Knitted component with buffer structure

Abstract

Aspects herein relate to knitted components having cushioning structures, window openings, and / or tensile elements, and articles of footwear incorporating the knitted components. In some aspects, a cushioning structure is positioned on an interior surface of the upper to protect a foot of a wearer. The cushioning structure may be formed from a single-sided plain weave construction, which curls the cushioning structure, thereby enhancing cushioning performance of the cushioning structure. A window opening may be formed in the upper (e.g., using an activatable yarn) to provide a visual indication of the cushioning structure and / or to act as an anchor point for the tensile element, which may provide a structure for the lacing system.

Description

TECHNICAL FIELD

[0001] Aspects herein relate to knitted components having a cushioning structure (e.g., for forming an upper of an article of footwear or an article of apparel) and a tensioning system for an article of footwear. BACKGROUND

[0002] Various articles of footwear, including footwear, are formed from fabric, which is often formed by interlacing or looping (e.g., knitting) one or more yarns. In particular, uppers for articles of footwear can be formed from knitted fabric. In some cases, an interior surface (e.g., a lateral surface or a medial surface) of an upper can rub against a wearer’s foot during wear, causing discomfort. BRIEF DESCRIPTION OF DRAWINGS

[0003] Examples of aspects herein are described in detail below with reference to the attached drawing figures, wherein:

[0004] Figure 1 illustrates a first side of a knitted component according to aspects herein;

[0005] Figure 2 illustrates a second side of a knitted component according to aspects herein;

[0006] Figure 3 illustrates a cross-sectional view of a knitted component according to aspects herein;

[0007] Figure 4 illustrates a method of forming a cushioning structure according to aspects herein;

[0008] Figure 5A illustrates an illustrative knitted component having a window region according to aspects herein;

[0009] Figure 5B illustrates an illustrative knitted component having a window opening according to aspects herein; Figure 5A

[0010] Figure 6 illustrates a method of forming a window opening in a knitted component according to aspects herein;

[0011] Figure 7 illustrates an external view of an article of footwear according to aspects herein;

[0012] Figure 8 illustrates a side of a knitted component that can be incorporated to form an interior of an article of footwear according to aspects herein;

[0013] Figure 9 illustrates an external view of an article of footwear according to aspects herein; and

[0014] Figure 10 ​FIG. 1 illustrates a side view of a knitted component that can be incorporated to form an interior of an article of footwear according to aspects herein. DETAILED DESCRIPTION

[0015] Various articles of manufacture, including footwear or apparel, are formed from fabrics that are typically formed by interlacing or interlooping (e.g., knitting) one or more yarns. In particular, uppers for articles of footwear can be formed from knitted fabrics. In some instances, interior surfaces (e.g., lateral or medial surfaces) of the upper can rub against a wearer’s foot during wear, causing discomfort. Some articles of footwear include structures (e.g., insoles or pads) intended to protect the wearer’s foot. However, such structures are typically added to articles of footwear via post-processing steps that increase manufacturing time and complexity, and are often formed from materials that negatively impact the recyclability of the article. Additionally, structures on interior surfaces of the upper are typically not visible from the exterior, thereby reducing the likelihood that a potential wearer will readily see the cushioning and support provided by the footwear. Similar issues can arise with articles of apparel.

[0016] At a high level, aspects herein relate to knitted components, knitted uppers, and articles of footwear that include one or more integral knitted cushioning structures. The cushioning structures can include yarns that are knitted into a single jersey construction, which can cause the cushioning structures to curl and form a tubular shape, thereby enhancing the cushioning performance of the cushioning structures. The cushioning structures can be at least partially formed from a marl yarn to increase comfort. In aspects, multiple cushioning structures extend parallel to one another. For example, the cushioning structures can be knitted to the interior of the lateral and / or medial sides of a knitted upper.

[0017] Additional aspects of the present disclosure relate to knitted components, knitted uppers, and articles of footwear that include window openings. The window openings can be formed in the same region of the knitted component or knitted upper as the cushioning structures, such that the cushioning structures are at least partially visible through the window openings, e.g., providing a visual indication of the cushioning structures to an observer. The window openings can also function as guides or anchor points for tensioning elements. In embodiments, the tensioning elements pass through the window openings and form loops superior to the window openings. For example, these loops can function as guides for laces of the article of footwear. In one example, by activating (e.g., heating) the releasable yarns, the edges of the window region are caused to separate from one another, thereby forming the window openings integrally with the knitted component or upper.

[0018] As used herein, the term "article of footwear" generally includes an upper and a sole structure. The upper is secured to the sole structure and forms a void within the article of footwear for comfortably and securely receiving a foot. As used herein, the term "upper" refers to the footwear component that, in addition to the sole structure, extends over the instep area and toe area of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot to form a void for receiving the foot of the wearer. Illustrative, non-limiting examples of uppers can include uppers incorporated into basketball shoes, cycling shoes, cross-training shoes, global football (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking shoes, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. Further, in other aspects, uppers can also be incorporated into non-athletic shoes, such as dress shoes, loafers, and sandals. Accordingly, the concepts disclosed with respect to the article of footwear apply to various footwear types.

[0019] As used herein, the term "exterior" means the surface of the upper or article of footwear that faces the external environment. In some aspects, the exterior surface can mean the outermost surface of the upper or article of footwear. As used herein, the term "interior" means the surface of the upper or article of footwear that faces the void for receiving the foot of the wearer. In some aspects, the interior surface can mean the innermost surface of the upper or article of footwear.

[0020] The terms "knit component" or "knit upper" refer to a fabric article formed of at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of interlooping loops that define courses and wales. As used herein, the term "course" refers to a primary horizontal row of knit loops produced by adjacent needles during the same knitting cycle (in an upright fabric as a knit). Courses can include one or more stitch types, such as knit stitches, tuck stitches, float stitches, purl stitches, miss stitches, rib stitches, and the like, which are known in the knitting arts. As used herein, the term "knit stitch" refers to a basic stitch type in which the yarn loop is pulled from the back of the fabric to the front by a previous stitch, the yarn is cleared from the needle, and can be referred to herein as a "knit loop." As used herein, the term "wale" refers to a primary vertical column of interlooping or intermeshing knit loops, typically produced by the same needle in successive (but not necessarily all) courses or knitting cycles. The knit components described herein can include weft-knit components or warp-knit components.

[0021] As used herein, the term "integrated knit" can mean that the knit fabric has yarn from one or more courses of knit loops in one area intermeshing with one or more courses of knit loops in another area. The intermeshing can be by simple knit stitches, tuck stitches, tuck stitches, float stitches, or miss stitches, among others. In this manner, the areas that are integrated knit together have a seamless transition.

[0022] Additionally, various measurements are provided herein. Unless otherwise indicated, all measurements provided herein are made at the knitted component, upper, and / or article of footwear at standard ambient temperature and pressure (298.15 K and 100 kPa) and in a resting (unstretched) state. Unless otherwise indicated, the terms“about” or“substantially” with reference to a measurement means within ±10% of the indicated value.

[0023] Figure 1 A knitted component 100 is illustrated. The knitted component 100 includes a first surface 120 forming a first side 103 of a body portion 104 of the knitted component 100. In embodiments where the knitted component 100 is incorporated into an article, the first surface 120 can correspond to an interior surface. The knitted component 100 includes cushioning structures 114 positioned on the first surface 120 such that the cushioning structures 114 are located on the body portion 104 of the knitted component 100. Each of the cushioning structures 114 extends away from the first surface 120 of the body portion 104 of the knitted component 100 and is at least partially compressible or extensible. Thus, each of the cushioning structures 114 can have a height 142 extending from the first surface 120 of the body portion 104 to a protruding end 144 of the cushioning structure 114. The cushioning structures 114 can have the same height 142, or the height 142 can vary between different cushioning structures 114. For example, in some embodiments, the height 142 can gradually increase or decrease from one cushioning structure 114 to an adjacent cushioning structure 114. That is, a first cushioning structure can have a first height, a second cushioning structure can have a second height, and the height of a cushioning structure located between the first and second cushioning structures can gradually change (i.e., increase or decrease) from the first height to the second height. Additionally, in some aspects, each of the cushioning structures 114 can have a uniform height 142, or the height 142 can vary within a single cushioning structure 114. The height 142 of the cushioning structures 114 at least partially contributes to providing cushioning to an article incorporating the knitted component 110.

[0024] In some embodiments, the cushioning structures 114 are formed from a knit construction. Further, the cushioning structures 114 can be integrally knit with the knit component 100. In some aspects, each cushioning structure 114 includes an elongate structure that includes one or more courses of stitches of yarn. In some embodiments, the cushioning structures 114 are at least partially formed from a spun yarn. Spun yarn is generally formed from two core yarns sandwiched with a staple yarn and twisted together, and fabric produced from spun yarn has a relatively large pile and soft hand. Thus, forming the cushioning structures 114 at least partially from spun yarn can create additional loft or cushioning to protect the wearer’s foot from abrasion or impact while simultaneously enhancing the comfort of an article (e.g., an article of footwear) into which the knit component 100 is incorporated.

[0025] The cushioning structures 114 can additionally (or alternatively) be at least partially formed from a yarn that includes recycled leather, which can be referred to herein as a leather scrap yarn (“SLY”). In some aspects, the recycled leather yarn includes a combination of leather scrap and polyethylene terephthalate (PET), which can be in the form of recycled PET. In one example, the recycled leather yarn is formed from about 50% leather scrap and about 50% PET (e.g., by weight). In other embodiments, the recycled leather yarn is formed from about 25% leather scrap and about 75% PET; about 35% leather scrap and about 65% PET; or about 70% leather scrap and about 30% PET. Other ratios of leather scrap and PET (or another material, including another renewable material) are also contemplated. The leather scrap and PET can be mixed together prior to being carded and spun into the recycled leather yarn. The leather scrap can impart a soft hand to the recycled leather yarn. Further, the recycled leather yarn is sustainable in that it can be formed from recycled materials (i.e., leather scrap, and in some aspects, recycled PET). The sustainability of the recycled leather yarn is further enhanced by its loft, which can allow portions of the knit component 100, such as the cushioning structures 114, to be formed with significantly less material (e.g., per unit area or unit volume) compared to traditional yarns. Further, forming the cushioning structures 114 from a combination of spun yarn and recycled leather yarn (e.g., at least one ply of spun yarn and at least one ply of recycled leather yarn) can enhance any of the foregoing benefits. For example, one or more of the cushioning structures 114 can be formed from one end of a spun yarn and one end of a recycled leather yarn.

[0026] Each of the cushioning structures 114 can have a length extending from a first end 116 to a second end 118. In some embodiments, one or more of the cushioning structures 114 extend in the course direction from the first end 116 to the second end 118. Further, in some aspects, the cushioning structures 114 extend from the first end 116 to the second end 118 parallel to the course direction of the body portion 104. At least some of the cushioning structures 114 can extend parallel (or substantially parallel) to one another. Any adjacent cushioning structures 114 can, for example, contact one another at one or more points along the entire length of one or more of the cushioning structures. For example, at least some of the surfaces of the cushioning structures 114 extending between the first end 116 and the second end 118 can abut a portion of a corresponding surface on an adjacent cushioning structure 114. The length of the cushioning structures 114 can vary between the first end 116 and the second end 118, for example, based on the length, width, or height of the knitted component 100 in the area or zone in which the cushioning structure is positioned.

[0027] Figure 2 The second side 105 of the knitted component 100 is depicted, showing that the knitted component 100 includes a second surface 102 of the body portion 104 opposite the first surface 120. In embodiments in which the knitted component 100 is incorporated into an article, the first surface 102 can correspond to an exterior surface of the article. Figure 1

[0028] In some embodiments, the knitted component 100 includes one or more window openings 112. The window openings 112 extend through the first surface 102 and the second surface of the body portion 104. At least some of the window openings 112 are positioned to view the cushioning structures 114 from the second side 105 of the knitted component 100. In other words, at least some of the window openings 112 are positioned in alignment with at least a portion of the cushioning structures 114 such that at least a portion of the cushioning structures 114 on the first side 103 of the knitted component 110 are visible through the window openings 112 when the knitted component 110 is viewed from the second side 105. The window openings 112 can also facilitate breathability, which can be particularly important when thicker yarns, such as a pile, form an interior of an article having the knitted component 100.

[0029] ​Any of the window openings 112 can be positioned in alignment with one another (e.g., horizontally or vertically) such that the window openings 112 can form a pattern of rows and / or columns within the knit component 100. Further, such an arrangement of window openings 112 can be used to form groupings of window openings 112 (e.g., a row of window openings 112 positioned at the same height) that expose a cushioning structure 114. Thus, if the cushioning structure 114 extends horizontally, for example, a first window opening 112a can reveal a first portion of the cushioning structure 114, and a second window opening 112b (e.g., positioned at the same height as the first window opening) can reveal a second portion of the same cushioning structure 114. In the same or other embodiments, different window openings 112 can reveal different cushioning structures 114. That is, a first cushioning structure 114a (see Figure 1 ) can be visible through a first window opening 112a, and a second (e.g., different) cushioning structure 114b (see Figure 1 ) can be visible through a different window opening 112c.

[0030] The window openings 112 can be formed integrally within the knit structure of the knit component 110 and formed through at least one post-processing step. For example, in some embodiments, the window openings 112 are formed by knitting loops of a fusible yarn (which can also be referred to herein as an activatable yarn) and heating the fusible yarn to cause the melting of such yarn to create the openings. Reference is made to Figures 5A to 6 for further details describing this process. In other embodiments, the window openings 112 are integral knit openings formed without post-processing, such as by omitting stitches in the knit component 100. In other embodiments, the window openings 112 can be punched or otherwise cut into the knit component 100 after a knit or other post-processing step.

[0031] Each window opening 112 is defined between at least a first edge 146 of the body portion 104 and a second edge 148 of the body portion 104. In some aspects, at least one of the first edge 146 and the second edge 148 includes a fusible material. For example, at least one of the first edge 146 and the second edge 148 can be formed from one or more courses of loops of yarn that include a fusible material, and when the fusible yarn is heated and melted, the fusible material can help to trim the respective edge, thereby preventing fraying at the window opening 112. In some aspects, both the first edge 146 and the second edge 148 can include a fusible material.

[0032] One or more of the cushioning structures 114 can be positioned on the knit component 100 such that one or more of the window openings 112 are obscured from view when the knit component 100 is viewed from the first side 103. For example, in Figure 1In particular aspects, the cushioning structures 126 are shown in a partially uncoiled state such that the window openings 128 are visible; when the cushioning structures 126 are in a coiled state (e.g., as depicted for the cushioning structures 122 and 124), the window openings 128 will be obscured by the cushioning structures 126 when the first side 103 of the knitted component 100 is viewed. In the coiled state, the cushioning structures 122 and 124 gradually bend as they extend upward from the first surface 120 and then gradually bend and extend downward back to the first surface 120. Each of the cushioning structures 122 and 124 can form a tubular structure. The curvature of the cushioning structures 122 and 124 and the tubular structures formed thereby enable the cushioning structures 122 and 124 to effectively distribute forces applied to their surfaces, mitigating impact and pressure points, which can enhance cushioning.

[0033] Turning now to Figure 3 , Figure 3 FIG. 13 illustrates a cross-sectional view of the knitted component 100, including the first surface 120, the second surface 102, and the cushioning structures 114 (including the uncoiled cushioning structure 126). Each of the cushioning structures 114 includes a first edge 130 that is secured to the first surface 120 of the body portion 104. The first edge 130 of the cushioning structure can be secured to the first surface 120 by any suitable means, such as knitting, stitching, welding, bonding, or adhesive. In exemplary aspects, the first edge 130 of the cushioning structures 114 is joined to the first surface 120 by knitting the cushioning structures 114 integrally with the body portion 104. Integrally knitting the edges of the cushioning structures with the first surface 120 can improve the recyclability of the resulting knitted component 100 (e.g., by reducing or eliminating the need for adhesives or other contaminants), while reducing manufacturing time. Further, each of the cushioning structures 114 includes a second edge 132. In aspects, the second edge 132 is not secured to the first surface 120 of the body portion 104. Further, the second edge 132 can not be secured to any portion of the knitted component 100. Alternatively, the second edge 132 can be secured to the first surface 120 of the body portion 104 in any of the ways disclosed for the first edge 130.

[0034] In aspects, the cushioning structures 114 each include a strip or flap formed from one or more courses of stitches. Further, the cushioning structures 114 can include or be formed from single jersey construction, e.g., formed on one bed of a knitting machine. For example, each cushioning structure 114 can include a single jersey knit portion extending between a first edge 130 and a second edge 132 opposite the first edge 130. Thus, in such aspects, the cushioning structures 114 can each curl into a convex shape when viewed from the side associated with the first surface 120. The curling of the material forming the cushioning structures 114 can also form a tubular shape. Thus, the second edge 132 can contact the first surface 120 (e.g., as shown in Figure 3 regarding the cushioning structures 134). In some aspects, at least some of the cushioning structures 114 curl such that the second edge 132 rests on an inner surface 152 of the tubular cushioning structure 114, while an opposite outer surface 154 of the cushioning structure 114 contacts the first surface 120 of the body portion 104. However, the tubular shape formed by the cushioning structures 114 is not necessarily always a closed tube. For example, in some embodiments, the cushioning structures 114 have a relatively small degree of curvature (i.e., a lesser degree of curling) such that the second edge 132 of the cushioning structure contacts the first surface 120 of the body portion 104, but is spaced apart from the second edge 130 of the cushioning structure 114. In another aspect, the cushioning structures 114 can have an even lesser degree of curvature such that the second edge 132 does not contact the first surface 120 of the body portion or the inner surface 152 of the cushioning structure 114 (e.g., the second edge 132 can be spaced apart from the second surface 120).

[0035] Further, the curled cushioning structures (e.g., 134) can be positioned adjacent to one or more window openings (e.g., 136) such that the window openings are hidden by the cushioning structures from a perspective facing the second surface 120 and / or the cushioning structures are visible through the window openings from a perspective facing the first surface 102. In some aspects, at least some of the cushioning structures are positioned relative to the window openings such that portions of two adjacent cushioning structures (e.g., the cushioning structures 135 and 137) are visible through a single window opening (e.g., the window opening 139). In some embodiments, there can be a gap between the adjacent cushioning structures 135 and 137 that is visible through the window opening 139. In other instances, the outer surfaces of the adjacent cushioning structures 135 and 137 abut each other such that the window opening 139 is completely covered by the cushioning structures 135 and 137.

[0036] Turning now to Figure 4 , a method 400 of forming a cushioning structure, such as the cushioning structures 114 from Figures 1 to 3 is provided. The steps provided in the method 400 are merely illustrative, and the method 400 can include additional steps not illustrated.

[0037] At step 410, the main body portion of the knitted component (e.g., Figures 1 to 3 At least a portion of the main body 104 is knitted on a knitting machine. Step 410 can be performed on an automatic knitting machine and therefore can be performed and / or controlled using a control unit having a processor or computer communicatively coupled to or integrated into the knitting machine. In an example context, the knitting machine for knitting a knitted part is a V-bed flat knitting machine with two needle beds (a front needle bed and a back needle bed) angled relative to each other to form a V-shape. The front and back needle beds may each include a plurality of independent needles extending across a common plane. A carriage can move a yarn feeder along the front and back needle beds to supply yarn to the needles. While a flat V-bed knitting machine has been described herein, it should be understood that this is an example and other knitting machines can be used to form a knitted part or a portion thereof.

[0038] Furthermore, step 410 may include knitting the main body portion of the knitted component on both needle beds of the knitting machine. In some instances, step 410 includes knitting the first portion into a double-sided plain knit construction. The main body portion of the knitted component may have previously been described... Figures 1 to 3 Any property of the knitted part 100 described in any of the above. For example, the knitted part can be an article or a component thereof, such as an upper for footwear articles or a garment article.

[0039] At step 420, at least some of the loops in the main body of the knitted part are transferred from the first needle bed of the knitting machine to the second needle bed. In this way, after step 420, at least a section of loops forming the main body is on the second needle bed, leaving a section of needles on the first needle bed idle. In some respects, loops are transferred from the front bed to the back bed of the V-bed knitting machine. In other respects, loops are transferred from the back bed to the front bed.

[0040] At step 430, loops of the cushioning structure are knitted on the first needle bed (e.g., the front needle bed of a V-bed knitting machine). At step 430, these loops are formed on the needle that has been released after the loops of the main body portion of the knitting component have been transferred at step 420. The loops of the cushioning structure can be knitted such that the cushioning structure includes, regarding Figures 1 to 3 The cushioning structure 114 describes any of the properties described. The cushioning structure can be knitted using a yarn different from any yarn used to form the body portion of the knitted part. For example, the cushioning structure can be formed from at least one strand of chenille yarn, at least one strand of recycled leather yarn, or both. The cushioning structure is formed on a single bed of a knitting machine. Furthermore, the cushioning structure can have a single-sided plain weave knit, such that the cushioning structure includes a crimping property capable of forming a tubular shape.

[0041] Step 430 can also include knitting a plurality of cushioning structures (which can include any of the properties of the cushioning structures previously described) integral with the knitted component. The cushioning structures can be positioned such that they extend parallel (or substantially parallel) to one another and / or in contact with one another.

[0042] After forming the cushioning structures at step 430, method 400 can include tucking the loops forming the tubular structure, thereby releasing the needles on the first needle bed and continuing to knit the remaining portion of the body portion. Continuing to knit the body portion can be similar to step 410, such that both needle beds can be used. Additionally, the loops previously transferred from the first needle bed to the second needle bed at step 420 can be transferred back to the first needle bed prior to knitting the remaining portion of the body portion.

[0043] In some aspects, method 400 can also include one or more steps of creating a window opening extending through the body portion, as further disclosed herein. Additionally, aspects of method 400 can include steps for forming the knitted component into an article, such as an article of footwear, which can include forming the knitted component into an upper and securing the upper to a sole structure, as further described herein.

[0044] Turning now to Figures 5A to 5B , an illustration of a window zone 500 and a window opening 520 is provided. At a high level, window zone 500 represents a window opening 520 prior to activation of a course of activatable yarn 506. Additionally, window opening 520 represents one embodiment of any of the window openings described herein, including the window openings previously described with respect to Figures 1 to 3 (e.g., window openings 112, 128, or 136).

[0045] In aspects, the window region 500 includes a first course of loops 502, a second course of loops 504, a third course of loops 506, a fourth course of loops 508, and a fifth course of loops 510 prior to activation. The first course of loops 502 includes a first yarn. The first yarn can be a type of yarn that at least partially forms a body portion of a knitted component (e.g., the body portion 104 of the knitted component 100). In one example, the first yarn forming the first course of loops 502 is a polyester yarn. The second course of loops 504 is directly interlooped with the first course of loops 502, and in some aspects, the third course of loops 506. The second course of loops 504 is at least partially formed from a second yarn that is capable of melting (e.g., is meltable) when heat is applied, as described further herein. In some aspects, the second course of loops 504 is formed from the first yarn and a second yarn that is activatable and plated with the first yarn. As used herein, an activatable yarn is defined as having a physical change in response to a stimulus. For example, a yarn that softens or melts in response to heat would be considered an activatable yarn, such as a meltable yarn; however, a yarn that is not meltable but has a physical change in response to a stimulus is also considered an activatable yarn.

[0046] The second yarn includes a material that melts, dissolves, shrinks, degrades, disintegrates, or otherwise changes a physical property in response to a treatment, exposure, treatment, and / or stimulus (e.g., heat). Any portion of the second yarn can have one or more thermoplastic polymers or other materials (collectively referred to as “thermoplastic materials”), and in some embodiments, the entirety or substantially the entirety of the second yarn can be formed from thermoplastic materials. In one non-limiting example, the second yarn can be a meltable yarn including a polyester base with a polyblock amide resin, a linear mass density of about 150 denier, a tenacity of about 2.5 cN / dtex, an elongation of about 80%, a twists per meter (TPM) of about 300 Z, and / or a melting temperature in the range of 55°C to 65°C based on atmospheric pressure at sea level. One suitable yarn is “Grilon® KE60,” commercially available from EMS-Chemie AG of Switzerland.

[0047] Illustrative, non-limiting examples of thermoplastic materials that may include a second yarn include polyurethane, polyamide, polyolefin, nylon, and resins. Thermoplastic polymers at least partially melt when heated to a certain temperature and revert to a solid state when cooled below a certain temperature. More specifically, when subjected to temperatures at or above their melting point, thermoplastic polymers transition from a solid state to a softened or liquid state, and then, upon sufficient cooling below their melting point, the thermoplastic polymer transitions from a softened or liquid state to a solid state. Furthermore, when heated to a temperature (approaching or exceeding the melting temperature), yarns made of thermoplastic materials may dissolve or shrink significantly in physical dimensions, creating voids where the yarn was previously present. Thus, thermoplastic materials can melt, mold, cool, harden, dissolve, and / or shrink in various heating and / or cooling cycles.

[0048] Coating the first yarn with the second yarn in the second loop 504 can provide several benefits. For example, it can provide advantages when the knitted part is exposed to stimuli (e.g., heat) and openings 522 are formed (as shown in the image). Figure 5B (As shown) After that, the second coil row 504 can form the edge of the opening 522 (e.g., Figure 2 and Figure 3 (either the first edge 146 or the second edge 148 in the first yarn). The second yarn in the second coil row 504 can melt during an activation (e.g., heating) process, thereby fusing it at least partially to the first yarn in the second coil row 504. Fusing material from the second yarn to the first yarn in the second coil row 504 strengthens the edges corresponding to the openings 522 of the second coil row 504, which limits fraying or abrasion.

[0049] In various respects, the third coil row 506 includes the second yarn. In some respects, the third coil row 506 does not include any yarn other than an activatable or fusible yarn (such as the second yarn). The third coil row 506 may be directly nested with the second coil row 504 and / or the fourth coil row 508. For example, when the window area 500 is exposed to a stimulus (e.g., heat), the second yarn in the third coil row 506 melts, creating a gap (e.g., window opening 522) between the second coil row 504 and the fourth coil row 508.

[0050] In an embodiment, the fourth coil row 508 may be directly nested with the third coil row 506 and the fifth coil row 510. The fourth coil row 508 may include a first yarn (or a different yarn with a melting point greater than that of the second yarn), which may be coated with the second yarn. In some instances, the fourth coil row 508 has the same yarn as the second coil row 504. Because the fourth coil row 508 forms the edge of the opening 522 after activation, coating the first yarn with the second yarn in the fourth coil row 508 can give the knitted part the same benefits as previously described with reference to the second coil row 504 (e.g., reinforcing the edges and preventing fraying or abrasion). The fifth coil row 510 may be nested with the fourth coil row 508. The fifth coil row may include the first yarn.

[0051] Additionally, in some aspects, the fourth coil row 508 (and in some aspects, the fifth coil row 510) is formed by a single-sided plain weave construction. In these aspects, after the third coil row 506 is melted, due to the single-sided plain weave construction, the fourth coil row 508 and / or the fifth coil row 510 can be coiled away from the second coil row 504 (i.e., in...). Figure 5B (In the example shown, downwards). Imparting curling characteristics to the fourth coil row 508 and / or the fifth coil row 510 can further define, expand, and / or provide stability to the opening 522. In some aspects, the second coil row 504 (and, in some aspects, the first coil row 502) is also formed of a single-sided plain weave construction, such that the second coil row 504 can curl away from the fourth coil row 508 after the third coil row 506 has melted. Other coil rows formed before the fifth coil row 510 and after the first coil row 502 can have a double-sided plain weave construction.

[0052] It should be understood that window area 500 can have more than Figure 5A and Figure 5B The illustration shows variations in the number of coil rows. For example, there may be two or more adjacent coil rows similar to a second coil row 504 formed by the first and second yarns, and similarly, there may be two or more adjacent coil rows similar to a fourth coil row 504 formed by the first and second yarns. Additionally, there may be two or more adjacent coil rows similar to a third coil row 506, wherein a section of the adjacent coils is formed solely by the second yarn, which will be melted to form the window opening 522.

[0053] Now go to Figure 6 A method 600 is provided for forming window openings (such as window opening 520) in a fabric. The steps provided in method 600 are illustrative only, and method 600 may include additional steps not shown. Method 600 can be used to formFigure 5A and Figure 5B the window region 500 and the window opening 522 of FIGS. 1-3, and any variations disclosed.

[0054] At step 610, a first course is knitted with a first yarn (e.g., the first yarn previously described with reference to Figures 5A to 5B The first course can be plated with a second yarn, e.g., similar to the second yarn of the second course 504 previously described with reference to Figures 5A to 5B For example, the second yarn is an activatable yarn and / or includes a lower melting temperature than the first yarn.

[0055] At step 620, a second course is knitted with the second yarn. Similar to the third course 506 described with reference to Figure 5A At least a portion of the second course is knitted with only the second yarn. The second course can intermesh with the first course.

[0056] At step 630, a third course is knitted with the first yarn plated with the second yarn, similar to the fourth course 508 described with reference to Figures 5A to 5B The third course can intermesh with the second course. The third course can be formed, for example, in a single jersey construction on a first bed, while the stitches of the second course are positioned on a second bed. In some aspects, at least the second course is formed on both beds of the knitting machine, and prior to step 630, the stitches of the second course are transferred from the first bed to the second bed to transition to a single jersey construction.

[0057] At step 640, the fabric is exposed to a stimulus to activate the second yarn and form a window opening similar to the window opening 522 of FIGS. 1-3. Figure 5B For example, the stimulus can include heat or an aqueous solution. As the second yarn melts and / or dissipates, a window opening is formed between the first course and the third course (e.g., in a portion of the fabric where the second course previously existed). Once the melted portion re-hardens after a cooling process and detaches from the opening through physical agitation (e.g., stretching of the knitted component), any remaining portion of the second yarn that did not dissipate can be removed from the window opening. Further, the second yarn can at least partially fuse to the first yarn (e.g., in the first course and the third course), thereby reinforcing the edges of the window opening. In aspects where the third course is knitted in a single jersey construction, the third course can be crimped, further defining the window opening.

[0058] Turning now to Figure 7A lateral side perspective view of an article of footwear 700 is provided. The article of footwear 700 includes a sole structure 702 and an upper 704. The upper 704 is coupled to and extends from the sole structure 702, and forms a foot-receiving void (which can also be referred to as a foot-receiving chamber) between the sole structure 702 and the upper 704. The area where the sole structure 702 of the article of footwear 700 meets or joins with the upper 704 is referred to as a biteline 706. The upper 704 can be joined to the sole structure 702 in a fixed manner using any suitable technique, such as by using adhesives, by stitching, and so on. It is contemplated that the upper 704 can extend partially or completely around a wearer’s foot, can extend under a wearer’s foot, and / or can be integral with a sole structure, including but not limited to the sole structure 702. A sockliner, which can be referred to as a strobel, can or can not be used. The sockliner can include a variety of materials, including textiles, leather, foam, and / or other types of materials.

[0059] The article of footwear 700 (and / or components thereof) can be divided into one or more zones (which can also be referred to as “regions” or “sections”). For example, in the anterior-to-posterior direction, the article of footwear 700 (and / or components thereof) can be divided into (and / or include) a forefoot region 708, a midfoot region 710, and a heel region 712. The forefoot region 708 of the article of footwear 700 can correspond with the anterior portion of the foot including the toes and the joints connecting the metatarsal bones with the phalanges. The midfoot region 710 of the article of footwear 700 can correspond with the arch area of the foot. The heel region 712 of the article of footwear 700 can correspond with the posterior portion of the foot including the calcaneus bone. In the medial-to-lateral direction, the article of footwear 700 (and / or components thereof) can be divided into a lateral side 714 and a medial side 716, each of which extends through the forefoot region 708, the midfoot region 710, and the heel region 712. More specifically, the lateral side 714 corresponds with the exterior area of the foot (i.e., the side facing away from the other foot) when the article of footwear 700 is worn, while the medial side 716 corresponds with the interior area of the foot (i.e., the side facing toward the other foot) when the article of footwear 700 is worn. These regions 708, 710, and 712, as well as sides 714 and 716, are not intended to demarcate precise areas of the article of footwear 700, but rather to represent general areas of the article of footwear 700 to aid in the understanding of various descriptions provided herein.

[0060] When the article of footwear 700 is worn, the sole structure 702 generally extends between the foot and the ground. The sole structure 702 can include a number of components, such as an outsole, a midsole, and an insole or sockliner. Various materials, such as rubber, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), thermoplastic elastomer (e.g., polyether block amide), and the like, can be used to form the sole structure 702. The sole structure 702 can also include various other elements, such as heel counters and toe caps. The sole structure 702 can include various other features, such as cleats, as understood by one of skilld in the art, to dampen forces, enhance stability, and / or provide traction.

[0061] The upper 704 defines a void within the article of footwear 700 for receiving and securing a foot relative to the sole structure 702. Access to the foot-receiving void is provided through an ankle opening 725 located in at least the heel region 712. The upper 704 includes an instep region 726 disposed in the midfoot region 710 between the ankle opening 725 and the forefoot region 708. The instep region 726 can be configured to cover a top side of the wearer's foot and thus form a portion of the top side (or supramalleolar region) of the upper 704 between the lateral side 714 and the medial side 716.

[0062] The article of footwear 700 depicted in the figures is intended for use with a right foot, however, it should be understood that the discussion below can also apply to a mirror image of the article of footwear 700 intended for use with a left foot. While an article of footwear is shown, it should be understood that the present disclosure also contemplates other articles of wear, including but not limited to apparel (e.g., a shirt, a sweatshirt, pants, shorts, gloves, glasses, socks, hats, caps, jackets, undergarments, or other apparel) and receptacles (e.g., a backpack, a bag, or other receptacle). Accordingly, various aspects disclosed herein can be incorporated into such other articles.

[0063] In example aspects, at least a portion of the upper 704 can be formed from at least one knitted component 720. The knitted component 720 forming the upper 704 can be an example embodiment of the knitted component 100, and thus, unless otherwise noted, the knitted component 720 can be formed by any process or can include any properties previously described with reference to the knitted component 100. In some aspects, the entire or substantially the entire upper 704 is formed from a knitted component.

[0064] The knit component 720 can incorporate various types of yarns that impart different properties to individual areas of the upper 704. That is, one area of the knit component 720 can be formed from a first type of yarn that imparts a first set of properties, while another area of the knit component 720 can be formed from a second type of yarn that imparts a second set of properties. In this way, properties can be varied throughout the upper 704 by selecting particular yarns for different areas of the knit component 720. The properties that a particular type of yarn will impart to an area of the knit component 720 depend in part on the materials that form the various filaments and fibers within the yarn. For example, cotton provides a soft hand, a natural aesthetic, and biodegradability. Spandex and stretch polyester fibers each provide significant stretch and recovery, while stretch polyester fibers also provide recyclability. Rayon provides a high luster and moisture absorption. Wool provides a high moisture absorption in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with a relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability.

[0065] In addition to the materials, other aspects of the yarns selected for the knit component 720 can influence the properties of the upper 704. For example, the yarns that form the knit component 720 can be monofilament yarns or multifilament yarns. Thus, unless otherwise noted, as used herein, the term “yarn” does not require multiple filaments or fibers. The yarns can also include individual filaments each formed from a different material. Additionally, the yarns can include filaments each formed from two or more different materials, such as bicomponent yarns having filaments with a sheath-core configuration or two halves formed from different materials. Different degrees of twist and crimp, as well as different gauges, can also influence the properties of the upper 704. Thus, the materials that form the yarns and other aspects of the yarns can be selected to impart various properties to individual areas of the upper 704. Additional properties of the yarns used in various aspects of the present disclosure are described in further detail below.

[0066] The knit component 720 can be formed as a single, monolithic, one-piece element during a knitting process, such as weft knitting or any other suitable knitting process. Additional elements, such as an underfoot portion and / or a heel element, can be formed integrally with the upper 704 as a single, one-piece structure. Alternatively, one or more such additional elements can be formed separately from the upper 704 and then attached, secured, or otherwise assembled as needed. Forming the upper 704 with the knit component 720 can provide the upper 704 with advantageous characteristics, including but not limited to a particular degree of elasticity, breathability, flexibility, strength, moisture absorption, weight, abrasion resistance, and / or combinations thereof. Moreover, forming the upper 704 with the knit component 720, which is integrally knit, can form various features and structures of the upper 704 without the need for significant additional manufacturing steps or processes, thereby improving production efficiency.

[0067] Exemplary embodiments of the knitted component 720 for the upper 704 include one or more cushioning structures (e.g., 730) extending from the body portion 707 on the first side 703. In some aspects, the body portion 707 of the knitted component 720 generally includes a continuous knitted structure extending from within the forefoot region 708, through the midfoot region 710, and to the heel region 712. Reference is made to Figures 1 to 3 The cushioning structures of the knitted component 100 further describe example aspects of the cushioning structures 730 on the upper 704. The cushioning structures 730 can be positioned at least partially in the midfoot region 710 of the upper 704 on at least one of the medial side 716 of the upper 704 and the lateral side 714 of the upper 704. In exemplary embodiments, the first side 703 of the knitted component 720 corresponds to the interior side or interior surface of the upper 704, such that the cushioning structures 730 extend inwardly into the foot-receiving void of the upper 704. In such embodiments, the cushioning structures 730 can, for example, cushion the wearer’s foot and / or protect the foot from abrasion, thereby enhancing comfort. The cushioning structures 730 can also be located in and / or extend into other portions of the article of footwear 700, such as the forefoot region 708 and the heel region 712.

[0068] Further, in some embodiments, the cushioning structures 730 each have an elongate body extending between a first end 717 and a second end 718 (e.g., as shown in Figure 8 At least some of the cushioning structures 730 can extend longitudinally between the first end 717 and the second end 718 in a heel-to-toe direction. In the same or other embodiments, at least some of the cushioning structures 730 extend laterally between the first end 717 and the second end 718 (i.e., in a direction parallel to the direction of the bite line 706 to the throat line 726). In some aspects, the lengths of the cushioning structures 730 vary and can vary in length across different zones, regions, or portions of the knitted component 720. For example, as shown in Figure 8 the first cushioning structure 722 in the forefoot region 708 (e.g., an upper portion of the forefoot region 708) is shorter than the second cushioning structure 724 (e.g., lower than the first cushioning structure 722). The respective heights of the cushioning structures can also vary. For example, a first cushioning structure can have a first height, a second cushioning structure can have a second height, and the height of a cushioning structure positioned between the first and second cushioning structures can gradually change from the first height to the second height. When the cushioning structures 730 are oriented in a heel-to-toe direction (as shown in Figure 8 the height of the cushioning structures 730 can increase from bottom to top or from top to bottom. As an example, a first cushioning structure positioned proximate the midfoot region can have a greater height than a second cushioning structure positioned proximate the bite line.

[0069] Additionally, some embodiments of the knit component 720 include window openings 740 that extend through the body portion 707. Examples aspects of the window openings of the knit component 100 of Figures 1 to 3 and the window openings 520 of Figure 5B of the knit component 720 are further described. In some instances, the window openings 740 are located in at least the midfoot region 710 on the lateral side 714 and / or the medial side 716. In some aspects, the window openings 740 are located in any of the regions 708, 710, and 712 on the lateral side 714 and / or the medial side 716.

[0070] The window openings 740 are visible at least on the second side 705 of the knit component 720, which can correspond to an exterior surface of the upper 704. Additionally, portions of the cushioning structures 730 are visible through the window openings 740, such that the cushioning structures 730 on the interior of the upper 704 can be visible when the upper 704 is viewed from the exterior of the upper 704.

[0071] In some embodiments, the body portion 707 includes a first color, and one or more of the cushioning structures 730 include a second color that is different from the first color. Thus, when the article of footwear 700 (or other article in which the knit component is incorporated) is viewed from the second side 705, the cushioning structures 730 can appear visually distinct from the surrounding areas of the body portion 707, thereby providing a visual indication to an observer that the cushioning structures 730 are present. Additionally, the first side 703 of the body portion 707 and the cushioning structures 730 can both include the first color, which can provide visual uniformity, for example, on the interior of the article of footwear 700. Furthermore, in some embodiments, the perimeters of one or more of the window openings 740 include the first color, and the second side 705 of the body portion 707 includes a second color that is different from the first color. This can be achieved, for example, by varying the color of one or more of the knit courses 504, 506, and 508 (as shown in Figure 5A ) relative to the surrounding knit structure.

[0072] Turning now to Figure 9An illustration of an article of footwear 900 is provided. For example, the article of footwear 900 can include any of the features of the article of footwear 700. The article of footwear 900 includes a tensioning system 902 that is generally configured to hold the article of footwear 900 fast to and taut against a wearer's foot when the article of footwear 900 is worn. The tensioning system 902 includes a lace 904 and a stretch element 906. The article of footwear 900 also includes a knitted component 920 and a window opening 908, which can correspond to and can include any of the properties of any of the window openings previously discussed in the present disclosure. At a high level, the stretch element 906 can serve as an anchor point for the lace 904. In some examples, the stretch element 906 is interlaced through the window opening 908, which can hold the stretch element 906 in place (at least partially).

[0073] The stretch element 906 can include one or more strands of yarn that includes any material suitable for forming the tensioning system 802, such as nylon, polyester, or cotton. The stretch element 906 can be one of various types of cables, such as a braided cable that has a diameter that is greater than the diameter of any single strand of yarn that forms the knitted component 920. The stretch element 906 can also have a higher tenacity and / or tensile strength than any of the yarn strands that form the knitted component 820. Further, the stretch element 906 can include polyester, nylon, or other high tenacity materials. In some examples, the stretch element 906 also includes elastomeric fibers.

[0074] The stretch element 906 can be attached to the article of footwear 900 at any suitable location, such as a portion of the upper 930 that is proximate to the bite line of the article of footwear 900 and / or a portion of the sole 940 of the article of footwear 900. In one example, the stretch element is attached to an interior surface of the upper proximate to the bite line (e.g., a surface similar to the first surface 120). Any suitable method can be used to attach the stretch element 906, such as stitching, knitting, welding, or bonding. In aspects, the stretch element 906 extends upward (e.g., vertically or diagonally) from the area proximate to the bite line and / or the sole 940 into a region of the upper 930 where the window opening 908 is present. The stretch element 906 can be interlaced through the window opening 908 such that the stretch element 906 is at least partially exposed on an exterior surface 910 of a body portion of the upper 930, which can correspond to the body portion 104 of the knitted component 100. For example, the stretch element 906 can include one or more covered portions that are held inside the knitted component 920 and one or more exposed portions that are outside the knitted component 920.

[0075] The stretch element 906 can also form a loop 912. The loop 912 can be positioned in or proximate to the throat area 926 of the upper 930. The loop 912 can be positioned at an uppermost portion or apex location of the stretch element 906, above at least one of the window openings 908 through which the stretch element 906 extends. The lace 904 can extend through the loop 912. Thus, in such embodiments, the stretch element 906 can act as an anchor point for the lace 904, imparting structure and / or stability to the tensioning system 902 and helping to distribute any tension applied to the lace 904 throughout the article of footwear 900. In some instances, the article of footwear 900 includes a tongue 928 positioned in the throat area 926. The tensioning system 902 can help keep the tongue 928 and the remainder of the upper 930 secured to the wearer’s foot. It should also be appreciated that even if the upper does not include a tongue 928, the tensioning system 902 can be beneficial in creating a desired amount of tension or fit around the wearer’s foot.

[0076] Furthermore, as Figure 9 shown, the article of footwear 900 can include a plurality of stretch elements that each include any of the properties of the stretch element 906. The lace 904 can extend through a plurality of loops formed by the respective stretch elements. For example, the lace 904 can extend through a first loop formed by a first stretch element on a first side (e.g., lateral side) of the article of footwear 900, extend across the article of footwear 900 (e.g., through the throat area 926), extend through a second loop formed by a second stretch element on a second side (e.g., medial side) of the article of footwear 900, extend back across the article of footwear 900 (e.g., through the throat area 926), extend through a third loop formed by a third stretch element on the first side of the article of footwear 900, and so on. In other embodiments, there is a first stretch element on a first side (e.g., lateral side) that forms a plurality of lace loops, and there is a second stretch element on a second side (e.g., medial side) that forms a plurality of lace loops. In another embodiment, there can be a single continuous stretch element that forms a plurality of lace loops on both the medial and lateral sides of the upper 930.

[0077] Turning now to Figure 10 , a diagram of the interior 1000 of the article of footwear 900 is provided. More specifically, Figure 10 an example manner in which the stretch element 906 can extend from an interior surface 1006 of the article of footwear 900 to the exterior of the article of footwear 900 is shown.

[0078] When the article of footwear 900 includes one or more cushioning structures 1002 (which can correspond to any of the cushioning structures described herein), the tensile elements 906 can extend through apertures 1004 in the cushioning structures 1002. The apertures 1004 can be positioned proximate to (e.g., near) and / or can abut an interior surface 1006 of the body portion of the knitted component 920. In the same or other embodiments, the apertures 1004 can be formed in the body portion of the upper 930 (e.g., through the upper 930) or at the intersection between the cushioning structures 1002 and the body portion of the upper 930 (e.g., the apertures 1004 can be formed in both the cushioning structures 1002 and the body portion of the upper). The apertures 1004 can be formed using any suitable process, such as stamping, or can be integrally knitted with the cushioning structures and / or the upper. Although only one aperture 1004 is shown in Figure 10 it is understood that there can be multiple apertures, each of which is present at a location where the tensile elements 906 will cross over the cushioning structures on the interior side of the upper.

[0079] The tensile elements 906 can extend through the apertures 1004 from the points at which the tensile elements 906 are attached to the upper and / or sole (as discussed with reference to Figure 9 ) and to the exterior of the article of footwear 900. The apertures 1004 allow the tensile elements 906 to be at least partially positioned on the interior side of the knitted component 920 when extending between the body portion and the cushioning structures 1002 (rather than extending on top of the cushioning structures 1002), which will reduce the effectiveness of the cushioning structures 1002 and result in the tensile elements 906 contacting the wearer’s foot. In this manner, due to the positioning of the apertures 1004 and / or the natural tendency of the cushioning structures 1002 to curl, one or more of the cushioning structures 1002 can form a barrier between the wearer’s foot and at least a portion of the tensile elements 906, thereby protecting the foot from abrasion.

[0080] While the present disclosure utilizes the articles of footwear 700 and 900 as example articles for incorporating the knitted component 100, it is understood that aspects of the present disclosure can be applicable to other articles, such as articles of apparel. Accordingly, embodiments can include articles of apparel, such as shirts, jerseys, pants, shorts, gloves, eyewear, socks, hats, caps, jackets, and undergarments.

[0081] The following clauses represent example aspects of the concepts contemplated herein. Any one of the following clauses can be combined in a multiple dependent manner to rely on one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly rely on a prior clause) can be combined while remaining within the scope of the aspects contemplated herein. The following clauses are examples and are not limiting.

[0082] Clause 1. An article of footwear comprising a knit upper, the knit upper comprising: a body portion having an interior surface and an exterior surface opposite the interior surface; a first cushioning structure integrally knit with the interior surface of the body portion; and a window opening in the body portion, the window opening extending through the exterior surface and the interior surface, wherein at least a portion of the first cushioning structure is visible through the window opening when the knit upper is viewed from an exterior of the knit upper.

[0083] Clause 2. The article of footwear according to Clause 1, wherein the first cushioning structure comprises a chenille yarn.

[0084] Clause 3. The article of footwear according to any one of Clauses 1-2, wherein the first cushioning structure further comprises a yarn comprising a regenerated leather.

[0085] Clause 4. The article of footwear according to any one of Clauses 1-3, wherein a first edge of the first cushioning structure is integrally knit with the body portion, and wherein a second edge of the first cushioning structure opposite the first edge is not integrally knit with the body portion.

[0086] Clause 5. The article of footwear according to Clause 4, wherein the first cushioning structure comprises a single face plain weave construction, and wherein the first cushioning structure comprises a crimping property such that the second edge contacts at least a portion of the interior surface of the body portion.

[0087] Clause 6. The article of footwear according to any one of Clauses 4-5, wherein the second edge is not secured to the body portion.

[0088] Clause 7. The article of footwear according to any one of Clauses 1-6, wherein the first cushioning structure forms a tubular shape.

[0089] Clause 8. The article of footwear according to any one of Clauses 1-7, wherein the first cushioning structure is positioned in a midfoot region of the upper on at least one of a medial side of the upper and a lateral side of the upper.

[0090] Clause 9. The article of footwear according to any one of Clauses 1-8, wherein the window opening comprises an edge comprising a fusible material.

[0091] Clause 10. The article of footwear according to any one of Clauses 1-9, wherein the knit upper further comprises a second cushioning structure integrally knit with the interior surface of the body portion.

[0092] Clause 11. The article of footwear according to any one of clauses 1-10, wherein the knitted upper further comprises a second window opening in the body portion, the second window opening extending through the exterior surface and the interior surface, wherein at least a second portion of the first cushioning structure is visible through the second window opening when the knitted upper is viewed from the exterior of the knitted upper.

[0093] Clause 12. The article of footwear according to any one of clauses 1-11, wherein each of the first cushioning structure and the second cushioning structure extend longitudinally in a heel-to-toe direction.

[0094] Clause 13. The article of footwear according to any one of clauses 1-12, wherein the second cushioning structure is positioned adjacent to and in contact with the first cushioning structure.

[0095] Clause 14. The article of footwear according to any one of clauses 1-13, wherein the article of footwear further comprises: a second window opening in the body portion of the knitted upper, the second window opening extending through the exterior surface and the interior surface; a stretch element interwoven through the window opening and the second window opening such that the stretch element is at least partially exposed on the exterior surface of the body portion, wherein the stretch element forms a loop over the window opening and the second window opening; and a lace coupled to the article of footwear and extending through the loop.

[0096] Clause 15. A knitted component comprising: a first surface; and a first cushioning structure formed from a single jersey construction, the first cushioning structure comprising: a first edge integrally knit with the first surface, and a second edge opposite the first edge, wherein the second edge is not integrally knit with the knitted component, and wherein the second edge contacts the first surface such that the first cushioning structure forms a tubular shape.

[0097] Clause 16. The knitted component according to clause 15, wherein the knitted component forms at least a portion of an upper of an article of footwear.

[0098] Clause 17. The knitted component according to any one of clauses 15-16, wherein the first surface at least partially forms an interior surface of a body portion of the upper.

[0099] Clause 18. A method of forming an upper for an article of footwear, the method comprising: knitting a main body portion of the upper with a first yarn, the main body portion including an exterior surface and an interior surface opposite the exterior surface; integrally knitting a first cushioning structure with the interior surface of the main body portion, wherein the first cushioning structure is formed from a single jersey construction; and knitting a window region within the main body portion, wherein the window region is positioned to overlap with a portion of the first cushioning structure that is not secured to the main body portion when the main body portion is removed from a knitting machine.

[0100] Clause 19. The method of clause 18, wherein knitting the window region comprises knitting a second yarn such that one or more courses of the second yarn connect a first course of the first yarn to a second course of the first yarn, the one or more courses of the second yarn connect the first course of the first yarn to the second course of the first yarn, wherein the second yarn is a fusible yarn.

[0101] Clause 20. The method of any one of clauses 18-19, wherein the method further comprises cladding the first course of the first yarn with the second yarn, and wherein the first yarn is not present in the one or more courses of the second yarn.

[0102] Clause 21. The method of any one of clauses 18-20, wherein the method further comprises exposing the second yarn to a stimulus in at least the window region such that a window opening is formed between the first course of the first yarn and the second course of the first yarn.

[0103] Clause 22. The method of any one of clauses 18-21, wherein the main body portion is knitted using needles on a first needle bed and needles on a second needle bed, and wherein knitting the first cushioning structure comprises: transferring a loop of the first yarn from the first needle bed to the second needle bed; forming a loop of a third yarn on the first needle bed; and integrally joining the loop of the third yarn with the loop of the first yarn.

[0104] Clause 23. The method of clause 22, wherein the third yarn is a sliver yarn.

[0105] Clause 24. The method of any one of clauses 18-23, wherein the method further comprises integrally knitting a second cushioning structure with the interior surface of the main body portion, wherein the second cushioning structure is formed from a single jersey construction, and wherein each of the first cushioning structure and the second cushioning structure are knitted to extend longitudinally in a heel-to-toe direction when the upper is incorporated into the article of footwear.

[0106] Clause 25. The article of footwear according to any one of clauses 1-14, the body portion having a first color, and the first cushioning structure having a second color different from the first color.

[0107] Clause 26. The article of footwear according to any one of clauses 1-14 and 25, the interior surface of the body portion having a first color, and the cushioning structure having the first color.

[0108] Clause 27. The article of footwear according to any one of clauses 1-14 and 25-26, wherein a perimeter of the window opening comprises a first color, and the exterior surface of the body portion comprises a second color different from the first color.

[0109] Clause 28. The knitted component according to any one of clauses 16-17, wherein the first cushioning structure is positioned in at least one of a medial portion of the upper, a lateral portion of the upper, and a heel portion of the upper.

[0110] Clause 29. An article of apparel comprising the knitted component according to clause 15.

[0111] Clause 30. The knitted component according to any one of clauses 15-17 and 28-29, further comprising: a second surface opposite the first surface; and a window opening extending through the first surface and the second surface in the knitted component, wherein at least a portion of the first cushioning structure is visible through the window opening when the knitted component is viewed from a side corresponding to the second surface of the knitted component.

[0112] Clause 31. An article of apparel comprising the knitted component according to clause 30.

[0113] Clause 32. A knitted component comprising: a first surface; a second surface opposite the first surface; a plurality of window openings each extending through the first surface and the second surface; and a cushioning structure positioned on and integrally knitted with the first surface, wherein the cushioning structure is visible through at least one of the plurality of window openings when viewed from a side of the knitted component corresponding to the second surface.

[0114] Clause 33. An article of footwear comprising an upper formed at least partially from the knitted component according to clause 32.

[0115] Clause 34. The article of footwear according to clause 33, wherein the cushioning structure extends from a heel region of the article of footwear to a toe region of the article of footwear.

[0116] Clause 35. The article of footwear according to Clause 33, wherein the cushioning structure is positioned in a toe region of the article of footwear and does not extend into a heel region of the article of footwear.

[0117] Clause 36. The article of footwear according to Clause 33, wherein the cushioning structure is positioned in a heel region of the article of footwear and does not extend into a toe region of the article of footwear.

[0118] Clause 37. The knitted component according to any one of Clauses 32 to 36, wherein the cushioning structure forms a tubular shape.

[0119] Clause 38. The knitted component according to any one of Clauses 32 to 37, wherein the cushioning structure is curved.

[0120] Clause 39. The knitted component according to any one of Clauses 32 to 38, wherein the cushioning structure is crimped such that, when viewed from a side corresponding to the first surface, the cushioning structure forms a convex shape.

[0121] Clause 40. An article of apparel comprising the knitted component according to any one of Clauses 32 to 39.

Claims

1. A footwear article comprising a knitted upper, said knitted upper comprising: The main body portion has an inner surface and an outer surface opposite to the inner surface; A first buffer structure is integrally knitted with the inner surface of the main body portion; and a window opening in the main body portion, the window opening extending through the outer surface and the inner surface, wherein at least a portion of the first cushioning structure is visible through the window opening when the knitted upper is viewed from the outside.

2. The footwear article according to claim 1, wherein the first edge of the first cushioning structure is integrally knitted with the main body portion, and wherein the second edge of the first cushioning structure opposite to the first edge is not integrally knitted with the main body portion.

3. The footwear article of claim 2, wherein the first cushioning structure comprises a single-sided plain weave construction, and wherein the first cushioning structure comprises a curling characteristic such that the second edge contacts at least a portion of the inner surface of the body portion.

4. The footwear article of claim 3, wherein the second edge is not fixed to the main body portion.

5. The footwear article according to claim 1, wherein the first cushioning structure is formed in a tubular shape.

6. The footwear article according to claim 1, wherein the first cushioning structure is positioned on at least one of the inner side and the outer side of the upper in the midfoot area of ​​the upper.

7. The footwear article according to claim 1, wherein the first cushioning structure is positioned on at least one of the inner side and the outer side of the upper in the midfoot area of ​​the upper.

8. The footwear article of claim 1, wherein the window opening includes an edge, the edge comprising a fusible material.

9. The footwear article according to claim 1, wherein the footwear article further comprises: A second window opening in the main body portion of the knitted shoe upper, the second window opening extending through the outer surface and the inner surface; A stretching element, the stretching element interlacing through the window opening and the second window opening, such that the stretching element is at least partially exposed on the outer surface of the body portion, wherein the stretching element forms a coil above the window opening and the second window opening; And shoelaces, which are attached to the footwear and extend through the coil.

10. A knitted component, comprising: First surface; The second surface opposite to the first surface; Multiple window openings, each of which extends through the first surface and the second surface; And a buffer structure positioned on the first surface and integrally knitted with the first surface, wherein the buffer structure is visible through at least one of the plurality of window openings when viewed from the side of the knitted part corresponding to the second surface of the knitted part.

11. A footwear article comprising an upper formed at least in part from a knitted component according to claim 10.

12. A garment article comprising the knitted component according to claim 10.

13. The knitted component of claim 10, wherein the cushioning structure is formed by a single-sided plain weave construction and further includes a first edge knitted integrally with the first surface and a second edge opposite to the first edge.

14. The knitted component of claim 13, wherein the second edge is not integrally knitted with the knitted component, and wherein the second edge contacts the first surface such that the first cushioning structure forms a tubular shape.

15. The knitted component of claim 10, wherein the cushioning structure is curled such that when viewed from the side corresponding to the first surface, the cushioning structure forms a convex shape.

16. A method for forming an upper for footwear articles, the method comprising: The main body portion of the shoe upper is knitted with a first yarn, the main body portion including an outer surface and an inner surface opposite to the outer surface; The first cushioning structure is knitted integrally with the inner surface of the main body portion, wherein the first cushioning structure is formed by a single-sided plain weave construction; and a window area is knitted within the main body portion, wherein the window area is positioned to overlap with a portion of the first cushioning structure that is not fixed to the main body portion when the main body portion is removed from the knitting machine.

17. The method of claim 16, wherein the body portion is knitted using needles on a first needle bed and needles on a second needle bed, and wherein knitting the first cushioning structure comprises: Transfer the loop of the first yarn from the first needle bed to the second needle bed; A loop of the third yarn is formed on the first needle bed; And to connect the coil of the third yarn to the coil of the first yarn as a whole.

18. The method of claim 16, wherein knitting the window area comprises knitting a second yarn such that one or more loop rows of the second yarn connect a first loop row of the first yarn to a second loop row of the first yarn, wherein the second yarn is a fusible yarn.

19. The method of claim 18, wherein the method further comprises coating the first row of loops of the first yarn with the second yarn, and wherein the first yarn is not present in the one or more rows of loops of the second yarn.

20. The method of claim 18, wherein the method further comprises exposing the second yarn to a stimulus in at least the window area such that a window opening is formed between the first row of coils of the first yarn and the second row of coils of the first yarn.

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