastic elastomers, although thermosetting materials such as elastane may also be used. Synthetic polymers commonly used to make fibers or filaments include polyesters (such as polyethylene terephthalate (PET)), polyamides (such as nylon-6, nylon 6,6, and nylon-11), polyolefins (such as propylene homopolymers and copolymers, and ethylene homopolymers and copolymers), and polyacetates (such as cellulose acetate fibers). Polyurethanes, such as thermoplastic polyurethanes, may also be used to prepare fibers or filaments. These strands may include or be composed of yarns that include natural fibers or filaments, man-made fibers or filaments, or a combination of natural and man-made fibers or filaments, such as textile yarns including blends of cotton and polyester fibers. These strands may include or be composed of multifilament yarns that include polyester or polyamide filaments, such as commercially available embroidery threads.

[0059] Typically, industrial knitting machines and other industrial-scale manufacturing processes require the use of yarns having a minimum tenacity of about 1.5 grams per denier. Tenacity is the amount of force required to break a yarn divided by the linear mass density of the yarn and is determined by, for example, subjecting a yarn sample to a known amount of force using a strain gauge pressure element until the sample breaks. Within the scope of the present disclosure, yarns having a tenacity greater than about 5 grams per denier are considered high-tenacity yarns. High-tenacity yarns can include fibers or filaments that include polymers such as aromatic polyamides and ultra-high molecular weight polyethylene (UHMWPE). The yarns used in accordance with the present disclosure can be low-tenacity yarns, high-tenacity yarns, or any combination thereof. In some instances, the strands can include or consist of textile yarns, monofilament yarns, or multifilament yarns having a tenacity of at least 1.5 grams per denier or at least 2.5 grams per denier. In other instances, the strands can include or consist of multifilament yarns having a tenacity of at least 11 grams per denier.

[0060] The sole 14 and the footwear upper 12 together define a foot receiving cavity 46, which is shown as partially exposed in Figure 3 and more exposed in Figure 4 The knitted medial quarter portion 30, the knitted lateral quarter portion 32, the knitted tongue 34, and the knitted heel portion 35 together define an ankle opening 48 at the foot receiving cavity 46. The knitted collar 42 extends along the knitted medial quarter portion 30, along the knitted lateral quarter portion 32, and along the knitted heel portion 35 at the ankle opening 48 and further defines the ankle opening 48.

[0061] As Figure 3 best shown, the knitted tongue 34 has an inner edge 50 that extends from the toe region 25 of the footwear article 10 to the ankle opening 48 at the medial side 28 and is stitched to the knitted medial quarter portion 30 from the toe region 25 to the ankle opening 48. As shown, the inner edge 50 is stitched to the edge 51 of the knitted medial quarter portion 30. In other embodiments, the inner edge 50 can be stitched to the medial quarter portion 30 only midway to the ankle opening 48 to provide the ability to open the foot receiving cavity 46 to a greater extent at the medial side 28 when inserting the foot. In other embodiments, the entire inner edge 50 can be unstitched and not fixed to the medial quarter portion 30.

[0062] The knitted tongue 34 has an outer edge 52 that extends from the toe region 25 to the ankle opening 48 at the lateral side 26. The knitted tongue 34 and the knitted lateral quarter portion 32 are unstitched and separated from each other at the outer edge 52 to widen the ankle opening 48 for easy access to the foot receiving cavity 46. For example, in Figure 3In [the situation], the knitted tongue 34 can be tightly grasped at or near the posterior lateral corner 54 and lifted forward to the medial side 28 (e.g., across the longitudinal midline (LM)) to further expose the foot receiving cavity 46. Figure 4 The knitted tongue 34 moved to this open position is shown, revealing more of the foot receiving cavity 46.

[0063] The footwear upper 12 has a knitted toe 38 in front of the knitted tongue 34. Specifically, the knitted toe 38 extends between the knitted tongue 34 and the sole 14 in the toe region 25 and is adjacent to the leading edge 58 of the knitted tongue 34. The leading edge 58 of the knitted tongue 34 is the same as and coincides with the boundary B2.

[0064] The knitted outer quarter portion 32 extends to form a strap 60. The strap 60 is an integral part of the knitted outer quarter portion 32. As is clearly visible in Figure 1 and 3 The knitted outer quarter portion 32 extends from the toe region 25 to the heel region 24 of the footwear article 10 and tapers in width from the proximal end 62 of the knitted outer quarter portion 32 at the sole 14 to the distal end 64 of the strap 60. The strap 60 is configured to span the knitted tongue 34 and be fixed at the knitted inner quarter portion 30 to secure the foot within the foot receiving cavity 46. More specifically, the tapered shape of the strap 60 along with its length from the proximal end 62 to the distal end 64 enables the strap 60 to be manipulated by moving the distal end 64 to the medial side 28 once the foot is fully inserted into the foot receiving cavity 46, such that the strap 60 spans the knitted tongue 34 and is fixed at the knitted inner quarter portion 30 to secure the foot within the foot receiving cavity 46.

[0065] Referring to Figure 3, the strap 60 has a first fastener portion 66 fixed to the inner side 68 (also referred to as the inner surface) of the strap 60, and the inner quarter portion 30 has a second fastener portion 70 at the outer side 73 (also referred to as the outer surface) of the inner quarter portion 30. In the illustrated embodiment, the first fastener portion 66 and the second fastener portion 70 together comprise a hook-and-loop fastener. One of the first fastener portion 66 and the second fastener portion 70 includes a plurality of loops, and the other of the first fastener portion 66 and the second fastener portion 70 includes a plurality of hooks, and the hooks engage the loops when the first fastener portion 66 and the second fastener portion 70 are pressed together. In the illustrated embodiment, the first fastener portion 66 includes hooks 72, and the second fastener portion 70 includes loops 74 with which the hooks 72 engage. Compared to other fastener types, hook-and-loop fastening may be easier for young children and people with limited dexterity to operate. Suitable materials having hooks and loops are available from the 3M Company at 3M Center, St. Paul, Minnesota under the trade name VELCRO TM.

[0066] The strap 60 is the only strap included in the footwear article 10, and the strap 60 secures the foot within the foot receiving cavity 46. Additionally, there are no zippers, laces, snaps, buttons, or other securing mechanisms to secure the upper 12 around the foot. In other words, a single strap 60 is used to secure the footwear article 10 to the foot. Additionally, the strap 60 wraps around the tongue 34 from the outer side 26 to secure at the inner side 28. Alternatively, in other embodiments, the strap 60 may wrap from the inner side 28 to secure at the outer side 26. In some embodiments, the footwear may be configured such that it is generally symmetric about the longitudinal midline LM, such that a wearer may choose to put on the footwear with the strap 60 wrapping from the outer side 26 to secure at the inner side 28, or wrapping from the inner side 28 to secure at the outer side 26.

[0067] When putting on their footwear, toddlers and young children may sit cross-legged, or may tend to squat and splay their feet outwards. Additionally, for most toddlers and young children, it is easier to pull towards the midline of their body than away from their body. Given this, compared to a strap 60 that wraps from the inner side 28 to the outer side 26 and secures at the outer side 26, a footwear article 10 configured with a strap 60 that wraps around the tongue 34 from the outer side 26 to secure at the inner side 28 may enable toddlers and young children to more easily secure and release the strap 60 independently. Additionally, toddlers and young children tend to walk in a manner where their feet are relatively splayed apart, such that the position of the secured first fastener portion 66 and second fastener portion 70 at the inner side 28 is unlikely to interfere with their walking mechanics or become an obstacle to their walking mechanics.

[0068] Each of the sole 14, the medial quarter portion 30, the lateral quarter portion 32 (including the strip 60), the tongue 34, the heel portion 35, the toe 38, the collar 42, the heel tab 44, and the sole 14 is knitted from a specific yarn or combination of yarns that enables the singly knitted, unitary footwear article 10 to provide the desired attachment friction, durability, flexibility, and other properties and characteristics with minimal waste and minimal post - processing after knitting of the footwear article 10.

[0069] Figure 5 is Figure 1 A side view of the footwear article turned inside - out from the inside. The inside of the knitted medial quarter portion 30, the sole 14, the heel portion 35, the collar 42, and a portion of the inside of the tongue 34 are exposed. Figure 5 Illustrated in is the footwear article 10 before the inner edge 50 of the tongue 34 is stitched to the edge 51 of the knitted medial quarter portion 30. The outer side 76 (also referred to as the outer surface) of the strip 60 is shown in Figure 5 is shown.

[0070] Figure 6 is opposite to Figure 5 A side view, where the footwear article 10 is turned inside - out from the inside. In, the inside of the knitted lateral quarter portion 32 and the strip 60, along with the remainder of the inside of the sole 14, the heel portion 35, and the tongue 34, are exposed. The inside 68 of the strip 60 is shown in Figure 6 before the fastener portion 70 is attached to the inside 68. Figure 6 is shown. Figure 5 and Figure 6 represent that the footwear article 10 is a unitary, singly knitted component after the knitting process and before any post - processing (such as stitching).

[0071] Figure 5 and Figure 6 The textured shading in and represents yarns that can be used on the inside of one or more of the medial quarter portion 30, the sole 14, the heel portion 35, and the tongue 34 to increase comfort for the wearer's foot. For example, the yarn can be a multi - component yarn, such as a yarn including two or more plied core yarns with cut - pile yarns positioned between the plied core yarns. For the purposes of discussion, such a yarn can be referred to herein as a chenille yarn, as discussed herein. In some embodiments, the inside 68 of the lateral quarter portion 32, including the strip 60, can also have the same yarn.

[0072] Referring again to Figure 3 , during the knitting process, Figure 5 and Figure 6After the integral, one-piece component shown, the inner edge 50 of the tongue 34 is stitched to the edge 51 of the inner quarter portion 30 using a stitch 80. The stitch 80 starts at 80A in the toe 38 in front of the edges 50, 51 and proceeds along the edges 50, 51 to the end 80B of the stitch 80 at the ankle opening 48. By starting the stitching in the toe 38, the seam formed by the adjacent edges 50, 51 is better reinforced.

[0073] To ensure that the strip 60 properly covers the tongue 34 without wrinkling or puckering, after the inner quarter portion 30 is stitched to the tongue 34, the front edge 82 of the strip 60 can be aligned with a mark or other positioning feature along the outer side of the tongue 34 when the strip 60 covers the tongue 34 to a fixed position. Then a reinforcing box stitch 84 can be applied that extends through the lower edge of the tongue 34 and the strip 60.

[0074] The profile of the toe region 25 is formed from the sole 14 to the tongue 34 and from the medial 28 to the lateral 26. The toe region 25 can be the most prominently contoured part of the article of footwear 10. For example, the toe region 25 is contoured in the vertical direction as it extends from the sole 14 under the foot to the tongue 34, and is contoured in the horizontal direction as it extends from the inner quarter portion 30 to the outer quarter portion 32 and extends over the toe of the foot. More specifically, the toe region 25 is convex on the outside of the toe region 25 in both the vertical and horizontal directions and is convex on the inside of the toe region 25. To accommodate this curvature, the knit toe 38 can include elastomeric yarn adjacent the front edge 58 of the knit tongue 34. In one non-limiting example, the elastomeric yarn of the knit toe 38 can be "E04" yarn supplied by Unifi, Inc. of Greensboro, N.C., USA, which preferably has greater elasticity than other yarns that can be used to form the article of footwear 10. The E04 yarn of the knit toe 38 and other yarns referred to herein as E04 yarn can include an elastomeric fiber core wrapped with polyester (i.e., can be obtained from E.I. duPont de Nemours Company) )

[0075] In addition, to reduce the volume of the article of footwear 10 at the lower front edge of the outer quarter portion 32 and to facilitate the easy movement of the strip 60 from an open position to a wrinkled fixed position, the lower edge 32A of the outer quarter portion 32 at the front edge 82 includes the same elastomeric yarn that forms the knit toe 38 and extends continuously from the knit toe 38. The lower edge 32A including the same elastomeric yarn is in Figure 1It is marked out and bounded by the boundary line B3 and the front edge 82. The remaining part of the outer quarter portion 32 may include different types of yarns or yarns that are thicker or less flexible in order to stabilize the foot on the sole 14. By including the lower edge 32A having the same flexible yarn as the toe 38, the extreme contour of the toe region 25 is accommodated without wrinkling the upper 12 in the toe region 25.

[0076] Other parts of the footwear article 10 that can benefit from the flexible and thin knitted construction provided by the elastomeric yarn include the knitted shoe collar 42, the knitted heel tab 44, and the outer perimeter 86 of the strip 60 at the front edge, rear edge, and distal end. Thus, in the illustrated embodiment, each of the outer perimeters 86 of the knitted shoe collar 42, the knitted heel tab 44, and the strip 60 includes the same or different types of elastomeric yarn as the toe 38.

[0077] As regarding Figure 15As further discussed, to reinforce at least the lower portion 88 (also referred to as the front portion) of the toe box 38, the knitted toe box 38 can include one or more interwoven yarns that include a first material that includes a thermoplastic material. The interwoven yarns can include a yarn that includes a second material that has a melting temperature different from that of the first material. The knitted toe box 38 can include a reflow polymer material of the thermoplastic material. The second material can have a melting temperature higher than that of the thermoplastic material. For example, the second material can be an elastomeric yarn that can be adjacent to the leading edge of the knitted tongue, and the yarn that includes the first material can be knitted with the elastomeric yarn of the toe box 38. For example, the yarn that includes the first material can include a core and a sheath, and the sheath can include a reflowed thermoplastic material, as described herein and referred to as a grip yarn. For example, one or more of the interwoven yarns in the toe box 38 can at least partially include a thermoplastic polymer material that, when subjected to a temperature at or above its melting temperature, transitions from a solid state to a softened state or a liquid state and then transitions back to a solid state when cooled. Additionally, in some instances, the thermoplastic polymer material can melt, reflow, and solidify. For example, the thermoplastic polymer material can be melted and reflowed over a desired area (e.g., a portion of the toe box 38, such as the lower portion 88) by applying one or more of heat (e.g., a temperature at or above the melting temperature of the thermoplastic polymer material) and pressure. After reflow, the knitted component (e.g., the integrally knitted footwear upper 12) can be cooled to solidify the reflowed thermoplastic polymer. As a result, the desired area (e.g., the lower portion 88) includes the reflowed and solidified thermoplastic polymer. In one example, the reflowed and solidified material can form a film (also referred to as a surface layer 91) over the desired area of the knitted component (e.g., the lower portion 88 of the toe box 38 described above). The film can increase durability, abrasion resistance, and weather resistance. In another example, the thermoplastic polymer material can be softened and cooled. For example, one or more of the temperature, pressure, and the time of applying heat and / or pressure can be adjusted to soften the thermoplastic material without melting. As a result, the softened thermoplastic polymer can have a higher viscosity compared to the melted thermoplastic material. The softened thermoplastic polymer can spread to an adjacent knitted portion (e.g., a knitted portion that includes the second material) and bond the knitted portions, thereby providing attachment strength.

[0078] In one example, one or more interwoven yarns can include a core and a sheath, where the sheath includes a thermoplastic polymer material. In some examples, one or more interwoven yarns that include a thermoplastic polymer can be coated yarns (e.g., a core coated with a sheath that includes a thermoplastic polymer material), monofilament yarns, bicomponent monofilament yarns (e.g., a thermoplastic polymer in a core and sheath or side-by-side configuration coextruded with another thermoplastic polymer), or multifilament yarns. Examples of thermoplastic polymer materials include but are not limited to thermoplastic elastomers, polyamides, polyesters, polyurethanes, and polyolefins.

[0079] After knitting and sewing the footwear article 10 to form the foot receiving cavity 46, in the post-treatment steps described herein, the traction yarn at the lower portion 88 of the toe box 38 can be thermoformed to flow back and form a reinforcing surface layer 91 at the lower portion 88 of the knitted toe box 38 adjacent to the sole 14.

[0080] Figure 7 is taken along Figure 1 line 7-7 in Figure 1 a cross-sectional view of the footwear article 10. Figure 7 Depicts a sole 14 having an outer layer 90 and an inner layer 92. The outer layer 90 can also be referred to as the outer-facing layer, and the inner layer 92 can also be referred to as the inner-facing layer. It should be understood that the outer layer 90 and the inner layer 92 are integrally knitted with each other but include at least one yarn that is different from each other. For example, the outer layer 90 of the sole 14 includes one or more traction yarns.

[0081] For example, in certain aspects, a "traction yarn" or traction fiber as described herein is a yarn that can be thermoformed to cause all or a portion of the yarn to flow back to form a surface or at least a flow-back region, such as a surface or region having specific attachment friction characteristics, "ball contact" characteristics, water-resistant or water-tolerant characteristics, accommodation characteristics, etc. Traction yarns are also fusible yarns. However, not all fusible yarns are traction yarns. For example, some fusible yarns can be heat-treated to cause a change in the characteristics of the fusible yarn but not cause the fusible yarn to flow back.

[0082] In one aspect, one or more traction yarns as described herein can have a breaking strength with an applied force from about 0.6 to about 0.9 kilograms, or from about 0.7 to about 0.9 kilograms, or from about 0.8 to about 0.9 kilograms, or an applied force greater than 0.9 kilograms.

[0083] Some traction yarns can include a traction material or consist essentially of a traction material. The traction material can be an elastic thermoplastic material since the traction material can include one or more thermoplastic elastomers or consist essentially of one or more thermoplastic elastomers.

[0084] A grip yarn that includes a grip material or consists essentially of a grip material should be understood to include a coating of the grip material, or to include one or more grip fibers, where each of the individual grip fibers includes the grip material, or to include both a coating of the grip material and grip fibers. The grip fibers of the grip yarn can include a plurality of short grip fibers, or can include a plurality of long grip filaments, or can include a single long grip filament (i.e., a monofilament), or can include a combination of short grip fibers and one or more filaments. Similarly, the grip yarn can include a single grip filament, or can include a plurality of grip fibers or grip filaments, or can include one or more core yarns. When the grip yarn includes one or more core yarns, each of the one or more core yarns can be individually at least partially coated with the grip material. Alternatively, when the grip yarn includes one or more core yarns, the one or more core yarns can form a twisted yarn, and the twisted yarn can be at least partially coated with the grip material.

[0085] In one aspect, when the grip yarn consists essentially of grip fibers, 95 wt% or more of the fibers present in the grip yarn are grip fibers. In other aspects, when the grip yarn includes two or more types of fibers, at least one of the two or more types of fibers is a grip fiber. When the grip yarn includes two or more types of fibers, the grip fibers can account for at least 10 wt%, or at least 25 wt%, or at least 50 wt%, or at least 75 wt% of the fibers present in the grip yarn.

[0086] In one aspect, the grip yarn can include a core coated with the grip material. The grip yarn core includes a core material, where the core material includes different types of polymers and / or has properties different from those of the grip yarn material. The core material can be a polymeric material including one or more polymers, or can include a non-polymeric material. When the core material is a polymer, the polymer present in the core material can be a different type of polymer from the polymer present in the grip material. For example, the core material can include one or more polyester homopolymers or polyamide homopolymers, while the grip 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 flexure or melting temperature than the grip material, where the flexure temperature is the temperature at which the core material temporarily changes shape. 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 grip material, where the degradation temperature is, for example, the temperature at which the physical or mechanical properties of the core material change. The core material can be non-elastic or less elastic than the grip material (e.g., having a lower percentage of elongation).

[0087] In one aspect, the core of the gripping yarn can include one or more fibers. In this aspect, the gripping material can completely or partially coat the core. The one or more core fibers can be multiple staple fibers, such as multiple staple length fibers spun into a single yarn, or multiple staple length fibers spun into two or more yarns, where the two or more yarns are twisted together. The one or more core fibers can be multiple filaments. The multiple filaments can be aligned, or can be aligned and entangled. The one or more core fibers can be a single long monofilament.

[0088] In one aspect, the gripping yarn can be a coated yarn, where the core yarn includes a core material and a coating disposed on the core yarn, the coating including the gripping material, where the gripping material has a gripping material melting temperature. In one aspect, the core material is thermoplastic and has a deformation temperature, i.e., the temperature at which the core material permanently changes shape, and the deformation temperature is at least 20 degrees Celsius higher, at least 50 degrees Celsius higher, at least 75 degrees Celsius higher, or at least 100 degrees Celsius higher than the melting temperature of the gripping material.

[0089] The gripping material can include one or more thermoplastic elastomers, or consist essentially of one or more thermoplastic elastomers. Optionally, in addition to including one or more thermoplastic elastomers, the gripping material can also include one or more additional polymers, or one or more additional non-polymer additives, or can include both. The one or more thermoplastic elastomers of the gripping material can include one or more thermoplastic polyurethane (TPU) elastomers, or one or more thermoplastic styrene elastomers, or a combination of both. In some aspects, the 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.

[0090] As used herein, a polymer composition (such as a grip composition or a core composition) should be understood to include a polymer component consisting of all the 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 single types of polymers. For example, the polymer component of the 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 the core material may consist of one or more polyesters. The polymer component of the core material may consist essentially of polyethylene terephthalate (PET). The polymer component of the grip material may consist of one or more TPU elastomers, or one or more styrene elastomers. The polymer component of the grip material may consist of one or more polyester-polyurethane elastomers. The polymer component of the grip material may consist of one or more styrene-butadiene-styrene (SBS) elastomers. The core material of the core fiber or core yarn may be any material that retains its strength at the temperature at which the grip material is applied to the core fiber or core yarn. The core fiber coated with the grip material, and / or the fiber used to form the core yarn may 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 a natural or regenerated material such as cotton, silk, wool or rayon or consists essentially of a natural or regenerated material such as cotton, silk, wool or rayon, which are not thermoplastic and thus have a degradation temperature but no 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 consists essentially of one or more synthetic thermosetting materials such as thermosetting polyurethane or thermosetting polyurea, which also have a degradation temperature but no melting or deformation temperature. In yet another aspect, the core material of the core fiber or core yarn comprises one or more synthetic thermoplastics or consists essentially of one or more synthetic thermoplastics, such as polyesters, polyamides, polyurethanes, polyolefins, their copolymers, and their mixtures. In one aspect, the core material comprises one or more polyesters or one or more polyamides or consists essentially of one or more polyesters or one or more polyamides. In one example, the one or more polyesters comprise polyethylene terephthalate (PET) or consist essentially 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.

[0091] Figures 10 to 12More particularly, two types of traction yarns utilized in the outer layer 90 of the sole 14 of the footwear article 10 and the yarns of the inner layer 92 of the sole 14 are described. The inner layer 92 includes yarns different from one or more of the traction yarns of the outer layer 90. The inner layer 92 forms the shoe bed and includes the foot contact surface 18. To enhance comfort, the yarns of the inner layer 92 may include chenille yarns.

[0092] Figure 7 Also illustrated is that the medial quarter portion 30 and the tongue 34 each also have an outer layer and an inner layer. The medial quarter portion 30 has an outer layer 94 and an inner layer 96 knitted integrally with the outer layer 94. The inner layer 96 includes at least one yarn different from the yarns of the outer layer 94. Similarly, the tongue 34 has an outer layer 98 and an inner layer 100 knitted integrally with the outer layer 98. The inner layer 100 includes at least one yarn different from the yarns of the outer layer 98. The yarns of the inner layer 96 and the outer layer 94 and the yarns of the inner layer 100 and the outer layer 98 will be discussed in more detail with respect to Figure 14 More particularly. It should be noted that the inner layer 96 of the medial quarter portion 30 and the inner layer 100 of the tongue 34 are located at the foot receiving cavity 46, similar to the inner layer 92 of the sole 14. To further enhance comfort, one or more of the yarns of the inner layer 96 and the inner layer 100 may also include, for example, chenille yarns.

[0093] Figure 7 It is shown that the outer layer 90 of the sole 14 may include integral attachment friction features 102, such as lugs at the ground contact surface 16. The integral attachment friction features 102 may also be referred to as raised attachment friction elements. For example, the reflow polymer material of one or more of the yarns used in the outer layer 90 of the sole 14 may be molded during the thermoforming of the sole 14 to define the attachment friction features 102. The sole 14 may include one or more interwoven yarns that include a first material that includes a thermoplastic material. The interwoven yarns may include a yarn that includes a second material that has a melting temperature different from that of the first material. The sole 14 may include a reflow polymer material of a thermoplastic material. The second material may have a melting temperature higher than that of the thermoplastic material. For example, the yarn that includes the first material may include a core and a sheath, and the sheath may include the reflowed thermoplastic material, as described herein and referred to as traction yarns. As with respect to Figures 10 to 12As discussed, the ground contact surface 16 can include a reflow polymer material of the yarn 104, which reflow polymer material can be referred to herein as a traction yarn, and in particular the reflow thermoplastic material 106 of the sheath 124 of the traction yarn 104. Additionally, a second traction yarn 110 can also be integrally knitted with the traction yarn 104 in the outer layer 90 of the sole 14. The ground contact surface 16 can also include a reflow polymer material of the second traction yarn 110 such that the outer layer 90 and the ground contact surface include a reflowed and re-cured polymer composition 112 that includes both the reflow thermoplastic material 106 and the reflow polymer material of the second traction yarn 110. The sole 14 includes one or more intersecting portions 93 at or near the junction 95 of the outer-facing layer (outer layer 90) and the inner-facing layer (inner layer 92) that includes a first material.

[0094] Figure 8 is Figure 1 a bottom view of the footwear article 10, showing the bottom of the sole 14 before heat treatment of the traction yarns 104, 110. Before heat treatment (e.g., thermoforming), the knitted fabric of the sole 14 can be more readily apparent. The traction yarn 104 can be knitted on the outermost side of the sole 14. Figure 9 is Figure 1 a bottom view of the footwear article 10, showing the sole 14 after heat treatment of the sole 14 such that the polymer composition 112 defines at least a portion of the ground contact surface 16 that includes the attachment friction features 102.

[0095] Figure 10 is a schematic illustration of an example combination of the knitted yarns of the knitted sole 14 as shown before post-knitting heat treatment. The sole 14 can include a first traction yarn 104, a second traction yarn 110, and a third yarn 120 knitted on one side, where the first traction yarn 104 will be the outer layer and become the ground contact surface 16, the type of the second traction yarn 110 interwoven with the first traction yarn 104 is different from that of the first traction yarn 104, and the type of the third yarn 120 is different from that of the first traction yarn 104 and the second traction yarn 110. The third yarn 120 is at least interwoven with the second traction yarn 110 and is disposed on the opposite side that will be the inner layer and become the foot contact surface 18.

[0096] Figure 11 is along Figure 10Schematic cross-sectional view of the first traction yarn 104 taken along line 11-11 in []. The traction yarn 104 includes a core 122 and a sheath 124 that surrounds and coats the core 122. The sheath 124 may also be referred to as a coating and includes a thermoplastic material 106. The core 122 does not include the thermoplastic material 106. As previously discussed herein with respect to the traction yarn, the core 122 may be a polymeric material that includes one or more polymers or may include a non-polymeric material. When the material of the core 122 is a thermoplastic material, it may have a higher flexure or melting temperature than the material of the sheath 124. When the material of the core 122 is a non-polymeric or thermosetting material, it may have a higher degradation temperature than the melting temperature of the material of the sheath 124. The material of the core 122 may be inelastic or less elastic than the material of the sheath 124 (e.g., having a lower percentage of elongation). In one non-limiting example, the melting temperature of the sheath 124 may be in the range from about 155 degrees Celsius to about 160 degrees Celsius.

[0097] Different from the first traction yarn 104, the second traction yarn 110 may include a uniform polymeric material instead of a core and a sheath and may fully reflow during the heat treatment. Both the thermoplastic material 106 of the sheath 124 and the polymeric material of the second traction yarn 110 may have a melting temperature within a given temperature range that is lower than the deformation temperature of the core 122 and lower than the deformation temperature of the third yarn 120. In other words, the second material of the core 122 has a higher melting temperature than the first material of the sheath 124, where the first material of the sheath 124 is the thermoplastic material 106. This enables the thermoplastic material 106 of the sheath 124 and the polymeric material of the second traction yarn 110 to reflow at the ground contact surface 16 during the hot pressing process described herein and together form a reflowed polymer composition 112, which also molds the attachment friction features 102.

[0098] Figure 12 Is a schematic illustration of a knitted shoe sole after the hot pressing process. The core 122 of the first traction yarn 104 remains intact and is now encapsulated in the reflowed polymer composition 112. The third yarn 120 remains extended at the foot contact surface 18. The third yarn 120 may be the same as or different from the material at the portion of the foot contact surface 18 in the foot receiving cavity 46 formed by a portion of the upper 12 and may be a chenille yarn. As Figure 12 Shown, the first material 106 now included in the reflowed polymer composition 112 is at least partially fused with one or more core yarns 122 and at least partially fused to a portion of one or more interwoven third yarns 120.

[0099] Accordingly, the outer-facing layer (outer layer 90) includes a first material that includes a thermoplastic material (e.g., the refluxed polymer composition 112), and the inner-facing layer (inner layer 92) includes a second material different from the first material (e.g., one or more plied core yarns, where cut pile yarns are between the core yarns, such as chenille). Accordingly, one or more portions of the outer-facing layer that include the first material have a different coefficient of friction relative to the inner-facing layer that includes the second material. The one or more portions can include, for example, integral attachment friction features 102 that can have a greater coefficient of friction relative to the inner-facing layer that includes the second material.

[0100] Figure 13 An exemplary combination of knitting yarns is shown, which can represent, for example, the yarns of the medial quarter portion 30, tongue 34, and heel portion 35. The first yarn 130 and the second yarn 132 can be interwoven and can together at least partially define the respective outer layers of the medial quarter portion 30, tongue 34, and heel portion 35. The third yarn 134 can be integrally knitted with at least one of the first yarn 130 and the second yarn 132 and is shown in Figure 13 interwoven with the second yarn 132. The first yarn 130 can include a first material, the second yarn 132 can include a second material different from the first material, and the third yarn 134 can include a third material different from both the first material and the second material.

[0101] In one example, the first yarn 130 can include a polyester yarn with an elastic core, such as a polyester yarn strand air bonded to a spandex strand. The first yarn 130 can be made of one or more organic, natural materials, and / or can be renewable, and / or can be biodegradable. For example, the second yarn 132 can include a high tenacity yarn.

[0102] The first yarn 130 and the second yarn 132 can each have a melting temperature or deformation temperature lower than that of the grip yarns 104, 110 of the sole 14.

[0103] The third yarn 134 can include chenille yarn such that the inner layer of each of the medial quarter portion 30, tongue 34, and heel portion 35 at the foot contact surface 18 includes chenille yarn, as Figures 5 to 7 indicated. The third yarn 134 can be the same type of chenille as the yarn 120 of the sole 14. In some embodiments, the yarns along the perimeter of the strip 60 at the outer side of the upper 12, the top edge of the tongue 34, and the upper edge of the ankle opening 48 can also include chenille yarn.

[0104] The fourth yarn 136 can be included in a combination of the inner quarter portion 30 of the knit yarn, the tongue 34, and the heel portion 35, and is shown in Figure 13 as being interwoven with the first yarn 130. The fourth yarn 136 can be referred to herein as a fusible yarn that is not a traction yarn. The fourth yarn 136 can be configured to melt or deform during a steaming process (e.g., the melting temperature or deformation temperature of the fourth yarn 136 is lower than the melting temperature of the traction yarns 104, 110 of the sole 14), and the steaming process applied to the fourth yarn 136 of the upper 12 is at a lower temperature or temperature range than the temperature or temperature range of the hot pressing process (e.g., the thermoforming process) described herein, at which the traction yarns of the sole 14 reflow. Thus, during the steaming process described herein, the fourth yarn 136 is heat-treated at a low enough temperature so as not to melt the traction yarns 104, 110 and not to cause them to reflow. For example, the melting temperature and / or deformation temperature of the fourth yarn 136 is lower than the melting temperature of the traction yarns 104, 110.

[0105] Figure 14 An exemplary combination of knit yarns is shown, which can represent, for example, the knit outer quarter portion 32 and the yarns of the strip 60 that is part of the knit outer quarter portion 32. The first yarn 130 and the second yarn 132 can be the same as those described with respect to Figure 13 The yarn 136 (referred to as the fourth yarn with respect to Figure 13 can also be used. It is noted that Figure 14 the yarn 120 (referred to as the third yarn with respect to Figure 13 is not present in the yarn combination for the knit outer quarter portion 32 and the strip 60, and the yarn 120 can be a chenille yarn. In other embodiments, such as those discussed with respect to Figure 16 the knit outer quarter portion 32 and the strip 60 defined thereby can also include the yarn 120.

[0106] Figure 15 A cross-sectional view shows the toe region 25 of the footwear article 10, including that schematically depicted with respect to Figures 10 to 13The yarns described. The knitted toe 38 may include elastomeric yarns 140 to provide flexibility for the contoured shape of the toe 38, as discussed herein. To reinforce the toe 38, the lower portion 88 of the toe 38 may be melted / reflowed to form a reinforcing surface layer 91 adjacent to the sole 14, as previously discussed. Thus, the first portion (e.g., the upper portion) of the toe 38 may have greater elasticity than the second portion (e.g., the lower portion 88 toward the bite line) of the toe 38. Accordingly, the reinforcing surface layer 91 improves wear resistance and weather resistance, while the more elastic portion improves flexibility during movement. In some instances, the entire toe 38 may be melted and reflowed to form the reinforcing surface layer 91.

[0107] The knitted collar 42 and the knitted heel tab 44 may also include one or more elastomeric yarns. In one example, both the knitted collar 42 and the knitted heel tab 44 include the same elastomeric yarns as the toe 38.

[0108] In a non-limiting exemplary embodiment, the chenille yarns discussed herein, such as yarn 120, may be 200TM (twisted multifilament chenille yarn); and / or

[0109] The elastomeric yarns of the knitted toe 38 may be "E04" yarn supplied by Yihui Co., Ltd. in Greensboro, North Carolina, USA. The "E04" yarn preferably has greater elasticity than other yarns that may be used to form the footwear article 10, and / or the E04 yarn of the knitted toe 38, and other yarns referred to as E04 yarns herein may include an elastic fiber core wrapped with polyester (i.e., may be obtained from DuPont ); and / or

[0110] The second traction yarn 110 may be a K140 500D traction yarn. As used herein, the "K140" traction yarn includes a fusible binder yarn having a melting temperature of about 140 degrees Celsius, and the K140 500D traction yarn has a linear mass density of about 500 denier. An example of a suitable K140 yarn is " K140" that can be commercially purchased from EMS-Chemie AG of Switzerland; and / or

[0111] The first yarn 130 may include a "P15" yarn. As used herein, the "P15" yarn is a polyester yarn with an elastic core, such as a polyester yarn strand air-bonded to spandex filaments, and / or may be made of one or more organic, natural materials, and / or may be renewable, and / or may be biodegradable; and / or

[0112] The second yarn 132 may include a high-tenacity yarn that includes polyester and other compositions formed into a yarn having a tenacity range of at least about 6 grams-force per denier, such as from about 6 to 10 grams-force per denier, such as a polyester yarn having a linear density in the range from about 275 to 325 denier and a maximum tensile strength of at least 1,650 grams-force; and / or

[0113] The fourth yarn 136 may be referred to as "KE60", such as KE60 167 dtex fusible yarn obtained from EMS (Domat / Ems, Switzerland), which has a melting temperature of about 60 degrees Celsius.

[0114] Figure 16 is a front perspective view of an alternative embodiment of the footwear article 210 within the scope of the present disclosure. The footwear article 210 is the same as the footwear article 10, except that the inner layer 114 at the inner side 68 of the strap 60 and the knitted outer quarter portion 32 further includes a yarn such as the yarn 120 described herein, which may be a chenille yarn such that the chenille yarn completely surrounds the foot in the foot receiving cavity 46.

[0115] Once the upper 12 and the sole 14 are integrally knitted and the edge 50 of the tongue 34 is stitched to the edge 51 of the inner quarter portion 30 to form the foot receiving cavity 46, the integrally knitted footwear upper 12 and sole 14 are placed on Figure 17 the foot-shaped shoe last 200 shown. The shoe last 200 extends from a base 202. In Figure 18 FIG., the integrally knitted footwear article 10 is shown placed on the shoe last 200. For the footwear article 10 on the shoe last 200, the strap 60 formed by the outer quarter portion 32 is secured to the inner quarter portion 30 using the fastener portions 66, 70 or otherwise such that the strap 60 does not contact any part of the hot press during processing.

[0116] The sole 14 and the lower portion 88 of the toe 38 are heat treated by thermoforming in a separate heat treatment step. To heat treat only the predetermined portions of the sole 14 and the toe 38 in these steps, the footwear article 10 is precisely positioned on the shoe last 200 by registering the knitted footwear upper 12 and sole 14 with the shoe last 200. This helps to minimize the heat transferred to other areas of the upper 12 that have been steamed prior to the stitching edges 50, 51 so as not to cause any other part of the upper 12 (including the fourth yarn 136 that may be therein) to be heated and cooled into the wrong shape.

[0117] Figure 18FIG. 0 illustrates one way in which the footwear article 10 can be registered with the shoe last 200. Specifically, the footwear article 10 can be registered with the shoe last 200 by fitting the toe adjustment block 204 to the toe region 25 of the integrally knit footwear upper 12 and sole 14. The hand 206 (shown in dashed lines) presses the toe adjustment block 204 against the sole 14 and around the front of the toe region 25. As Figure 19 shown, the toe adjustment block 204 has a concave surface 208 that is partially defined by a peripheral flange 213 that partially surrounds the toe adjustment block 204. The concave surface 208 and the peripheral flange 213 are shaped to match the contour of the toe region 25 of the footwear article 10 when properly positioned on the shoe last 200. By pressing the toe adjustment block 204 against the sole 14 and upper 12 on the shoe last 200 and sliding and pivoting it slightly into the most conforming position, the sole 14 and toe 38 of the upper 12 are properly seated on the shoe last 200 to ensure that only the desired regions of the sole 14 and toe 38 are subjected to the subsequent thermoforming steps described herein.

[0118] Figure 20 FIG. 6 illustrates another way of registering the integrally knit footwear upper 12 and sole 14 with the shoe last 200, which can be used as an alternative or addition to registration using the toe adjustment block 204. Specifically, the laser system 211 is fixedly positioned relative to the shoe last 200, such as by fixedly mounting the laser system 211 to the base 215 relative to the base 202. Since the shoe last 200 is also fixed to the base 202, the laser system 211 projects a laser mark 212 at a predetermined location on the shoe last 200. The laser mark 212 is a light beam that is arranged to fall as a line on the shoe last 200 and the footwear article 10 when the footwear article 10 is mounted on the shoe last 200. When the sole 14 and upper 12 are properly positioned on the shoe last 200, the laser mark 212 coincides with the boundary B1 between the knitting yarns of the sole 14 and the knitting yarns of the toe 38. The yarns of the sole 14 can be a different color than the yarns of the toe 38, such that the boundary B1 is readily visible and the operator can easily manipulate the position of the footwear article 10 on the shoe last 200 to align the boundary B1 with the laser mark 212. In Figure 20 FIG. 8, for purposes of illustration, the boundary B1 is shown slightly below the laser mark 212. By adjusting the footwear article 10 such that the boundary B1 is shifted upward in Figure 20 FIG. 10 to align with the Figure 20 laser mark 212 in

[0119] Figure 21 FIG. 16, the operator registers the footwear article 10 properly on the shoe last 200. Figure 22When the hot press 224 is heated and pressurized, the sole 14 is fitted to the mold cavity 222. Since the mold 220 includes a recessed mold cavity 222 having a peripheral side wall 225, the resulting sole 14 with the refluxed polymeric material extends upwardly at the front of the toe region 25, the rear of the heel region 24 and along the outer side 26 and the inner side 28, for example as Figure 1 and Figure 2 as indicated by the position of the boundary B1 in. The bottom of the mold cavity 222 includes spaced depressions 226 which are configured to form the attachment friction features 102 of the sole 14 when the grip yarns 104, 110 of the sole are refluxed during the hot pressing process.

[0120] Figure 22 The hot press 224 is only schematically shown in dashed lines in. The hot press 224 may be referred to herein as the first hot press. The base 202 is fixed to the first part 230 (also referred to as the lower part) of the hot press 224, and the mold 220 is fixed to the second part 232 (also referred to as the upper part). The controller 234 is programmed to control the actuator 236 which moves the second part 232 towards the first part 230 to the shown molding position, and to control the pressure F1 of the actuator 236, the temperature range of the mold 220 and the duration of holding the second part 232 in the molding position to perform a hot pressing program which results in the thermoforming of the sole 14. In other words, the second part 232 of the hot press provides a temperature sufficient to melt at least a portion of the grip yarns of the sole 14.

[0121] Once the sole 14 has been hot pressed, a second hot pressing operation may be performed to heat treat the grip yarns of the lower part 88 of the toe 38 of the footwear 10 to form the reinforcement surface layer 91. Figure 23 is a perspective view of the support 240 mounted on the base 242. During the hot pressing of the toe 38, the forefoot region 20 of the sole 14 rests on the support 240, as Figure 25 shown.

[0122] Figure 24 is a perspective view of the toe mold 246 mounted to another base 248. The mold 246 includes a mold cavity 249, and when the hot press 250 of Figure 25 is heated and pressurized, the lower part 88 of the toe 38 is fitted to the mold cavity 249. The toe hot press 250 is also referred to as the second hot press. Although the content discussed herein is after the hot pressing of the sole 14, the hot pressing of the toe 38 may also be performed before the hot pressing of the sole 14.

[0123] Figure 25Is an outside view of a footwear article 10 mounted on a shoe last 200 during a second hot pressing operation. The second hot pressing operation is also referred to herein as the thermoforming of the toe 38. The second hot pressing operation uses Figures 23 to 24 a support member 240 and a mold 246. Figure 25 The toe hot press 250 is only schematically shown in Figure 25 in dashed lines. The toe hot press 250 may be referred to herein as the second hot press. The base 242 is mounted on a first part 252 (also referred to as the lower part) of the hot press 250, and the base 248 is mounted to a second part 254 (also referred to as the upper part). The controller 264 is programmed to control the actuator 266 that moves the second part 254 towards the first part 252 to the shown molding position, and to control the pressure F2, the temperature range of the mold 246, and the duration of holding the second part 254 in the molding position to perform a hot pressing program that causes the lower part 88 of the toe 38 to be thermoformed. In other words, the second part 254 of the hot press 250 provides a temperature sufficient to melt a portion of the grip yarn of the toe 38. Specifically, a grip yarn that may be knitted together with the elastomeric yarn of the toe 38 as described herein is thermoformed to form a reinforcing surface layer 91 at the lower part 88 of the knitted toe 38 adjacent to the sole 14.

[0124] Figure 26 Is a flow chart of an example method 300 for manufacturing a footwear article 10. The method starts at step 302, and the footwear upper 12 and the sole 14 of the footwear article 10 are integrally knitted using various yarns discussed herein, including one or more grip yarns of the sole 14.

[0125] After step 302, the method 300 may proceed to step 304 to steam the integrally knitted footwear upper 12 and sole 14. The steaming may be performed on a jig or otherwise, and may be based on a temperature and duration sufficient to activate and heat treat the medial quarter 30, the lateral quarter 32, the heel portion 35, and the tongue 34 of any fusible yarn (such as the yarn 136 described herein), but the temperature is lower than the temperature at which any grip yarn of the sole 14 (such as the grip yarns 104 and 110) melts, and lower than the temperature at which any grip yarn of the toe 38 reflows to form the surface layer 91 of the toe 38.

[0126] The steaming in step 304 relieves any wrinkles by curing the medial quarter 30, the lateral quarter 32, the heel portion 35, and the tongue 34 having fusible yarn therein, preparing for the next step 306 of sewing the edges of the footwear upper 12 to each other to form a foot receiving cavity 46. More specifically, in step 306, the edge 50 of the tongue 34 is sewn to the edge 51 of the medial quarter 30 with a stitch 80.

[0127] After step 306, in step 308, the lower edge of the strip 60 can be stitched to the tongue 34 with a reinforced box stitch 84 to reinforce the strip 60 and properly align the strip 60 to lie flat on the tongue 34 in a fixed position.

[0128] Next, method 300 can proceed to step 310, placing the footwear article 10 on the shoe last 200 such that the shoe last 200 is within the foot receiving cavity 46. The shoe last 200 is configured to have a "one-to-one" fit with the footwear article 10. In other words, when the footwear article 10 is placed on the shoe last 200 and the strip 60 is secured with the fastener portions 66, 70, the shoe last 200 fully fills the foot receiving cavity 46 such that the footwear article 10 snugly fits to the shoe last 200.

[0129] To ensure that the footwear article 10 is properly positioned on the shoe last 200 prior to the heat pressing operations discussed herein, method 300 can proceed to step 312, registering the integrally knitted footwear upper 12 and sole 14 with the shoe last 200. One or more different ways of registering the footwear article 10 can be implemented. For example, the toe adjustment block 204 can be implemented as discussed with respect to Figures 18 to 19 Alternatively or additionally, a laser system 211 can be implemented as discussed with respect to Figure 20

[0130] Once the footwear article 10 is properly registered on the shoe last 200, method 300 can move to step 314, heat treating the traction yarns of the sole 14 with a first hot press 224 to form the ground contact surface 16 of the sole 14 including the attached friction features 102. As discussed above, one or more traction yarns can be included in the sole 14. When using the traction yarn 104, heat treating the traction yarn in step 314 includes melting the sheath 124 to form at least a portion of the ground contact surface 16. Additional traction yarns 110 that can also be included in the sole 14 are also melted in step 314 and refluxed with the thermoplastic material 106 of the sheath 124 to partially form the ground contact surface 16.

[0131] After step 314, in step 316, the footwear article 10 on the shoe last 200 is removed from the first hot press 224 and secured in a second hot press 250, in preparation for step 318, heat treating the traction knitted yarns included in the lower portion 88 of the toe box 38 with the second hot press 250 to form the reinforcement surface layer 91.

[0132] Figures 27 to 28 ​An alternative embodiment of a footwear article 410 within the scope of the present teachings is shown. The footwear article 410 has many of the same features as the footwear article 10, and these features are indicated by the same reference numerals, and the description regarding the footwear article 10 applies equally to the footwear article 410.

[0133] One significant difference between the footwear article 10 and the footwear article 410 is that the footwear article 410 has an upper 412 that has a knitted underfoot portion 415, and a separate sole 414 is secured to the knitted underfoot portion 415. In other words, the footwear article 410 does not include a sole that includes traction yarns heat-treated as in the footwear article 10. Instead, the medial quarter portion 30 of the footwear article and the lateral quarter portion 432 of the footwear article 410 extend to the underfoot portion 415 and are integrally knitted with the underfoot portion 415. Similarly, the heel portion 35 and the toe 38 extend to the underfoot portion 415 and are integrally knitted with the underfoot portion 415. The underfoot portion 415 includes an outer layer 450 and an inner layer 452. The inner layer defines a foot contact surface 18.

[0134] The lateral quarter portion 432 of the footwear article 410 is the same as the lateral quarter portion 32 of the footwear article 10, except that in addition to including the same yarns in the outer layer 454 as described regarding the lateral quarter portion 32, the lateral quarter portion 432 also includes an inner layer 456 that may include the same yarns as the inner layer 452 of the underfoot portion 415. Thus, the same yarns of the inner layer 96 of the medial quarter portion 30, the inner layer 100 of the tongue 34, and the inner layer 452 of the underfoot portion 415 also extend along the inner layer 456 of the lateral quarter portion 432 and a strip 460 defined by the lateral quarter portion 432. For example, the yarns of the inner layer 456 may be chenille. The strip 460 of the footwear article is part of the lateral quarter portion 432 and is the only strip included in the footwear article 410 that secures the foot within the foot receiving cavity 46. The knitted lateral quarter portion 432 extends from the toe region 25 of the footwear article 410 to the knitted heel portion 35 and tapers in width towards the distal end 64 of the strip 460.

[0135] Thus, the method of manufacturing the footwear article 410 can be the same as the method 300 described regarding the footwear article 10, except that since there is no sole having traction yarns or other fusible yarns, there is no heat pressing operation or other heat operation to heat-treat any traction yarns of the sole. A heat pressing operation may be performed to heat-treat the lower portion 88 of the toe 38 to provide a film or surface layer, such as the surface layer 91 described herein. Alternatively or additionally, the sole 414 may extend sufficiently upwardly over the lower portion 88 such that no heat treatment of the surface layer 91 is required. For example, in Figure 27In [description], the sole 414 extends upward to form a toe protector 462 that covers the toe 38. Thus, instead of the step 314 of heat-treating the sole, in addition to some or all of the other steps of the method 300, the method of manufacturing the footwear 410 may include the step of attaching the sole 414 to the underfoot portion 415. This can be via thermal bonding, adhesives, or both. In either case, the upper layer 91 or the toe protector 462 may extend over the lower portion of the tongue 34, the medial quarter portion 30, and the lateral quarter portion 432, including a part of any stitching or seam that joins the medial quarter portion 30 and the tongue 34 or joins the lower end of the lateral quarter portion 432 and the tongue 34. In this way, the upper layer 91 and / or the toe protector 462 reinforce these portions and the stitching or seam that joins these portions.

[0136] The following clauses provide example configurations of the footwear disclosed herein and methods of manufacturing the footwear.

[0137] Clause 1. A footwear, comprising: an integrally knitted footwear upper and a sole, the sole including grip yarns.

[0138] Clause 2. The footwear according to Clause 1, wherein: the grip yarns include yarns, the yarns including a first polymer component and a second polymer component; and the second polymer component is configured to flow back when thermoformed.

[0139] Clause 3. The footwear according to Clause 1, wherein the first polymer component and the second polymer component have different melting temperatures.

[0140] Clause 4. The footwear according to Clause 1, wherein the sole includes a flow-back polymer material of the grip yarns.

[0141] Clause 5. The footwear according to Clause 4, wherein the ground contact surface of the sole includes the flow-back polymer material.

[0142] Clause 6. The footwear according to any one of Clauses 1 to 5, wherein the grip yarns include a core and a sheath, and the sheath includes a thermoplastic material.

[0143] Clause 7. The footwear according to any one of Clauses 1 to 5, wherein: the grip yarns of the sole are first grip yarns; the sole further includes a flow-back polymer material of second grip yarns.

[0144] Clause 8. The footwear according to Clause 7, wherein the ground contact surface of the sole includes a polymer composition, the polymer composition including the flow-back polymer material of the first grip yarns and the flow-back polymer material of the second grip yarns.

[0145] Clause 9. The footwear article according to any one of Clauses 1 to 5, wherein: the footwear upper includes fusible yarns; and the deformation temperature of the fusible yarns of the footwear upper is lower than the melting temperature of the traction yarns of the sole.

[0146] Clause 10. The footwear article according to any one of Clauses 1 to 5, wherein: the sole includes a reflow polymer material of the traction yarns; the reflow polymer material is at an outer layer of the sole; the sole further includes an inner layer knitted integrally with the outer layer; and the inner layer includes yarns different from the traction yarns and forms a shoe bed having a foot contact surface.

[0147] Clause 11. The footwear article according to Clause 10, wherein the yarns of the inner layer forming the shoe bed include two or more plied core yarns, and cut pile yarns are between the plied core yarns.

[0148] Clause 12. The footwear article according to any one of Clauses 1 to 5, wherein the footwear upper includes: a knitted medial quarter portion at an inner side of the footwear article; a knitted lateral quarter portion at an outer side of the footwear article; a knitted tongue fixed to the knitted medial quarter portion; and a knitted heel portion extending between the knitted medial quarter portion and the knitted lateral quarter portion at a rear of the footwear article; wherein the sole and the footwear upper together define a foot receiving cavity; wherein the knitted medial quarter portion, the knitted lateral quarter portion, the knitted tongue, and the knitted heel portion together define an ankle opening at the foot receiving cavity; and wherein the knitted lateral quarter portion extends to form a strap configured to span the knitted tongue and be fixed at the knitted medial quarter portion to secure a foot within the foot receiving cavity.

[0149] Clause 13. The footwear article according to Clause 12, wherein the strap is the only strap included in the footwear article for securing a foot within the foot receiving cavity.

[0150] Clause 14. The footwear article according to Clause 12, wherein the knitted lateral quarter portion extends from a toe region of the footwear article to the knitted heel portion and tapers in width towards a distal end of the strap.

[0151] Clause 15. The footwear article according to Clause 12, wherein the knitted tongue has an inner side that extends from the toe region of the footwear article to the ankle opening and is stitched to the inner edge of the knitted inner quarter portion from the toe region at least midway to the ankle opening, and has an outer side that extends from the toe region to the outer edge of the ankle opening, and the knitted tongue and the knitted outer quarter portion are not stitched and are separated from each other at the outer edge to widen the ankle opening for easy access to the foot receiving cavity.

[0152] Clause 16. The footwear article according to Clause 12, wherein the knitted inner quarter portion, the knitted tongue, and the knitted outer quarter portion each comprise at least a first yarn knitted with a second yarn, the first yarn comprising at least a first material, the second yarn comprising at least a second material different from the first material, and the first yarn and the second yarn each have a deformation temperature lower than the melting temperature of the gripping yarn of the sole.

[0153] Clause 17. The footwear article according to Clause 16, wherein the first yarn is at the outer surface of the footwear upper.

[0154] Clause 18. The footwear article according to Clause 16, wherein the first yarn and the second yarn are at the outer layer of the knitted tongue, and the knitted tongue further comprises an inner layer knitted integrally with the outer layer, and the inner layer comprises a third yarn, and the third yarn comprises at least a third material different from the first material and the second material.

[0155] Clause 19. The footwear article according to Clause 18, wherein the third yarn comprises two or more plied core yarns, and a cut pile yarn is between the plied core yarns.

[0156] Clause 20. The footwear article according to Clause 16, wherein the first yarn and the second yarn are at the outer layer of the knitted inner quarter portion, and the knitted inner quarter portion further comprises an inner layer knitted integrally with the outer layer, and the inner layer comprises a third yarn, and the third yarn comprises at least a third material different from the first material and the second material.

[0157] Clause 21. The footwear article according to Clause 20, wherein the third yarn comprises two or more plied core yarns, and a cut pile yarn is between the plied core yarns.

[0158] Clause 22. The footwear article according to Clause 16, wherein the first yarn and the second yarn are at an outer layer of the outer quarter portion of the knit, and at least the strip of the outer quarter portion of the knit further includes an inner layer knitted integrally with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

[0159] Clause 23. The footwear article according to Clause 22, wherein the third yarn includes two or more plied core yarns, and a frieze yarn is between the plied core yarns.

[0160] Clause 24. The footwear article according to Clause 16, wherein the footwear upper has a knit toe in front of the knit tongue, the knit toe including an elastomeric yarn adjacent to a leading edge of the knit tongue.

[0161] Clause 25. The footwear article according to Clause 24, wherein the knit toe further includes a reflux polymer material of additional traction yarns, the additional traction yarns being knitted together with the elastomeric yarn and forming a reinforcing surface layer at a lower portion of the knit toe adjacent to the sole.

[0162] Clause 26. The footwear article according to Clause 25, wherein: the additional traction yarns include a yarn including a first polymer component and a second polymer component; and the second polymer component is configured to reflux when thermoformed.

[0163] Clause 27. The footwear article according to Clause 24, wherein a lower edge of a front edge of the outer quarter portion of the knit includes the elastomeric yarn continuously extending from the knit toe.

[0164] Clause 28. The footwear article according to Clause 27, further including: a reinforcing box stitch extending through the strip and the tongue at the lower edge of the front edge of the strip.

[0165] Clause 29. The footwear article according to Clause 12, wherein the footwear upper further includes: a knit collar extending along the inner quarter portion of the knit, along the outer quarter portion of the knit, and along the heel portion of the knit at the ankle opening; and the knit collar includes an elastomeric yarn.

[0166] Clause 30. The footwear article according to Clause 12, wherein the footwear upper further includes: a knit heel tab extending from the heel portion of the knit; and the knit heel tab includes an elastomeric yarn.

[0167] Clause 31. A method of manufacturing a footwear article, the manufacturing method comprising: integrally knitting a footwear upper and a sole of the footwear article, the sole comprising a traction yarn; and thermoforming the traction yarn such that the sole comprises a reflow polymer material of the traction yarn.

[0168] Clause 32. The method according to Clause 31, wherein: the traction yarn comprises a yarn that comprises a first polymer component and a second polymer component; and the second polymer component is configured to reflow when thermoformed.

[0169] Clause 33. The method according to Clause 32, wherein the reflow polymer material of the traction yarn forms at least a portion of a ground contact surface of the sole.

[0170] Clause 34. The manufacturing method according to any one of Clauses 32 to 33, wherein the traction yarn comprises a core and a sheath, the sheath comprises a thermoplastic material, and wherein thermoforming the traction yarn comprises melting the sheath such that the reflow polymer material of the traction yarn comprises the thermoplastic material of the sheath.

[0171] Clause 35. The manufacturing method according to any one of Clauses 32 to 33, further comprising: before thermoforming the traction yarn, stitching edges of the footwear upper together to form a foot receiving cavity; after stitching the edges of the footwear upper together, placing the footwear article on a shoe last, wherein the shoe last is within the foot receiving cavity; and wherein thermoforming the traction yarn comprises heating the sole with a hot press having a temperature sufficient to melt at least a portion of the traction yarn.

[0172] Clause 36. The manufacturing method according to Clause 35, further comprising: before stitching the edges of the footwear upper together to form a foot receiving cavity: steaming the integrally knitted footwear upper and sole.

[0173] Clause 37. The manufacturing method according to Clause 36, further comprising: after stitching the edges of the footwear upper together to form the foot receiving cavity: placing the integrally knitted footwear upper and sole on a shoe last; and registering the integrally knitted footwear upper and sole with the shoe last.

[0174] Clause 38. The manufacturing method according to Clause 37, wherein registering the integrally knitted footwear upper and sole with the shoe last comprises fitting a toe adjustment block to a toe region of the integrally knitted footwear upper and sole.

[0175] Clause 39. The manufacturing method according to Clause 37, wherein registering the integrally knitted footwear upper and sole with the shoe last includes projecting a laser mark onto the footwear article.

[0176] Clause 40. The manufacturing method according to any one of Clauses 32 to 33, wherein the traction yarn of the sole is thermoformed using a first hot press, and the method further includes: after thermoforming the traction yarn of the sole: placing the footwear article on a second hot press; and thermoforming additional traction yarn in at least a portion of the toe of the footwear article using the second hot press.

[0177] Clause 41. A footwear article, comprising: an integrally knitted footwear upper including a sole portion and defining a foot receiving cavity above the sole portion; wherein the footwear upper includes: a knitted medial quarter portion at the medial side of the footwear article; a knitted lateral quarter portion at the lateral side of the footwear article; a knitted tongue fixed to the knitted medial quarter portion; and a knitted heel portion extending between the knitted medial quarter portion and the knitted lateral quarter portion at the rear of the footwear article; a sole fixed to the outer surface of the sole portion; wherein the knitted medial quarter portion, the knitted lateral quarter portion, the knitted tongue and the knitted heel portion together define an ankle opening at the foot receiving cavity; and wherein the knitted lateral quarter portion extends to form a strap configured to span the knitted tongue and be fixed at the knitted medial quarter portion to secure the foot within the foot receiving cavity.

[0178] Clause 42. The footwear article according to Clause 41, wherein the strap is the only strap included in the footwear article for securing the foot within the foot receiving cavity.

[0179] Clause 43. The footwear article according to any one of Clauses 41 to 42, wherein the knitted lateral quarter portion extends from the toe region of the footwear article to the knitted heel portion and tapers in width towards the distal end of the strap.

[0180] Article 44. A footwear article according to any one of Articles 41 to 42, wherein the knitted tongue has an inner edge that extends from the toe region of the footwear article to the ankle opening at the inner side and is stitched to the inner edge of the knitted inner quarter portion from the toe region at least midway to the ankle opening, and has an outer edge that extends from the toe region to the ankle opening at the outer side, and the knitted tongue and the knitted outer quarter portion are not stitched and are separated from each other at the outer edge to widen the ankle opening for easy access to the foot receiving cavity.

[0181] Article 45. A footwear article according to any one of Articles 41 to 42, wherein the knitted inner quarter portion, the knitted tongue, and the knitted outer quarter portion each include at least a first yarn knitted with a second yarn, the first yarn includes at least a first material, and the second yarn includes at least a second material different from the first material.

[0182] Article 46. A footwear article according to Article 45, wherein the first yarn is at the outer surface of the footwear upper.

[0183] Article 47. A footwear article according to Article 45, wherein the first yarn and the second yarn are at the outer layer of the knitted tongue, and the knitted tongue further includes an inner layer knitted integrally with the outer layer, and the inner layer includes a third yarn, and the third yarn includes at least a third material different from the first material and the second material.

[0184] Article 48. A footwear article according to Article 47, wherein the third yarn includes two or more plied core yarns, and a cut pile yarn is between the plied core yarns.

[0185] Article 49. A footwear article according to Article 45, wherein the first yarn and the second yarn are at the outer layer of the knitted inner quarter portion, and the knitted inner quarter portion further includes an inner layer knitted integrally with the outer layer, and the inner layer includes a third yarn, and the third yarn includes at least a third material different from the first material and the second material.

[0186] Article 50. A footwear article according to Article 49, wherein the third yarn includes two or more plied core yarns, and a cut pile yarn is between the plied core yarns.

[0187] Clause 51. The footwear article according to Clause 45, wherein the first yarn and the second yarn are at an outer layer of the outer quarter portion of the knit, and at least the strip of the outer quarter portion of the knit further includes an inner layer knitted integrally with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

[0188] Clause 52. The footwear article according to Clause 51, wherein the third yarn includes two or more plied core yarns, and a cut pile yarn is between the plied core yarns.

[0189] Clause 53. The footwear article according to any one of Clauses 41 to 42, wherein the footwear upper has a knit toe in front of the knit tongue, the knit toe including an elastomeric yarn adjacent to a leading edge of the knit tongue.

[0190] Clause 54. The footwear article according to Clause 53, wherein the knit toe further includes a grip yarn, the grip yarn being knitted together with the elastomeric yarn and forming a reinforcing surface layer at a lower portion of the knit toe adjacent to the sole.

[0191] Clause 55. The footwear article according to Clause 54, wherein: the grip yarn includes a yarn that includes a first polymer component and a second polymer component; and the second polymer component is configured to flow back when thermoformed.

[0192] Clause 56. The footwear article according to Clause 55, wherein the first polymer component and the second polymer component have different melting temperatures.

[0193] Clause 57. The footwear article according to Clause 53, wherein a lower edge of a front edge of the outer quarter portion of the knit includes the elastomeric yarn continuously extending from the knit toe.

[0194] Clause 58. The footwear article according to any one of Clauses 41 to 42, further including: a reinforcing box stitch that extends through the strip and the tongue at a lower edge of a front edge of the strip.

[0195] Clause 59. The footwear article according to any one of Clauses 41 to 42, wherein the footwear upper further includes: a knit collar that extends along the inner quarter portion of the knit, along the outer quarter portion of the knit, and along the heel portion of the knit at the ankle opening; and the knit collar includes an elastomeric yarn.

[0196] Article 60. The footwear article according to any one of Articles 41 to 42, wherein the footwear upper further comprises: a knitted heel tab that extends from the knitted heel portion; and the knitted heel tab comprises an elastomeric yarn.

[0197] Article 61. A footwear article comprising: a knitted component that forms one or more of the on-foot portion and the underfoot portion of the footwear; wherein the underfoot portion comprises an outer-facing layer that forms a ground contact portion and an inner-facing layer that forms a foot contact portion, the outer-facing layer comprises a first material that comprises a thermoplastic material, and the inner-facing layer comprises a second material that is different from the first material; wherein one or more portions of the outer-facing layer that comprise the first material have a different coefficient of friction relative to the inner-facing layer that comprises the second material.

[0198] Article 62. The footwear article according to Article 61, wherein the one or more portions of the outer-facing layer have a greater coefficient of friction relative to the inner-facing layer that comprises the second material.

[0199] Article 63. The footwear article according to any one of Articles 61 to 62, wherein the outer-facing layer further comprises one or more raised attachment friction elements that comprise the first material.

[0200] Article 64. The footwear article according to Article 63, wherein the one or more raised attachment friction elements comprise a reflowed first material.

[0201] Article 65. The footwear article according to any one of Articles 61 to 62, wherein the outer-facing layer comprises one or more interwoven yarns, and each of the one or more interwoven yarns has a coating of the first material around a core yarn, and the core yarn has a second material that does not comprise the thermoplastic material and has a melting temperature higher than that of the first material.

[0202] Article 66. The footwear article according to Article 65, wherein the first material is at least partially fused to one or more core yarns.

[0203] Article 67. The footwear article according to Article 65, wherein the inner-facing layer comprises one or more second interwoven yarns that comprise the second material; and wherein the first material is at least partially fused to a portion of the one or more second interwoven yarns.

[0204] Clause 68. The footwear article according to Clause 65, wherein one or more intersecting portions at or near the junction of the outer-facing layer and the inner-facing layer comprise the first material.

[0205] Clause 69. The footwear article according to any one of Clauses 61 to 62, wherein the foot upper portion comprises: a knitted medial quarter portion at the medial side of the footwear article; a knitted lateral quarter portion at the lateral side of the footwear article; a knitted tongue fixed to the knitted medial quarter portion; and a knitted heel portion extending between the knitted medial quarter portion and the knitted lateral quarter portion at the rear of the footwear article; wherein the knitted medial quarter portion, the knitted lateral quarter portion, the knitted tongue and the knitted heel portion together define an ankle opening leading to a foot receiving cavity above the foot lower portion; and wherein the knitted lateral quarter portion extends to form a strap configured to span the knitted tongue and be fixed at the knitted medial quarter portion to secure the foot within the foot receiving cavity above the foot lower portion.

[0206] Clause 70. The footwear article according to Clause 69, wherein the strap is the only strap included in the footwear article for securing the foot within the foot receiving cavity.

[0207] Clause 71. The footwear article according to Clause 69, wherein the knitted lateral quarter portion extends from the toe region of the footwear article to the knitted heel portion and tapers in width towards the distal end of the strap.

[0208] Clause 72. The footwear article according to Clause 69, wherein the knitted tongue has an inner edge that extends from the toe region of the footwear article to the ankle opening at the medial side and is stitched to the medial edge of the knitted medial quarter portion at least midway to the ankle opening, and has an outer edge that extends from the toe region to the ankle opening, and the knitted tongue and the knitted lateral quarter portion are not stitched and are separated from each other at the outer edge to expand the ankle opening for easy access to the foot receiving cavity.

[0209] Clause 73. The footwear article according to Clause 69, wherein the knitted medial quarter portion, the knitted tongue and the knitted lateral quarter portion each comprise at least a first yarn knitted with a second yarn, the first yarn comprising at least a first material and the second yarn comprising at least a second material different from the first material.

[0210] Clause 74. The footwear article according to Clause 73, wherein the first yarn is at an outer surface of the footwear upper.

[0211] Clause 75. The footwear article according to Clause 73, wherein the first yarn and the second yarn are at an outer layer of the knitted tongue, and the knitted tongue further includes an inner layer knitted integrally with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

[0212] Clause 76. The footwear article according to Clause 775, wherein the third yarn includes two or more plied core yarns, with cut pile yarns between the plied core yarns.

[0213] Clause 77. The footwear article according to Clause 73, wherein the first yarn and the second yarn are at an outer layer of the knitted medial quarter, and the knitted medial quarter further includes an inner layer knitted integrally with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

[0214] Clause 78. The footwear article according to Clause 76, wherein the third yarn includes two or more plied core yarns, with cut pile yarns between the plied core yarns.

[0215] Clause 79. The footwear article according to Clause 73, wherein the first yarn and the second yarn are at an outer layer of the knitted lateral quarter, and at least the strip of the knitted lateral quarter further includes an inner layer knitted integrally with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

[0216] Clause 80. The footwear article according to Clause 79, wherein the third yarn includes two or more plied core yarns, with cut pile yarns between the plied core yarns.

[0217] Clause 81. The footwear article according to Clause 69, wherein the footwear upper has a knitted toe in front of the knitted tongue, the knitted toe including elastomeric yarns adjacent to a leading edge of the knitted tongue.

[0218] Clause 82. The footwear article according to Clause 81, wherein the knitted toe further includes grip yarns knitted together with the elastomeric yarns and forming a reinforcing surface layer at a lower portion of the knitted toe adjacent to the sole.

[0219] Clause 83. The footwear article according to Clause 82, wherein: the gripping yarn includes a yarn, the yarn includes a first polymer component and a second polymer component; and the second polymer component is configured to flow back when thermoformed.

[0220] Clause 84. The footwear article according to Clause 83, wherein the first polymer component and the second polymer component have different melting temperatures.

[0221] Clause 85. The footwear article according to Clause 81, wherein the lower edge of the front edge of the knitted outer quarter portion includes the elastomeric yarn continuously extending from the knitted toe.

[0222] Clause 86. The footwear article according to Clause 69, further comprising: a reinforced box stitch that extends through the strip and the tongue at the lower edge of the front edge of the strip.

[0223] Clause 87. The footwear article according to Clause 69, wherein the footwear upper further comprises: a knitted shoe collar that extends along the knitted inner quarter portion, along the knitted outer quarter portion, and along the knitted heel portion at the ankle opening; and the knitted shoe collar includes elastomeric yarn.

[0224] Clause 88. The footwear article according to Clause 69, wherein the footwear upper further comprises: a knitted heel tab that extends from the knitted heel portion; and the knitted heel tab includes elastomeric yarn.

[0225] Clause 89. A footwear article comprising: an integrally knitted footwear upper and sole, the sole including one or more interwoven yarns, the one or more interwoven yarns including a first material, the first material including a thermoplastic material.

[0226] Clause 90. The footwear article according to Clause 89, wherein the sole includes a flow-back polymer material of the thermoplastic material.

[0227] Clause 91. The footwear article according to Clause 90, wherein the ground contact surface of the sole includes the flow-back polymer material.

[0228] Clause 92. The footwear article according to any one of Clauses 89 to 91, wherein at least one of the one or more interwoven yarns includes a core and a sheath, and the sheath includes the thermoplastic material.

[0229] Clause 93. The footwear article according to any one of Clauses 89 to 91, wherein: the one or more interwoven yarns comprising the first material are first yarns, the one or more interwoven yarns comprise second yarns, the second yarns comprise a second thermoplastic material, and the ground contact surface of the sole is a polymer composition of the reflow polymer material of the first yarn and the reflow polymer material of the second yarn.

[0230] Clause 94. The footwear article according to any one of Clauses 89 to 91, wherein: the one or more interwoven yarns comprising the first material are at an outer layer of the sole; the sole further comprises an inner layer knitted integrally with the outer layer; and the inner layer comprises yarns, the yarns comprise a material different from the first material, and form a shoe bed having a foot contact surface.

[0231] Clause 95. The footwear article according to Clause 94, wherein the ground contact surface of the sole comprises the reflow polymer material of the thermoplastic material, and one or more portions of the ground contact surface comprising the reflow polymer material have a different coefficient of friction relative to the foot contact surface of the yarns comprising the inner layer.

[0232] Clause 96. The footwear article according to Clause 94, wherein the yarns of the inner layer forming the insole comprise two or more plied core yarns, and cut pile yarns are between the plied core yarns.

[0233] Clause 97. The footwear article according to any one of Clauses 89 to 91, wherein the footwear upper comprises: a knitted medial quarter portion at an inner side of the footwear article; a knitted lateral quarter portion at an outer side of the footwear article; a knitted tongue fixed to the knitted medial quarter portion; and a knitted heel portion extending between the knitted medial quarter portion and the knitted lateral quarter portion at a rear portion of the footwear article; wherein the sole and the footwear upper together define a foot receiving cavity; wherein the knitted medial quarter portion, the knitted lateral quarter portion, the knitted tongue and the knitted heel portion together define an ankle opening at the foot receiving cavity; and wherein the knitted lateral quarter portion extends to form a strap configured to span the knitted tongue and be fixed at the knitted medial quarter portion to secure a foot within the foot receiving cavity.

[0234] Clause 98. The footwear article according to Clause 97, wherein the footwear upper has a knitted toe in front of the knitted tongue, and the knitted toe comprises elastomeric yarns adjacent to a leading edge of the knitted tongue.

[0235] Clause 99. The footwear article according to Clause 98, wherein the knitted toe further comprises a backflow polymer material of additional yarn, the additional yarn being knitted together with the elastomeric yarn and forming a reinforcing surface layer at a lower portion of the knitted toe adjacent to the sole.

[0236] To assist and clarify the description of the various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Additionally, all references cited are incorporated herein by reference in their entirety.

[0237] "Footwear article", "footwear manufacture", and "footwear" may be considered as machines and manufactures. The assembled finished footwear article (e.g., shoes, sandals, boots, etc.) and discrete components of the footwear article (such as midsoles, outsoles, upper components, etc.) are considered herein and alternatively referred to in the singular or plural as "footwear article" prior to final assembly into a finished footwear article.

[0238] "A", "an", "the", "at least one", and "one or more" may be used interchangeably to indicate the presence of at least one of the items. Unless the context clearly indicates otherwise, there may be more than one such item. Unless explicitly or clearly indicated otherwise in the context (including the appended claims), all numerical values of parameters (e.g., amounts or conditions) in this specification should be understood to be modified in all instances by the term "about", whether or not "about" actually appears before the numerical value. "About" indicates that the stated numerical value allows some slight imprecision (numerically close to the exact; close to or reasonably close to the value; approximate). If the imprecision provided by "about" is not understood in the ordinary sense in the art, then "about" as used herein indicates at least the variation that can be caused by ordinary methods of measuring and using such parameters. In addition, the disclosure of a range should be understood to specifically disclose all values within the range and further divided ranges.

[0239] The terms "comprising", "including", and "having" are inclusive and thus specify the presence of the stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. When possible, the order of steps, processes, and operations may be changed, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any one of..." should be understood to include any possible combination of the recited items, including "any one of" the recited items. The term "any one of..." should be understood to include any possible combination of the recited claims in the appended claims, including "any one of" the recited claims.

[0240] For consistency and convenience, directional adjectives may be employed throughout the detailed description corresponding to the illustrated embodiments. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," etc. may be used descriptively with respect to the figures without indicating a limitation on the scope of the invention as defined by the claims.

[0241] The term "longitudinal" particularly refers to the direction extending along the length of an elongate member. For example, the longitudinal direction of a shoe extends between the forefoot region and the heel region of the shoe. The terms "forward" or "front" are particularly used to refer to the general direction from the heel region toward the forefoot region, and the terms "backward" or "rear" are particularly used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a member may be identified as having a longitudinal axis and forward and backward longitudinal directions along that axis. The longitudinal direction or axis may also be referred to as the anteroposterior direction or axis.

[0242] The term "lateral" particularly refers to the direction extending along the width of an elongate member. For example, the lateral direction of a shoe extends between the outer side and the inner side of the shoe. The lateral direction or axis may also be referred to as the outer direction or axis or the mediolateral direction or axis.

[0243] The term "vertical" particularly refers to the direction generally perpendicular to both the lateral direction and the longitudinal direction. For example, in the case where the sole is flat on a ground surface, the vertical direction may extend upward from the ground surface. It should be understood that each of these directional adjectives may be applied to the various components of the sole. The terms "upward" or "upwardly" particularly refer to the vertical direction pointing toward the top of a member, which may include the dorsal surface of the upper, the fastening region, and / or the throat of the upper. The terms "downward" or "downwardly" particularly refer to the vertical direction opposite the upward direction and pointing toward the bottom of a member, and generally may point to the bottom of the sole structure of a footwear article.

[0244] The "interior" of a footwear item, such as a shoe, particularly refers to the portion at the space occupied by the wearer's foot when the shoe is being worn. The "inner side" of a component particularly refers to the side or surface of the component that is oriented towards (or will be oriented towards) the interior of the component or the footwear item in an assembled footwear product. The "outer side" or "exterior" of a component particularly refers to the side or surface of the component that is oriented away from (or will be oriented away from) the interior of the shoe in an assembled shoe. In some cases, other components may be between the inner side of the component and the interior of the assembled footwear product. Similarly, other components may be between the outer side of the component and the space outside the assembled footwear product. Additionally, the terms "inward" and "inwardly" particularly refer to the direction towards the interior of a component or a footwear item, such as a shoe, and the terms "outward" and "outwardly" particularly refer to the direction towards the exterior of a component or a footwear item, such as a shoe. Further, the term "proximal" particularly refers to the direction that is closer to the center of the footwear component or closer to the foot when the user inserts the foot into the footwear item while wearing the footwear product. Similarly, the term "distal" particularly refers to the relative position that is farther from the center of the footwear component or farther from the foot when the user inserts the foot into the footwear item while wearing the footwear product. Thus, the terms proximal and distal can be understood as generally relative terms that provide a description of relative spatial positions.

[0245] Although various embodiments have been described, the description is intended to be exemplary rather than restrictive, and it will be apparent to those of ordinary skill in the art that many other embodiments and implementations within the scope of these embodiments are possible. Unless explicitly restricted, any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment. Thus, these embodiments are not limited except as defined by the appended claims and their equivalents. Moreover, various modifications and variations are possible within the scope of the appended claims.

[0246] Although several modes for implementing multiple aspects of the present teachings have been described in detail, those skilled in the art of the fields to which these teachings pertain will recognize various alternative aspects for practicing the present teachings within the scope of the appended claims. It is intended that all of the content contained in the above description or shown in the accompanying drawings be interpreted as illustrative and exemplary of the entire scope of alternative embodiments that those skilled in the art will recognize, which are implied by the content included, structurally and / or functionally equivalent or otherwise apparent based on the content included, and not limited to only those embodiments explicitly depicted and / or described.

Claims

1. A footwear article, comprising: An integrally knitted footwear upper, the integrally knitted footwear upper including a sole portion and defining a foot receiving cavity above the sole portion; Wherein the footwear upper includes: A knitted medial quarter portion at the medial side of the footwear article; A knitted lateral quarter portion at the lateral side of the footwear article; A knitted tongue fixed to the knitted medial quarter portion; and A knitted heel portion extending between the knitted medial quarter portion and the knitted lateral quarter portion at the rear of the footwear article; and A sole fixed to the outer surface of the sole portion; Wherein the knitted medial quarter portion, the knitted lateral quarter portion, the knitted tongue and the knitted heel portion together define an ankle opening at the foot receiving cavity; and Wherein the knitted lateral quarter portion extends to form a strap configured to span the knitted tongue and be fixed at the knitted medial quarter portion to secure the foot within the foot receiving cavity.

2. The footwear article according to claim 1, wherein the strap is the only strap included in the footwear article for securing the foot within the foot receiving cavity.

3. The footwear article according to any one of claims 1 to 2, wherein the knitted lateral quarter portion extends from the toe region of the footwear article to the knitted heel portion and tapers in width towards the distal end of the strap.

4. The footwear article according to any one of claims 1 to 2, wherein the knitted tongue has an inner edge that extends from the toe region of the footwear article to the ankle opening at the medial side and is stitched to the medial edge of the knitted medial quarter portion at least midway to the ankle opening, and has an outer edge that extends from the toe region to the ankle opening at the lateral side, and the knitted tongue and the knitted lateral quarter portion are not stitched and are separated from each other at the outer edge to widen the ankle opening for easy access to the foot receiving cavity.

5. The footwear article according to any one of claims 1 to 2, wherein the knitted medial quarter portion, the knitted tongue and the knitted lateral quarter portion each include at least a first yarn knitted with a second yarn, the first yarn including at least a first material, and the second yarn including at least a second material different from the first material.

6. The footwear article according to claim 5, wherein the first yarn is at the outer surface of the footwear upper.

7. The footwear article according to claim 5, wherein the first yarn and the second yarn are at the outer layer of the knitted tongue, and the knitted tongue further includes an inner layer integrally knitted with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

8. The footwear article according to claim 7, wherein the third yarn includes two or more plied core yarns, with cut pile yarns between the plied core yarns.

9. The footwear article according to claim 5, wherein the first yarn and the second yarn are at an outer layer of the knitted medial quarter portion, and the knitted medial quarter portion further includes an inner layer knitted integrally with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

10. The footwear article according to claim 9, wherein the third yarn includes two or more plied core yarns, with cut pile yarns therebetween.

11. The footwear article according to claim 5, wherein the first yarn and the second yarn are at an outer layer of the knitted lateral quarter portion, and at least the strip of the knitted lateral quarter portion further includes an inner layer knitted integrally with the outer layer, the inner layer including a third yarn, the third yarn including at least a third material different from the first material and the second material.

12. The footwear article according to claim 11, wherein the third yarn includes two or more plied core yarns, with cut pile yarns therebetween.

13. The footwear article according to any one of claims 1 to 2, wherein the footwear upper has a knitted toe in front of the knitted tongue, the knitted toe including one or more interlaced yarns, the one or more interlaced yarns including a first material, the first material including a thermoplastic material.

14. The footwear article according to claim 13, wherein the knitted toe includes a reflow polymer material of the thermoplastic material.

15. The footwear article according to claim 14, wherein: the one or more interlaced yarns include an elastomeric yarn adjacent to a leading edge of the knitted tongue.

16. The footwear article according to claim 15, wherein a lower edge of a front edge of the knitted lateral quarter portion includes the elastomeric yarn continuously extending from the knitted toe.

17. The footwear article according to any one of claims 1 to 2, further comprising: a reinforced box stitch extending through the strip and the tongue at a lower edge of a front edge of the strip.

18. The footwear article according to any one of claims 1 to 2, wherein the footwear upper further includes: a knitted collar extending along the knitted medial quarter portion, along the knitted lateral quarter portion, and along the knitted heel portion at the ankle opening; and the knitted collar includes an elastomeric yarn.

19. The footwear article according to any one of claims 1 to 2, wherein the footwear upper further includes: a knitted heel tab extending from the knitted heel portion; and the knitted heel tab includes an elastomeric yarn.

20. A footwear article, comprising: an integrally knitted footwear upper and sole, the sole including one or more interlaced yarns, the one or more interlaced yarns including a first material, the first material including a thermoplastic material.

21. The footwear article according to claim 20, wherein the sole includes a reflow polymer material of the thermoplastic material.

22. The footwear article according to claim 21, wherein the ground contact surface of the sole includes the reflow polymer material.

23. The footwear article according to any one of claims 20 to 22, wherein at least one of the one or more interwoven yarns includes a core and a sheath, and the sheath includes the thermoplastic material.

24. The footwear article according to any one of claims 20 to 22, wherein: The one or more interwoven yarns including the first material are first yarns, the one or more interwoven yarns include second yarns, the second yarns include a second thermoplastic material, and the ground contact surface of the sole is a polymer composition of the reflow polymer material of the first yarns and the reflow polymer material of the second yarns.

25. The footwear article according to any one of claims 20 to 22, wherein: The one or more interwoven yarns including the first material are at an outer layer of the sole; The sole further includes an inner layer knitted integrally with the outer layer; and The inner layer includes yarns, the yarns include a material different from the first material, and form a shoe bed having a foot contact surface.

26. The footwear article according to claim 25, wherein the ground contact surface of the sole includes a reflow polymer material of the thermoplastic material, and one or more portions of the ground contact surface including the reflow polymer material have a different coefficient of friction relative to the foot contact surface of the yarns including the inner layer.

27. The footwear article according to claim 25, wherein the yarns of the inner layer forming the shoe bed include two or more plied core yarns, and cut pile yarns are between the plied core yarns.

28. The footwear article according to any one of claims 20 to 22, wherein the footwear upper includes: A knitted medial quarter portion at the medial side of the footwear article; A knitted lateral quarter portion at the lateral side of the footwear article; A knitted tongue fixed to the knitted medial quarter portion; And A knitted heel portion extending between the knitted medial quarter portion and the knitted lateral quarter portion at the rear of the footwear article; Wherein the sole and the footwear upper together define a foot receiving cavity; Wherein the knitted medial quarter portion, the knitted lateral quarter portion, the knitted tongue and the knitted heel portion together define an ankle opening at the foot receiving cavity; And Wherein the knitted lateral quarter portion extends to form a strap configured to span the knitted tongue and be fixed at the knitted medial quarter portion to secure the foot within the foot receiving cavity.

29. The footwear article according to claim 28, wherein the footwear upper has a knitted toe in front of the knitted tongue, and the knitted toe includes elastomeric yarns adjacent to the leading edge of the knitted tongue.

30. The footwear article according to claim 29, wherein the knitted toe further comprises a backflow polymer material of additional yarn, the additional yarn being knitted together with the elastomeric yarn and forming a reinforcing surface layer at a lower portion of the knitted toe adjacent to the sole.

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