Knitted component for article of footwear with two or more material compositions

Abstract

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

Description

[0001] This application is a divisional application of an application with an application date of May 3, 2018, an application number of 202210410364.1, and an invention title of "Knit Component for Footwear with Two or More Material Combinations".

[0002] The "application with an application date of May 3, 2018, an application number of 202210410364.1, and an invention title of 'Knit Component for Footwear with Two or More Material Combinations'" is a divisional application of an application with an application date of May 3, 2018, an application number of 201880029824.8, and an invention title of "Knit Component for Footwear with Two or More Material Combinations".

[0003] Related Applications

[0004] This application claims the benefit of U.S. Provisional Application No. 62 / 502,362, filed May 5, 2017, which is hereby incorporated by reference in its entirety. Background

[0006] Conventional footwear typically includes two main elements: an upper and a sole structure. The upper is attached to the sole structure and forms a cavity within the footwear for comfortably and securely receiving a foot. The sole structure is attached to the lower surface of the upper so as to be positioned between the upper and the ground. In some footwear, the sole structure can include a midsole and an outsole. The midsole can be formed from a polymeric foam material that attenuates ground reaction forces to reduce stress on the foot and leg during walking, running, and other locomotive movements. The outsole can be attached to the lower surface of the midsole and forms the ground-engaging portion of the sole structure, which is formed from a durable and abrasion-resistant material.

[0007] The upper of a footwear typically extends over the dorsal and toe regions of the foot, along the medial and lateral sides of the foot, and around the heel region of the foot. An ankle opening in the heel region typically provides an entrance to the cavity within the upper. A lacing system is typically incorporated into the upper to adjust the fit of the upper, thereby facilitating entry of the foot into and removal from the cavity within the upper. The upper can include a tongue that extends under the lacing system to enhance the adjustability of the footwear, and the upper can incorporate a heel counter to limit movement of the heel.

[0008] Brief Summary

[0009] One general aspect of the present disclosure includes a knitted component for an article of footwear, the knitted component having an overfoot portion and an underfoot portion; a first yarn, wherein the first yarn at least partially forms the overfoot portion and at least partially forms the underfoot portion; and a second yarn, wherein the second yarn at least partially forms the overfoot portion and at least partially forms the underfoot portion. The first yarn may comprise a first material composition having a first melting point, and the second yarn may comprise a second material composition having a second melting point. The first melting point may be at least 20 degrees Celsius higher than the second melting point.

[0010] Another general aspect of the present disclosure includes a knitted component having an overfoot portion; a first underfoot segment extending from a first side of the overfoot portion, the first underfoot segment having a first end; and a second underfoot segment extending from a second side of the overfoot portion, the second underfoot segment having a second end. The first end may be configured to be secured to the second end such that the first underfoot segment and the second underfoot segment form the underfoot portion of the article of footwear, wherein at least one of the first underfoot segment and the second underfoot segment is formed from both a first material composition and a second material composition, and wherein the first material composition and the second material composition have different melting points.

[0011] Another general aspect of the present disclosure includes an article of footwear having a knitted component with an overfoot portion and an underfoot portion. The knitted component may have a fusion zone located at least partially on the underfoot portion, wherein the fusion zone is at least partially formed from a first yarn and a second yarn, wherein the first yarn comprises a first material composition having a first melting point, wherein the second yarn comprises a second material composition having a second melting point, and wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0012] Another general aspect of the present disclosure includes a knitted component having a first zone located between a second zone and a third zone, wherein the first zone has a first number of courses per unit length, wherein the second zone has a second number of courses per unit length, and wherein the third zone has a third number of courses per unit length. The first number of courses per unit length may be less than the second number of courses per unit length and the third number of courses per unit length such that the first zone of the knitted component includes a tendency to bend. Brief Description of the Drawings

[0014] Figure 1 is an illustration showing a side view of an article of footwear in accordance with an embodiment of the present disclosure.

[0015] Figure 2 is showing Figure 1Illustration of a magnified view of a first region of the outer surface of a footwear item.

[0016] Figure 3 is an illustration showing Figure 1 a magnified view of another region of the outer surface of a footwear item.

[0017] Figure 4 is an illustration showing Figure 1 a magnified view of yet another region of the outer surface of a footwear item.

[0018] Figure 5 is an illustration showing an embodiment of a knitted component for forming an upper of a footwear item for Figure 1 a footwear item.

[0019] Figure 6 is an illustration showing Figure 5 the knitted component being manipulated into a wearable shape.

[0020] Figure 7 is an illustration showing Figure 1 a bottom view of a footwear item.

[0021] Figure 8 is an illustration showing a bottom view of a second embodiment of a footwear item according to the present disclosure.

[0022] Figure 9 Shows four embodiments of yarns that can be used to form a knitted component according to the present disclosure. Detailed description

[0024] Aspects are described below with reference to the accompanying drawings, in which like elements are generally identified by like numerals. The relationships and functions of the various elements can be better understood with reference to the following description. However, the aspects are not limited to those illustrated in the drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale and that in some cases, details that are not necessary for understanding the aspects disclosed herein may have been omitted.

[0025] Certain aspects of the present disclosure relate to knitted textiles or other textiles for use in an article and, in particular, for use in constructing an upper of a footwear item. The upper can be used with any type of footwear. Illustrative, non-limiting examples of footwear items include basketball shoes, cycling shoes, cross-training shoes, global football (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski boots or snowboard boots, tennis shoes, running shoes, and walking shoes. The upper can also be incorporated into non-sports footwear and shoes, such as dress shoes, loafers, and sandals.

[0026] Figure 1 FIG. Figure 1 is a diagram showing a footwear item 100 having an upper 102 formed thereon, where the upper 102 is generally formed as a knitted component 104. As shown, the upper 102 may be secured to at least one sole structure, such as a first sole structure 106 and a second sole structure 108. A first stitch line 110 may be located at the edge of the first sole structure 106 where the upper 102 is joined, and a second stitch line 112 may be located at the edge of the second sole structure where the upper 102 is joined. The upper 102 may be joined to at least one of the sole structures in a fixed manner using any suitable technique, such as by using an adhesive, by sewing, etc.

[0027] The knitted component 104 may additionally include a throat region 114 extending from an ankle opening 116 and the ankle opening 116 leading to a cavity 118, and a collar 120 may at least partially surround the ankle opening 116. The cavity 118 of the footwear item 100 may be configured (e.g., sized and shaped) to receive and accommodate a person's foot. The throat region 114 may be generally disposed in a midfoot region 122 of the upper 102. The midfoot region 122 of the upper 102 may be located between a heel region 124 and a forefoot region 126 (the forefoot region 126 may include a toe region 128). In some embodiments, an optional tongue, such as the depicted tongue 130, may be provided in the throat region 114. The tongue 130 may be any type of tongue, such as a gusseted tongue or a burrito tongue.

[0028] The footwear item 100 may include a fastening element (not shown). Any suitable type of fastening element may be used, such as a shoelace, a cable-tensioning system, and / or any other suitable device. The upper 102 may be configured to be secured to and communicate with the fastening element such that the fastening element may adjust and / or tighten the upper 102 around the wearer's foot. For example, the upper 102 may include a set of holes 132 for receiving the fastening element, but other suitable elements for communicating with the fastening system may alternatively be used.

[0029] At least a portion of the upper 102, and potentially substantially the entire upper 102, can be formed by the knitted component 104 (or another suitable textile component). The knitted component 104 can be formed as an integral one-piece element during a 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 the knitting machine can substantially form the knitted structure of the knitted component 104 without a large number of post-knitting processes or post-knitting steps. Alternatively, two or more portions of the knitted component 104 can be separately formed as different integral one-piece elements and then attached to the corresponding elements.

[0030] Forming the upper 102 with the knitted component 104 can provide the upper 102 with advantageous properties, including but not limited to a particular degree of elasticity (e.g., as represented by Young's modulus), breathability, bendability, strength, moisture absorbency, weight, abrasion resistance, and / or combinations thereof. These properties can be achieved by selecting a particular single-layer or multi-layer knitted structure (e.g., a rib knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knitted structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), and / or combinations thereof. The knitted component 104 can also provide the desired aesthetic properties by incorporating yarns of different colors, textures, or other visual properties arranged in a particular pattern. The yarns themselves and / or the knitted structure formed by one or more yarns of the knitted component 104 can vary at different locations such that the knitted component 104 has two or more portions with different properties (e.g., the portion forming the throat region 114 of the upper 102 can be relatively elastic while another portion can be relatively inelastic). In some embodiments, the knitted component 104 can incorporate one or more materials that have properties that change in response to a stimulus (e.g., temperature, humidity, electric current, magnetic field, or light). For example, the knitted component 104 can include yarns formed of at least one thermoplastic polymer material or material composition (e.g., at least one polyurethane, polyamide, polyolefin, and / or nylon) that transitions from a solid state to a softened state or a liquid state when subjected to certain temperatures at or above its melting point and then transitions back to a solid state when cooled. The one or more thermoplastic polymer materials can provide the ability to thermally process (e.g., heat and then cool) at least a portion of the knitted component 104 to form a region of bonded or continuous material (referred to herein as a "fusion zone" and depicted as fusion zone 134) that exhibits certain advantageous properties, including, for example, a relatively high degree of rigidity, strength, and water resistance. In this specification, the term "fusion zone" generally refers to a region of the upper 102 where portions of the material forming the upper (e.g., material initially contained in different individual yarns of the knitted component 104) are partially or substantially bonded together. A "fusion zone" does not need to be formed by any particular process. In a non-limiting example, two or more separate yarns, including monofilament yarns and / or multifilament yarns, can form a fusion zone when at least a portion of the material initially contained in the yarns is bonded such that at least a portion of the separate yarns becomes continuous with each other.In addition, after combining to form the fusion zone, the materials of the initially separated yarns may become visually and / or physically indistinguishable, although this is not the case for all embodiments.

[0031] The fusion zone 134 can have any suitable size and shape, and the upper 102 can have multiple fusion zones (which can be discrete and separated by zones without fusion material). As shown, the fusion zone 134 can have different regions with different properties (such as a first region 136, a second region 138, and a third region 140). For example, the first region 136 can have a relatively high density of fusion material (defined as the amount (mass) of the fused thermoplastic polymer material composition per unit surface area), such that the first region has relatively low elasticity, low rigidity, high strength, and high water resistance. The second region 138 can have a lower density of fusion material than the first region 136 and can thus be more elastic than the first region 136, potentially lower in rigidity, and potentially lower in water resistance. Similarly, the third region can have a lower density of fusion material than the first region 136 and the second region 138. More or fewer than three regions can be included, and Figure 1 the specific orientation, order, and position of each of the regions are included only as non-limiting examples.

[0032] The fusion zone 134 can define a portion of the outer surface 142 of the upper 102. In at least some positions of the knitted component 104, the fusion zone 134 can be generally limited to the outer surface 142 of the knitted component 104, and the inner surface (shown in Figure 6 can not include the fusion zone 134. The inner surface of the knitted component can face relatively outwardly from the outer surface 142 and can at least partially form the cavity 118 of the footwear item. In other words, the inner surface can be located between the outer surface 142 and the cavity 118 (such that the fusion zone 134 is separated from the cavity at least at one position).

[0033] Advantageously, the inner surface can include softness, abrasion resistance, and other comfort-related properties that can be associated with the knitted component 104 in the zones without the fusion zone 134. A multi-layer knitted component having a fusion zone located on the outer surface (but not necessarily the inner surface) is fully described in U.S. Patent Application No. 15 / 443,808, filed on February 27, 2017, which is incorporated herein by reference in its entirety.

[0034] When a thermoplastic polymer material or a thermoplastic polymer composition is included in a yarn, any portion of the yarn can have one or more thermoplastic polymers (collectively referred to as "thermoplastic polymer material composition"), and in some embodiments, substantially the entire yarn can be formed of the thermoplastic polymer material composition. Optionally, the yarn can have a polyester core and a thermoplastic polymer sheath. The thermoplastic polymer material composition of the sheath can have a melting temperature less than the melting temperature or decomposition temperature of the polyester core. For example, in some embodiments, the melting temperature of the thermoplastic polymer material composition can have a melting temperature that is about 100 degrees Celsius less than the melting temperature of the polyester core, but any other suitable melting temperature difference is contemplated. All melting points and other temperatures mentioned herein are approximate and are based on atmospheric pressure at sea level. In one example, the melting temperature of the polyester core can be about 260 degrees Celsius, and the decomposition temperature can be about 350 degrees Celsius or greater. The melting temperature of the thermoplastic polymer material composition can be, for example, between about 80 degrees Celsius and about 200 degrees Celsius, such as from about 120 degrees Celsius to about 180 degrees Celsius. In an exemplary embodiment, the yarn can comprise thermoplastic polyurethane, and the yarn can specifically be Dream- Thermoplastic polyurethane-coated yarns are sold.

[0035] Figure 2 is a diagram showing an enlarged view of a first region 136 of the fusion zone 134. As Figure 2 shown, in some embodiments, more than one thermoplastic polymer material composition can be included. For example, when the upper 102 is formed of a knitted component 104, the knitted component 104 can include more than one yarn type, where different yarn types contain different material compositions. Thus, it is contemplated that the knitted component 104 can include a first yarn 144 comprising a first material composition and a second yarn 146 having a second material composition, where the first material composition and the second material composition have different melting points. In a non-limiting exemplary embodiment, the first material composition can include a composition of a thermoplastic polyurethane material having a melting point of about 140 degrees Celsius or lower, such as about 120 degrees Celsius. The second material composition can include a different composition of a thermoplastic polyurethane material having a melting point of about 195 degrees Celsius or lower, such as about 175 degrees Celsius. Thus, the second melting point can be higher than the first melting point (e.g., at least 5 degrees Celsius higher, at least 10 degrees Celsius higher, at least 20 degrees Celsius higher, at least 50 degrees Celsius higher, at least 100 degrees Celsius higher, or even higher). Other suitable material compositions having different melting points can be included additionally or alternatively.

[0036] Including a plurality of thermoplastic polymer material compositions may be advantageous for providing a footwear upper with desired properties that may be difficult to achieve when using only one composition. For example, a fusion zone formed of a thermoplastic polymer material composition having a relatively low melting point (e.g., 120 degrees Celsius) may have the desired water resistance properties, but it may be prone to wear. A thermoplastic polymer material composition having a higher melting temperature (e.g., 175 degrees Celsius) may lack the desired degree of water resistance, but may be associated with a high degree of abrasion resistance. Thus, by including both material compositions in the fusion zone, the fusion zone can have the desired water resistance properties as well as the desired abrasion resistance. While this paragraph uses abrasion resistance and water resistance as examples, other properties may additionally or alternatively be associated with a fusion zone formed of a particular material composition having a particular melting point.

[0037] In the first region 136, the ratio of one material composition to another (measured as the mass ratio of one material composition to another per unit surface area) can be any suitable ratio. For example, in some non-limiting exemplary embodiments, the ratio of the first thermoplastic polymer material composition (of the first yarn 144) to the second thermoplastic polymer material composition (of the second yarn 146) can be about 1:1, but other ratios are also contemplated (e.g., 1:0.1, 1:0.25, 1:0.5, 1:0.75, 1:1, 1:1.5, 1:2, 1:5, 1:10, etc.). The ratio can be determined by the amount of the first yarn 144 used relative to the amount of the second yarn 146, the amount of the first thermoplastic polymer material composition per unit length of the first yarn 144, and / or the amount of the second thermoplastic polymer material composition per unit length of the second yarn 146, etc. Additionally, the ratio of one material composition to another can vary throughout the footwear article 100 and even throughout the first region 136 of the fusion zone 134, particularly when different properties (e.g., different material compositions) are desired at different locations within the fusion zone 134.

[0038] Figure 3It is an illustration showing an enlarged view of a second region 138 of the fusion zone 134. As shown, in the second region 138, the amount of the first thermoplastic polymer material composition per unit surface area can be less than that in the first region 136, which may be due to the fact that less of the first yarn 144 (per unit surface area) is used in the second region 138 than in the first region 136. Similarly, the amount of the second thermoplastic polymer material composition per unit surface area can be less in the second region 138 than in the first region 136. The knitted component 104 can also include a third yarn 148 formed of a third material composition different from the first and second material compositions. In one example, the third yarn 148 can be formed generally of a material having a melting point (e.g., if the material is a thermoplastic polymer material) and / or decomposition point (e.g., if the material is a thermosetting material) higher than those of the first yarn 144 and the second yarn 146. Illustrative, non-limiting examples of materials that can form the third yarn 148 can include thermosetting polymer materials and natural fibers such as cotton, silk, and wool; or thermoplastic polymer materials having a relatively high melting point such as polyester. These materials tend to remain stable when subjected to a medium level of heat. Note that the reference herein to the first yarn 144 and the second yarn 146 formed of a thermoplastic polymer material composition does not limit the third yarn 148 to also being a separate thermoplastic polymer material composition with an even higher melting point, even when the third yarn 148 will generally not form a fusion zone when thermally processed according to the present disclosure.

[0039] Advantageously, when the first yarn and / or the second yarn are thermally processed, the relatively high melting point and / or decomposition point of the third yarn 148 can indicate that the third yarn 148 remains relatively stable. Thus, the general properties that the third yarn had prior to the thermal processing step can be maintained during and after the thermal processing. In some embodiments, the third yarn 148 can have a melting point and / or decomposition temperature of about 140 degrees Celsius or higher, about 175 degrees Celsius or higher, about 200 degrees Celsius or higher, about 250 degrees Celsius or higher, or even higher. A specific example is a yarn formed generally of polyester, which can have a melting point of about 250 degrees Celsius and a boiling point or decomposition point of about 350 degrees Celsius.

[0040] When the knitted component 104 includes a knitted structure formed on two needle beds (e.g., a double jersey knitted structure), the material ratio can be changed by varying the yarns exposed on the outer surface 142. For example, in a first region 136 of the fusion zone 134, the third yarn 148 can be knitted primarily on the back needle bed of the knitting machine such that the third yarn is located primarily on the inner side of the knitted component. In a second region 138, a greater portion of the third yarn 148 can be incorporated into the outer side of the knitted component 104 (e.g., by knitting the third yarn 148 with the front needle bed of the knitting machine), while a greater portion of the first yarn 144 and / or the second yarn 146 can be incorporated into the inner side. Processes for varying the amounts of different yarn types on corresponding sides of a component are fully described in U.S. Patent Application No. 15 / 443,808 (above, which is incorporated by reference into this description).

[0041] Reference Figure 1 , in some embodiments, the ratio of fused material to unfused material present in a region of the knitted component 104 can be varied. For example, as moving from the bite line towards the throat region 114 of the shoe, the amount and / or density of the fused thermoplastic polymer material composition may decrease. By way of illustration, the first region 136 can be formed primarily of the fused thermoplastic polymer material composition. In the second region 138, the knitted component 104 can include a relatively reduced amount of the thermoplastic polymer material composition, and the third region 140 can include even less of the fused thermoplastic polymer material than the second region 138. In one non-limiting example, the ratio of the fused thermoplastic polymer material composition to other materials can be about 90:10 (or greater) in the depicted first region 136, about 50:50 in the second region 138, and about 25:75 in the third region 140. Other ratios in the first region 136, the second region 138, and / or the third region 140 are contemplated. It is also contemplated that one or more of the regions can gradually decrease the ratio of fused material to another material in a gradient manner, and in some embodiments, the different regions may not be discrete and / or may not be visible or otherwise distinguishable.

[0042] It is also contemplated that, instead of (or in addition to) varying the amount of the thermoplastic polymer material, different zones of the knitted component 104 having the thermoplastic polymer material composition can be processed differently (e.g., more heat and / or pressure can be applied in one or more regions than in other regions). In some embodiments, some selected regions of the knitted component 104 may not form a fusion zone at all, even when including the thermoplastic polymer material composition. For example, if the knitted component 104 includes the thermoplastic polymer material composition in a zone that does not require the properties associated with the fusion zone, those zones can be shielded from heat during, for example, a heat processing step.

[0043] Figure 4 It is an illustration showing an enlarged view of the throat region 114 of the shoe. The outer surface of the knitted component 104 at the throat region 114 can be formed entirely of the third yarn 148 (and / or can include unfused portions of the first yarn 144 and / or the second yarn 146). Advantageously, the throat region 114 can include the desired elasticity for providing a comfortable and / or adjustable fit around the wearer's foot for the footwear item 100. At least one surface of the throat region 114 can be mainly formed of polyester, but can additionally or alternatively include other suitable materials. Similarly, the collar 120 and / or the tongue 130 of the knitted component 104 can exclude the fusion zone 134, such that they have a relatively high degree of elasticity, flexibility, resilience, breathability, adjustability, softness, and abrasion resistance and / or other desired properties for receiving the foot and providing a comfortable and / or adjustable fit. Other regions of the upper 102 can additionally or alternatively exclude the fusion zone. It is contemplated that these regions can be covered with a film (such as a sprayed film or an adhesive film) to protect the knitted component from abrasion (especially abrasion on the outer surface), but such a film is optional.

[0044] Figure 5 The knitted component 104 of the upper 102 is shown as it might appear after the knitting process (e.g., after leaving a flat - bed knitting machine) but before being manipulated into its wearable shape. Optionally, the knitted component 104 can be cut into its desired shape after knitting, but cutting is not required in some embodiments. The knitted component 104 can be thermally processed before being manipulated into its wearable shape to form the first region 136, the second region 138, and / or the third region 140 of the fusion zone 134. Thermal processing after the knitting step but before manipulating the upper 102 into its wearable shape can be advantageous because it can be relatively easily accomplished and is relatively efficient when the knitted component 104 is generally flat, using a hot press or other device. A method of thermally processing a knitted component to form the fusion zone 134 is fully described in U.S. Patent Application No. 15 / 443,808 (incorporated by reference above).

[0045] As shown, the knitted component 104 can include at least one underfoot segment, such as the depicted medial underfoot segment 150 and lateral underfoot segment 152. The medial underfoot segment 150 and the lateral underfoot segment 152 can be constructed (e.g., sized, shaped, and positioned) to form the underfoot portion 154 of the footwear item. The underfoot portion 154 (also at Figure 7as shown) may be associated with the plantar aspect of the foot (also referred to as the sole or bottom of the foot). The remainder of the knitted component 104 may be configured to form an upper portion 156 associated with the remainder of the foot, and the upper portion 156 includes a dorsal surface (i.e., the top of the foot). The underfoot portion 154 may extend from the outer side 158 of the shoe upper 102 to the inner side 160 of the shoe upper, and from the toe region 128 to the heel region 124.

[0046] In some embodiments, the hot working step may be twice the step of molding at least one rib structure 162 or other feature within the fusion zone 134. Thus, it is envisioned that the hot press for the hot working step may have at least one die, or alternatively, a separate die may be applied to the thermoplastic polymer material composition during or after application of heat. The rib structure 162 may be beneficial for providing the desired surface characteristics for the fusion zone 134. For example, the rib structure 162 may be configured (e.g., sized, shaped, and positioned) to provide traction or provide another desired function during a movement activity (e.g., when kicking a ball). The rib structure 162 or other molded structure may additionally or alternatively provide the desired aesthetics to the outer surface 142 of the knitted component 104. In some embodiments, a logo, label, or another suitable image or design may be molded within the fusion zone 134.

[0047] The fusion zone 134 may be at least partially located on the underfoot portion 154. As shown, the fusion zone 134 may extend upward along the upper portion 156 on the underfoot portion 154 and terminate at the edge of the throat region 114. In some embodiments (as depicted), the fusion zone 134 may generally cover the entire underfoot portion 154. Advantageously, the fusion zone 134 may provide the desired characteristics associated with the fusion zone 134 to the underfoot portion 154, such as suitable strength, durability, flexibility, water permeability, stretchability, and similar characteristics. Since the underfoot portion 154 may bear the weight of the wearer during use, the fusion zone 134 may be particularly thick and / or dense on the underfoot portion 154 relative to other locations to provide a relatively high degree of support, durability, protection, and even cushioning between the ground and the plantar aspect of the foot. For example, during hot working, it is envisioned that the hottest part of the hot press may be applied to the underfoot portion 154 (since the molten thermoplastic polymer material has a tendency to flow towards heat), thereby facilitating a dense and / or thick fusion zone 134 at the underfoot portion 154.

[0048] Figure 6Is an illustration showing the knitted component 104 being folded or otherwise manipulated into a wearable shape. As shown, the outer surface 142 formed by the knitted component 104 can face outward, and the inner surface 164 can face inward and ultimately define the cavity of the footwear item. The outer heel region 176 and the inner heel region 178 can be joined at this step to form a heel seam 166 in the heel region 124. Connecting the outer heel region 176 to the inner heel region 178 at the heel seam 166 can include sewing, adhesive bonding, heat bonding, welding, using mechanical clamps, or any other suitable device or method, and it is contemplated that another device can be placed between the inner heel region 178 and the outer heel region 176. The folding step / manipulation step and / or the step of forming the heel seam 166 can be performed at least in part when the upper 102 is located on a shoe last. Examples of shoe lasts and associated lasting processes are described in U.S. Patent Application Serial No. 12 / 848,352, filed on August 2, 2010, and issued as U.S. Patent No. 8,595,878, which is incorporated herein by reference in its entirety.

[0049] Similarly, the outer lower foot section 152 and the inner lower foot section 150 can be joined at this step to form a sole seam 168 on the underfoot portion 154 of the upper 102. Connecting the outer lower foot section 152 to the inner lower foot section 150 can include sewing, adhesive bonding, heat bonding, welding, using mechanical clamps, or any other suitable device or method, and it is contemplated that another device can be placed between the inner lower foot section 150 and the outer lower foot section 152. The folding step / manipulation step and / or the step of forming the sole seam 168 can be performed at least in part when the upper 102 is located on a shoe last (not shown).

[0050] Before, during, or after the step of manipulating the knitted component 104 into its wearable shape, one or more insert elements can be included. For example, a bottom layer 170 can be included to facilitate maintaining the wearable shape of the upper 102. The bottom layer 170 can be secured to the knitted component (e.g., by sewing, using an adhesive, etc.) and can provide suitable structure, durability, strength, rigidity, etc., particularly in the heel region 124 and the underfoot portion 154 (but also additionally or alternatively in other regions). In some embodiments, the bottom layer 170 can be joined to the shoe last during the lasting step and then detached from the shoe last when the upper 102 is removed from the shoe last. A second insert element can be included for providing cushioning, for facilitating the connection of the outer lower foot section 152 to the inner lower foot section 150, or for any other suitable purpose. More or fewer than two insert elements can be included for a wide range of functions.

[0051] As Figure 6As shown, the tongue 130 and / or the throat region 114 of the knitted component 104 may include a knitted structure such that the tongue 130 has a tendency to bend. The tongue 130 may be configured to be pulled by a user to facilitate placement of the foot in the upper 102. Thus, the tongue 130 may include a tendency to bend away from the user's leg such that it can be easily and effectively positioned and grasped. The tendency to bend may be formed by any suitable knitted structure (or other structure). For example, the tendency to bend may be provided by providing more courses on one surface (e.g., the bottom surface) of the tongue 130 than on the other surface (e.g., the top surface), such that when the tongue 130 is forced into a flat state, the tension in the top surface is higher than the tension in the bottom surface. This structure and the associated knitting process are fully described in U.S. Provisional Patent Application No. 62 / 421,850, filed Nov. 14, 2016, which is incorporated herein by reference in its entirety.

[0052] Additionally or alternatively, the throat region 114 may include fewer courses than at least a portion of one of the outer side 158 and the inner side 160 of the knitted component adjacent to the throat region 114. For example, for every two courses of the outer side 158 and / or the inner side, the throat region 114 may include one course. Other ratios are also contemplated (e.g., the course ratio of the throat region to the adjacent portion may be about 0.1:1, 0.2:1, 0.5:1, 0.8:1, etc.). At least when the knitted component is forced into a flattened state, the resulting knitted component 104 may have a structure that provides a higher tension in the yarns of the throat region 114 than in the surrounding yarns, due to the fewer courses covering a substantially equal distance (i.e., the distance along the knitting direction). When the knitted component 104 is deformed in a manner such that the tongue 130 is pulled upward, the higher tension in the tongue 130 and / or the throat region 114 may be balanced, and thus the natural tendency may be included within the knitted structure for bending the tongue 130. This feature may be enhanced when the throat region 114 and / or the tongue 130 are formed from yarns having relatively high elasticity. Thus, it may be advantageous for the throat region 114 and / or the tongue 130 to include at least one yarn that is more elastic (before or after heat processing) than the yarns primarily forming the outer side 158 and / or the inner side 160 of the knitted component 104. Similarly, since heat processing the outer and inner sides to form the fused region 134 may increase the rigidity of the outer side 158 and the inner side 160 and reduce their flexibility, forming the fused region 134 may enhance the tendency of the tongue 130 to bend.

[0053] Figure 7It is an illustration showing a bottom view of the footwear item 100. As shown, the underfoot seam 168 can be located on the underfoot portion 154, where the outer underfoot segment 152 and the inner underfoot segment 150 are secured. The underfoot seam 168 can be generally in the center of the underfoot portion 154 and can extend along the longitudinal direction of the footwear item 100. However, in other embodiments, the underfoot seam 168 can be offset relative to the center of the underfoot portion 154 and / or can extend in different directions or be otherwise oriented.

[0054] The underfoot portion 154 can be configured to be attached to at least one sole structure (such as the first sole structure 106 and / or the second sole structure 108). The underfoot portion 154 can be coupled to the first sole structure 106 and / or the second sole structure 108 using any suitable technique such as by using adhesives, by sewing, bonding, welding, etc. Thus, the underfoot portion 154 can be formed with a particular yarn and / or knit structure such that the underfoot portion 154 has suitable surface characteristics for adequately bonding to and supporting the sole structure. The first sole structure 106 and the second sole structure 108 can be located in the forefoot region 126 and the heel region 124 of the underfoot portion 154, respectively. These respective positions can be advantageous because the forefoot region 126 and the heel region 124 are typically the main contact areas with the ground when the footwear item is in normal use.

[0055] As shown, the underfoot portion 154 can include an exposed area 172 where the knit component 104 faces the ground and is not covered by the sole structure. Advantageously, the exposed area 172 can provide the required flexibility and / or other desired characteristics in the midfoot region 122 (or another location) such that the footwear item 100 can flex, stretch, etc. (e.g., during running). It is also contemplated that, in some cases, such as when the cleats 174 of at least one of the first sole structure 106 and the second sole structure 108 are embedded in the ground, the exposed area 172 of the underfoot portion 154 can be configured to directly contact the ground. Thus, the fused area 134 can be sufficiently strong, durable, protective, or otherwise configured to serve as the bottom terminal surface of the footwear item at least at one location of the underfoot portion 154.

[0056] Figure 8FIG. is a bottom view illustration showing a second embodiment of a footwear article 200 in accordance with the present disclosure. As shown, the footwear article 200 may include a sole portion 254 having a base element 276. The outer sole segment 252 and the inner sole segment 250 of the sole portion 254 may be formed of a knitted component as described above and may be secured to the first edge 278 and the second edge 280 of the base element, respectively. In some embodiments, the outer sole segment 252 and / or the inner sole segment 250 may continue to extend adjacent to the base element 276 (e.g., as viewed from Figure 8 the perspective of being covered by the base element 276), and the outer sole segment 252 and the inner sole segment 250 may meet to form a seam (or not meet). The base element 276 may be formed of any suitable material, such as a plastic material, a rubber material, a metal, a carbon fiber or other composite material, a textile material (such as a knitted material), or any other suitable material or combination of materials. Advantageously, the base element 276 may facilitate a secure, durable, and otherwise adequate fixation between the two sole segments of the sole portion 254, between the sole portion 254 and at least one of the first sole structure 206 and the second sole structure 208 (or another sole structure), and / or between any other fixed elements. The base element 276 may additionally or alternatively provide cushioning and protection to the plantar aspect of the wearer's foot. In some embodiments, the base element 276 may be integral with the sole structure (e.g., integrally formed), but this is not required. The base element 276 may be secured to the knitted component 204 during a lasting step or in another step.

[0057] Figure 9 Four embodiments of yarns that may be used to form a knitted component in accordance with the present disclosure are shown. Figure 9 The yarns depicted in may be included as any of the yarns described above (e.g., the first yarn 144, the second yarn 146, and / or the third yarn 148 described above), and / or may be included as another yarn.

[0058] The first yarn type 302 may include a generally circular cross-section. The first yarn type 302 may be formed at least in part of a thermoplastic polymer material composition or another material. As shown, the first yarn type 302 may be generally formed of a single material or material composition and may not have a distinct core. Thus, if the first yarn type 302 is formed of a thermoplastic polymer material composition, the entire first yarn type 302 may melt or at least partially melt when heated to a medium to high temperature (e.g., a temperature within the range of 120 degrees Celsius to about 200 degrees Celsius).

[0059] The second yarn type 304 may also include a generally circular cross-section. The second yarn type 304 may be formed at least in part from a thermoplastic polymer material composition or another material. As shown, the second yarn type 304 may include two different materials or compositions, where one material forms the core 306 and the second material forms the sheath 308. Thus, if the second yarn type 304 has a sheath 308 formed from a thermoplastic polymer material composition and a core formed from a different material (e.g., a material having a higher melting point and / or decomposition point), the sheath may melt or at least partially melt when heated to a medium to high temperature (e.g., a temperature within the range of 120 degrees Celsius to about 200 degrees Celsius), but the core 306 may remain stable. Advantageously, the material of the sheath 308 may form a fusion zone as described above, while the core 306 ensures that the yarn maintains its desired orientation, structure, and other properties during and after the thermal processing steps.

[0060] The third yarn type 310 may be similar to the first yarn type, but may have a trilobal cross-section. Advantageously, a yarn having a trilobal cross-section may be used alone or in combination with other yarns of other cross-sections to form a knitted component having a desired water resistance. As Figure 9 shown, the spaces or cavities located between the yarns may be minimized by the unique cross-sectional shape of the convex corners of the trilobal cross-section, which may prevent and / or limit the flow of water or other fluids from one side of the associated knitted component to the other side. The advantages of the trilobal shape may be enhanced when the third yarn type 310 is at least partially melted and cooled to form a fusion zone as described above.

[0061] Like the second yarn type 304, the fourth yarn type 312 (which has a trilobal cross-section) may include a core 314 having a material different from the sheath 316. Thus, if the fourth yarn type 312 has a sheath 316 formed from a thermoplastic polymer material composition and a core 314 formed from a different material (e.g., a material having a higher melting point and / or decomposition point), the sheath 316 may melt or at least partially melt when heated to a medium to high temperature (e.g., a temperature within the range of 120 degrees Celsius to about 200 degrees Celsius), but the core 314 may remain stable. Advantageously, the material of the sheath 316 may form a fusion zone as described above, while the core 314 ensures that the yarn maintains its desired orientation, structure, and other properties during and after the thermal processing steps.

[0062] According to the present disclosure, all of the structures and methods disclosed and claimed herein can be made and executed without undue experimentation. Although the present disclosure may be embodied in many different forms, specific aspects of the present disclosure are described in detail herein. The present disclosure is an example of the principles of the disclosure and is not intended to limit the present disclosure to the specific aspects illustrated. Further, unless expressly stated to the contrary, the use of the term "a" is intended to include "at least one" or "one or more." For example, "a yarn" is intended to include "at least one yarn" or "one or more yarns."

[0063] Any range given in absolute terms or in approximate terms is intended to cover both, and any definition used herein is intended to be illustrative and not limiting. Although the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Further, all ranges disclosed herein should be understood to encompass any and all sub-ranges subsumed therein (including all fractional and integral values).

[0064] In addition, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. Accordingly, it is intended that such changes and modifications be covered by the appended claims.

[0065] The present invention also relates to the following items:

[0066] 1. A knitted component, comprising:

[0067] An upper portion and a sole portion for forming corresponding upper and sole portions of a footwear item;

[0068] A first yarn, wherein the first yarn at least partially forms the upper portion and at least partially forms the sole portion; and

[0069] A second yarn, wherein the second yarn at least partially forms the upper portion and at least partially forms the sole portion,

[0070] wherein the first yarn comprises a first material composition, the first material composition including a first melting point,

[0071] wherein the second yarn comprises a second material composition, the second material composition including a second melting point, and

[0072] Wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0073] 2. The knitted component according to item 1, wherein the first melting point is about 195 degrees Celsius or lower, and wherein the second melting point is about 140 degrees Celsius or lower.

[0074] 3. The knitted component according to item 1, further comprising a third yarn having a third material composition, wherein the third material composition includes a third temperature equal to the lower of the melting point and the decomposition point of the third material composition, and wherein the third temperature is higher than the first melting point.

[0075] 4. The knitted component according to item 1, wherein the sole portion is formed by a first lower foot segment extending from a first side of the upper foot portion and a second lower foot segment extending from a second side of the upper foot portion.

[0076] 5. The knitted component according to item 4, wherein a first end of the first lower foot segment is fixed to a second end of the second lower foot segment at a sole seam.

[0077] 6. The knitted component according to item 1, wherein the knitted component includes an exposed area on the sole portion.

[0078] 7. The knitted component according to item 1, wherein the exposed area is positioned between a first sole structure and a second sole structure fixed to the sole portion of the knitted component, wherein the first sole structure is positioned on a front shoe area of the sole portion, and wherein the second sole structure is positioned on a heel area of the sole portion.

[0079] 8. The knitted component according to item 7, wherein the first sole structure is positioned at a front shoe area of the knitted component, and the second sole structure is positioned at a heel area of the sole portion.

[0080] 9. The knitted component according to item 7, wherein the first sole structure and the second sole structure are separated by at least a portion of the exposed area on a mid - shoe area of the sole portion.

[0081] 10. A knitted component, comprising:

[0082] An upper foot portion;

[0083] A first lower foot segment extending from a first side of the upper foot portion, the first lower foot segment having a first end; and

[0084] The second lower foot segment, which extends from a second side of the upper foot portion and has a second end, wherein the first end is configured to be secured to the second end such that the first lower foot segment and the second lower foot segment form the underfoot portion of the footwear item.

[0085] At least one of the first lower foot segment and the second lower foot segment is formed from both a first material composition and a second material composition, wherein the first material composition and the second material composition have different melting points.

[0086] 11. The knitted component according to item 10, wherein the first material composition is contained in a first yarn, wherein the second material composition is contained in a second yarn, and wherein the first yarn and the second yarn are looped around each other to form at least a part of the knitted component.

[0087] 12. The knitted component according to item 11, wherein the first material composition includes a first melting point, wherein the second material composition includes a second melting point, and wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0088] 13. The knitted component according to item 12, wherein the first melting point is about 195 degrees Celsius or lower, and wherein the second melting point is about 140 degrees Celsius or lower.

[0089] 14. The knitted component according to item 12, further comprising a third yarn having a third material composition, wherein the third material composition includes a third temperature equal to at least one of the melting point or the decomposition point of the third material composition, and wherein the third temperature is higher than the first melting point.

[0090] 15. The knitted component according to item 14, wherein the third temperature is at least 50 degrees Celsius higher than the first melting point.

[0091] 16. The knitted component according to item 14, wherein the third material composition is substantially formed from polyester.

[0092] 17. The knitted component according to item 10,

[0093] wherein the knitted component has a first zone and a second zone,

[0094] wherein a first ratio of the amount of the first material composition to the amount of the second material composition per surface area is included in the first zone,

[0095] wherein a second ratio of the amount of the first material composition to the amount of the second material composition per surface area is included in the second zone,

[0096] Wherein, the first ratio is greater than the second ratio.

[0097] 18. A method, comprising:

[0098] Forming a knitted component for a footwear item, the knitted component comprising:

[0099] An upper portion and a sole portion;

[0100] A first yarn, wherein the first yarn at least partially forms the upper portion and at least partially forms the sole portion; and

[0101] A second yarn, wherein the second yarn at least partially forms the upper portion and at least partially forms the sole portion,

[0102] Wherein the first yarn comprises a first material composition, the first material composition including a first melting point,

[0103] Wherein the second yarn comprises a second material composition, the second material composition including a second melting point, and

[0104] Wherein the first melting point is at least 20 degrees Celsius higher than the second melting point.

[0105] 19. The method according to item 18, wherein the first melting point is about 195 degrees Celsius or lower, and wherein the second melting point is about 140 degrees Celsius or lower.

[0106] 20. The method according to item 18, wherein the knitted component further comprises a third yarn having a third material composition, wherein the third material composition includes a third temperature equal to the lower of the melting point and the decomposition point of the third material composition, and wherein the third temperature is higher than the first melting point.

Claims

1. A knitted component for a footwear item, the knitted component comprising: An upper portion, which includes: A fusion zone, the upper portion of the knitted component being configured to form the upper portion of the footwear item, the fusion zone having at least a first region including more than one first row alternating with more than one second row, each row of the more than one first rows including a first yarn having a first thermoplastic polymer material composition, and each row of the more than one second rows including a second yarn having a second thermoplastic polymer material composition, wherein the first thermoplastic polymer material composition has a first melting temperature, and wherein the second thermoplastic polymer material composition has a second melting temperature that is at least 20 degrees Celsius greater than the first melting temperature; and A tongue portion, which includes: A non-fusion zone, the tongue portion of the knitted component being configured to form the tongue of the footwear item, the non-fusion zone including a third yarn having a third material composition, the third material composition having a third temperature greater than the first melting temperature and the second melting temperature, the third temperature being the melting temperature or decomposition temperature of the third material composition.

2. The knitted component according to claim 1, wherein the first melting temperature is 140 degrees Celsius or lower, wherein the second melting temperature is 195 degrees Celsius or lower, and wherein the third temperature is 200 degrees Celsius or higher.

3. The knitted component according to claim 1, further comprising a sole portion configured to form the sole portion of the footwear item, the sole portion of the knitted component being knitted integrally with the upper portion of the knitted component.

4. The knitted component according to claim 1, wherein the upper portion of the knitted component has a double-sided plain knit structure having an outer surface and an inner surface, wherein the fusion zone has the first yarn and the second yarn on the outer surface, and wherein the inner surface includes a non-fusion zone.

5. The knitted component according to claim 4, wherein the non-fusion zone of the inner surface includes the third yarn.

6. The knitted component according to claim 1, wherein the fusion zone of the upper portion further includes: A second region including the first yarn and the second yarn, wherein the density of the first thermoplastic polymer material composition and the density of the second thermoplastic polymer material composition are both less in the second region than in the first region.

7. The knitted component according to claim 6, wherein the second region includes the third yarn, and wherein the third temperature is 200 degrees Celsius or higher.

8. The knitted component according to claim 1, wherein one or more of the first yarn and the second yarn include a core / sheath configuration.

9. A footwear item, comprising: A knitted component, the knitted component including a fusion zone forming at least a part of the upper portion of the footwear item, the fusion zone having a first region and a second region; The first region includes a first yarn having a first thermoplastic polymer material composition and a second yarn having a second thermoplastic polymer material composition; The second region includes the first yarn and the second yarn, wherein the density of the first thermoplastic polymer material composition and the density of the second thermoplastic polymer material composition are both less in the second region than in the first region; The first thermoplastic polymer material composition has a first melting temperature, and the second thermoplastic polymer material composition has a second melting temperature that is at least 20 degrees Celsius greater than the first melting temperature; Wherein the knitted component includes a non-fused region forming a tongue of the footwear item, the non-fused region including a third yarn having a third material composition, the third material composition having a third temperature greater than the first melting temperature and the second melting temperature, the third temperature being the melting temperature or decomposition temperature of the third material composition.

10. The footwear item according to claim 9, further comprising an underfoot portion, the fused region forming at least a part of the underfoot portion.

11. The footwear item according to claim 10, wherein the fused region forming at least a part of the underfoot portion has a greater thickness relative to other parts of the knitted component.

12. The footwear item according to claim 11, further comprising a first sole structure and a base element having a first edge, the base element being fixed to the underfoot portion at the first edge.

13. The footwear item according to claim 9, wherein a first ratio of the fused thermoplastic polymer material composition to the non-fused thermoplastic polymer material composition in the first region is at least 90:10, and wherein a second ratio of the fused thermoplastic polymer material composition to the non-fused thermoplastic polymer material composition in the second region is 50:

50.

14. The footwear item according to claim 9, wherein the upper portion has a double-sided plain knit structure having an outer surface and an inner surface, wherein the fused region having the first yarn and the second yarn is located on the outer surface, and wherein the inner surface includes a non-fused region.

15. The footwear item according to claim 9, wherein the second region further includes the third yarn.

16. The footwear item according to claim 9, wherein the non-fused region further forms a throat region of the footwear item, and wherein the fused region further forms at least an outer side portion adjacent to the throat region and at least an inner side portion adjacent to the throat region of the footwear item, and a ratio of the number of courses of the throat region to the number of courses of the inner side portion or the outer side portion is 0.8:1 or less.

17. The footwear item according to claim 9, wherein the first region includes more than one first course alternating with more than one second course, each course of the more than one first course including the first yarn, and each course of the more than one second course including the second yarn.

18. An article of footwear comprising: A knitted component, the knitted component comprising: A fused zone forming at least a portion of the upper portion of the article of footwear, the fused zone having a first region and a second region, The first region includes more than one first row alternating with more than one second row, each row of the more than one first rows includes a first yarn having a first thermoplastic polymer material composition, and each row of the more than one second rows includes a second yarn having a second thermoplastic polymer material composition; and The second region includes the first yarn, the second yarn, and a third yarn having a third material composition, the first thermoplastic polymer material composition has a first melting temperature, the second thermoplastic polymer material composition has a second melting temperature that is at least 20 degrees Celsius greater than the first melting temperature, and the third material composition has a third temperature, the third temperature being the melting temperature or decomposition temperature of the third material composition; and A non-fused zone forming the throat of the article of footwear, the non-fused zone includes the third yarn, the third temperature being greater than the first melting temperature and the second melting temperature.

19. The article of footwear according to claim 18, wherein the density of the first thermoplastic polymer material composition and the density of the second thermoplastic polymer material composition are both less in the second region than in the first region.

20. The article of footwear according to claim 18, wherein the third temperature is 200 degrees Celsius or higher.

21. A yarn, the yarn comprising a core and a sheath; Among them, A first material forms the core, and a second material forms the sheath, the second material being different from the first material; And Wherein, the first material is a material having a higher melting point and / or decomposition point, and the second material is a thermoplastic polymer material composition.

22. The yarn according to claim 21, wherein, When heated to a medium-high temperature, the sheath melts or at least partially melts, but the core remains stable.

23. The yarn according to claim 21, wherein, The yarn includes a generally circular cross-section.

24. A knitted component, the knitted component comprising: A first zone; A second zone; And A third zone; Wherein, the first zone is located between the second zone and the third zone; and Wherein, the first zone has a first number of rows per unit length, the second zone has a second number of rows per unit length, and the third zone has a third number of rows per unit length.

25. The knitted part according to claim 24, wherein, The first number of rows per unit length is less than the second number of rows per unit length and the third number of rows per unit length, such that the first zone of the knitted component includes a tendency to bend.

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