ARTICLE OF FOOTWEAR WITH A KNITTED NET LAYER

Abstract

Aspects herein are directed to, among other things, a knitted component for an article of footwear. The knitted component includes a knitted base layer secured to a knitted net layer. The knitted net layer may have a yarn defining cells with openings through which the knitted base layer is exposed. A thermoplastic polymer material, which may initially form yarn that forms the knitted net layer or the knitted base layer, may at least partially fuse the knitted base layer to the knitted net layer. In some aspects, the knitted component further includes one or more inlaid strands at least partially arranged between the knitted base and net layers. The inlaid strands may also include a thermoplastic polymer material that is at least partially melted during heating of the knitted component and, when cooled, fuses the inlaid strands to the knitted base layer and knitted net layer.

Description

BACKGROUND

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the footwear for comfortably and securely receiving a foot. Uppers may be formed by a variety of materials, including knitted textiles. When an athlete moves their foot within a knitted upper, a force may be exerted on the athlete's foot that pushes the foot partially off the sole structure. Performance and comfort may be improved by keeping the foot contained over the sole structure during movement. Various components (e.g., synthetic leather textiles, laminate film layers) may be added and secured (e.g., glued, stitched) to a knitted upper through post-knitting processes to keep the foot contained and/or increase durability of the upper. However, such components added through post-knitting processes may increase the weight of the upper, increase production time, reduce recyclability of the upper, and impact performance in unintentional and possibly undesirable ways.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1A illustrates a medial view of an example article of footwear in accordance with aspects herein;

FIG. 1B illustrates a lateral view of the example article of footwear of FIG. 1A, in accordance with aspects herein;

FIG. 2 illustrates a top view of a knitted component of the article of footwear of FIG. 1A, in accordance with aspects herein;

FIG. 3 illustrates a close-up view of a portion of the knitted component of FIG. 2, in accordance with aspects herein;

FIG. 4 illustrates a close-up of another knitted component, in accordance with aspects herein;

FIGS. 5A and 5B illustrate an example stitch notation diagram that may be used to form a portion of a knitted component, in accordance with aspects herein;

FIGS. 6A and 6B depict a portion of another knitted component, in accordance with aspects herein;

FIG. 7 depicts a schematic representation of some example knit courses within the portion of the knitted component of FIGS. 6A-6B, in accordance with aspects herein;

FIG. 8 depicts an exploded close-up view of a portion of another example knitted component, in accordance with aspects herein;

FIG. 9 depicts a partially exploded close-up view of a portion of another example knitted component, in accordance with aspects herein; and

FIG. 10 depicts a portion of another knitted component, in accordance with aspects herein.

DETAILED DESCRIPTION

In general, aspects herein are directed to an article of footwear having a knitted component and methods of manufacturing a knitted component for an article of footwear, where the knitted component includes a knitted base layer and knitted net layer secured to the knitted base layer. The knitted base layer and the knitted net layer can be secured together in a way that provides desired containment, e.g., without relying on components added through post-knitting processes. The aspects described herein may reduce the weight of an upper, reduce production time, and improve recyclability and sustainability of footwear manufacturing, among other benefits.

In aspects, a knitted net layer may be formed with yarns defining a plurality of cells (e.g., quadrilaterals) adjoined along one or more vertices. The yarns of the knitted net layer define the perimeter of each cell, while the center of the cell is open and exposes the knitted base layer. The knitted net layer may have a lower degree of stretch than the knitted base layer and may provide a lower degree of stretch (e.g., containment) to the knitted upper. Further, in aspects, one or more inlaid strands may be positioned between the knitted base layer and knitted net layer, e.g., providing further support and containment. In some aspects, there may be multiple inlaid strands extending across each cell of a knitted net layer.

The knitted net layer is secured to the knitted base layer. In some aspects, the knitted net layer is integrally knit with the knitted base layer. For example, yarn forming the knitted base layer may be interlooped with yarn forming the knitted net layer. In some aspects, a strand of yarn forming the knitted net layer is tucked with a loop of yarn forming the knitted base layer. Additionally or alternatively, the one or more strands of the knitted net layer may be at least partially fused to one or more strands of the knitted base layer. In some aspects, the knitted net layer is formed with yarn having a thermoplastic polymer material with a lower melting temperature than yarn forming the knitted base layer. After knitting, the yarn of the knitted net layer may be at least partially melted so that the thermoplastic polymer material of the knitted net layer may fuse with yarn of the knitted base layer. Fusing the knitted net layer to the knitted base layer may provide further containment and reduce or inhibit stretch.

Herein, an article of footwear generally includes a sole structure secured to an upper. The articles of footwear described herein can be a running shoe, a baseball shoe, a basketball shoe, a cycling shoe, an American football shoe, a tennis shoe, a global football shoe, a training shoe, a walking shoe, a hiking shoe, or the like. The concepts described herein may also be applied to other footwear types that are considered non-athletic such as dress shoes, loafers, sandals, and work boots. Herein, an article of footwear may be divided into different general regions. A forefoot region generally includes portions of the article of footwear that correspond to the toes and joints connecting the metatarsals with the phalanges. A midfoot region generally includes portions of the article of footwear corresponding with an arch area and an instep area of the foot. A heel region generally corresponds with rear portions of the foot including the calcaneus bone. The article of footwear described herein may include a lateral side which corresponds with an outside area of the foot (e.g., the surface that faces away from the other foot) and a medial side which corresponds with an inside area of the foot (e.g., the surface that faces toward the other foot). The different regions and sides described above are intended to represent general areas of footwear to aid in the following discussion and are not intended to demarcate precise areas. The different regions and sides may be applied to the article of footwear as a whole, to the knitted upper, and to the sole structure.

The term “outer-facing surface,” as used herein, is a surface of the knitted upper or article of footwear that faces the external environment. In some aspects, the outer-facing surface can refer to the outermost-facing surface of the knitted upper or article of footwear. The term “inner-facing surface,” as used herein, refers to a surface of the knitted upper or article of footwear that faces a void for receiving the wearer's foot. In some aspects, the inner-facing surface can be the innermost-facing surface of the knitted upper or article of footwear.

The term “knit,” as used herein, such as to describe the knitted component, refers to a textile piece that is formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops (also known as interlooping) that define courses and wales. The term “course,” as used herein, refers to a predominantly horizontal row of knit loops (in an upright textile as it is knit on the knitting machine) that is produced by adjacent needles during the same knitting cycle. The course may comprise one or more stitch types, such as a knit stitch, a missed stitch, a tuck stitch, a transfer stitch, a rib stitch, and the like, as these terms are known in the art of knitting. The term “course-wise direction” refers to a direction that is parallel to the knit courses of the textile piece. The term “wale,” as used herein, is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles. The term “wale-wise direction” refers to a direction that is parallel to the knit wales of the textile piece.

The term “integrally knit,” as used herein, refers to a knit textile having a yarn from one or more knit courses in a first area being interlooped with one or more knit courses of another area. The interlooping may be through a simple knit stitch, a tuck stitch, a held stitch, a float or miss stitch, and the like. In this way, areas that are integrally knit together have a seamless transition such that they seamlessly extend from one another. In some cases, the term is used to describe two layers covering the same area, where those two layers are interconnected through a common yarn forming at least part of a course on one layer and moving to form part of a course on the other layer, a yarn extending between and forming at least some of each of the two layers, and/or yarns from each layer being formed using overlapping sets of needles on a needle bed at the same time such that the yarns of each layer may be intertwined even if they do not interloop one another. In these cases, the two layers are integrally knit in that they are connected at one or more locations through the knitted process and not through stitches, adhesive, or other bonding.

The term “radially extending,” as used herein, refers to an orientation of a knit course that radiates out from a common portion of the knitted component. In aspects, a knit course may be radially extending if it extends between an outer perimeter of the knitted component and the common portion. In this manner, the courses may radiate inwards from the outer perimeter towards the common portion and do not, for example, extend continuously across the body of the knitted component from a lateral side edge to a medial side edge of the outer perimeter, e.g., generally parallel with each other. To state it differently, in aspects, radially extending knit courses may extend outward from a common portion, e.g., a throat area or collar area, generally at an angle with respect to each other, e.g., such that a distance between the radially extending courses increases outward from the common portion. The structures of the knitted component may be radially extending from the common portion when the knitted component is laid out in a flat configuration after knitting, but it is also contemplated that determining whether structures are radially extending may be based on the orientation of the structures towards the common portion after the knitted component is folded into the shape of an upper or a portion of an upper.

The term “common portion,” as used herein, refers to an area of the knitted component towards which multiple similar structures (e.g., multiple courses) extend. As such, courses may extend from an outer perimeter to a single common portion rather than extending from the outer perimeter towards the other side generally parallel to each other. The common portion is spaced apart from the outer perimeter and, in various aspects, may be relatively centrally located within the knitted component. In this way, the common portion may encompass and/or be directly adjacent to the longitudinal axis of the knitted component. In some examples disclosed herein, the common portion may include a throat area or a portion thereof.

As used herein, the term “throat area” refers to an area on a top (upward-facing) side of an upper generally extending between an ankle opening and a forefoot region. The throat area may include an opening formed between a lateral side and medial side of the upper when formed into the shape of the article of footwear, and in some aspects, the throat area may include a tongue extending across the opening in the throat area. In some aspects, the throat area does not have an opening but, rather, includes a continuous integrally knit area of a knit component extending between the medial and lateral sides, e.g., one that can be formed of elastic yarns, material, and/or other components that include a degree of stretchability.

As used herein, the term “perimeter” refers to an area forming the boundary of the object referred to. For example, a perimeter of a knitted component is the area that extends along the boundary of that structure. The “outer perimeter” may refer to portions of a perimeter of a knitted component that, once formed into an article of footwear, are secured to the sole structure or form a seam between two ends of the outer perimeter (such that they may at least partially extend under the foot of the wearer when the article of footwear is worn. In contrast, an “inner perimeter” may refer to portions of the perimeter of a knitted component that, once formed into an article of footwear, define openings, such as an opening in a throat area and/or the ankle opening. The perimeter (outer perimeter or inner perimeter) may refer to an edge of the knitted component or to a peripheral area adjacent to the edge.

Forming an article, such as an upper, using a knit construction may provide advantages including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. These characteristics may be accomplished by selecting a particular knit structure, by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, a thermoplastic material, a relatively elastic material such as elasticated yarns, and/or a combination thereof), by selecting yarns of a particular size (e.g., denier), and/or a combination thereof. Using a knit construction may also provide desirable aesthetic characteristics by incorporating yarns having different colors, textures, and/or other visual properties arranged in a particular pattern. The yarns themselves and/or the knit structure formed by one or more of the yarns may be varied at different locations such that a knitted upper may have different properties as described herein.

The yarns, in accordance with aspects herein, may include monofilament yarns and/or multifilament yarns formed from, for example, synthetic materials. In example aspects, yarns used to knit the knitted base layer (which are referred to herein as a first yarn or first yarns) may include high-melting polymer yarns (e.g., yarns that melt at about 175 degrees Celsius or higher) including polyamide yarns (commonly known as nylon), polyethylene terephthalate (PET) yarns (commonly known as polyester), recycled PET yarns, elastane yarns, and other high-melting synthetic yarns. In one example, the first yarn is a nylon yarn coated with a high-melting thermoplastic polyurethane material that melts at about 175 degrees Celsius. In other examples, the first yarn may include natural fibers with a higher decomposition temperature (e.g., above 200 degrees Celsius). In other example aspects, the first yarn may be entirely formed from a thermoplastic polymer material.

In example aspects, the yarns used to form the knitted net layer (referred to herein as a second yarn or second yarns) include yarn(s) with a lower melting temperature than the melting or decomposition temperature of the first yarn forming the knitted base layer. For example, the second yarn that forms the knitted net layer may include low-melting thermoplastic yarns (e.g., yarns that melt at about 170 degrees Celsius or less). The low-melting thermoplastic yarns comprise a synthetic polymeric material (i.e., a thermoplastic polymer material) formed from a polymer that melts at relatively low temperatures (e.g., a low-melting thermoplastic polymer material). The terms “high-melting” and “low-melting” as used herein are intended to be relative terms in that “low-melting” refers to materials with a lower melting temperature than the melting or decomposition temperature of the high-melting yarns and vice versa. In example aspects, the second yarn may include a low-melting thermoplastic elastomer, such as thermoplastic polyurethane (TPU) yarns, thermoplastic polyethylene (TPE) yarns, and other synthetic polymeric materials having a low melting point. In some examples, the second yarns include a thermoplastic elastomer that is either TPU or a styrene ethylene/butylene styrene (SEBS).

In some example aspects, the second yarn may comprise a core-sheath configuration in which the low-melting thermoplastic polymer material (e.g., TPU) surrounds a core of a high-melting material such as, for example, high-melting PET. In example aspects, the melting temperature of the sheath of the second yarn may be sufficiently lower than the melting temperature of the core of the second yarn such that the low-melting thermoplastic polymer material of the sheath may be at least partially, or in some aspects fully, melted without melting or adversely affecting (e.g., burning, charring, or singeing) characteristics of the high-melting core. Similarly, in some aspects, the melting temperature of the low-melting thermoplastic polymer material of the second yarn (whether in the form of a sheath on a core-sheath yarn or in another configuration) may be sufficiently lower than the melting temperature of the first yarn(s) forming the knitted base layer such that the low-melting thermoplastic polymer material of the second yarn may be at least partially, or in some aspects fully, melted without melting or adversely affecting (e.g., burning, charring, or singeing) the characteristics of the high-melting material of the first yarn(s). In some aspects, the melting temperature of the low-melting polymer of the second yarn(s) is no greater than 180 degrees Celsius and, in some aspects, at least 120 degrees Celsius. In one example, the melting temperature is between approximately 120 degrees Celsius and 170 degrees Celsius. Further, in an example, the melting temperature of the second yarn is 120 degrees Celsius. In another example, it is 160 degrees Celsius. Although this application uses the core-sheath configuration as one example configuration for the second yarn, it should be understood that the second yarn may have a different configuration, such as a side-by-side configuration or trilobular configuration, with each of a low-melting thermoplastic polymer material and a high-melting material, or the second yarn may be a multifilament yarn or monofilament yarn with only the low-melting thermoplastic polymer material.

These examples of the yarns of the knitted base layer and knitted net layer are only example configurations. It should be understood that these layers may be formed with other combinations of yarns, including but not limited to the other examples described further herein.

Unless indicated otherwise, all measurements provided herein are taken when the upper and/or article of footwear is at standard ambient temperature and pressure (298.15 K and 100 kPa) and is in a resting (non-tensioned) state. As used herein, the terms “substantially” and “about” mean within ±10% of an indicated value.

FIGS. 1A and 1B respectively schematically depict a medial view and a lateral view of an example article of footwear 100 having an upper 110 and a sole structure 112 secured to the upper 110. A biteline 115 represents where the upper 110 meets the sole structure 112. The article of footwear 100 is shown in the form of an athletic shoe, but other types of shoes (e.g., sandals, leisure shoes, and the like) are contemplated herein. The article of footwear 100 includes a forefoot region 114, midfoot region 116, a heel region 118, a medial side 120, and a lateral side 122. The article of footwear 100 includes an ankle collar 124 having an opening 125 for receiving a wearer's foot, a throat area 126, which may include a tongue and one or more fasteners, such as laces 128. Although not shown, aspects herein contemplate that the article of footwear 100 may include additional elements layered on top of the upper 110, including, for example, leather materials, synthetic leather materials, knitted or woven textiles, polymer skins, and the like. The additional elements may be positioned at discrete locations of the upper 110, including, for example, a toe area (e.g., a toe cap), the heel area (e.g., a heel counter), and the like.

In example aspects, the upper 110 includes a knitted component 130 that forms at least part of the upper 110. For example, the knitted component 130 may form at least part of the midfoot region 116 and at least part of the forefoot region 114 of the upper 110. The knitted component 130 may form all or substantially all of the upper 110 aside from additional pieces applied on top of or underneath the knitted component 130. In the example shown, the knitted component 130 forms the forefoot region 114, the midfoot region 116, and the heel region 118.

The knitted component 130 includes a knitted base layer 140 and a knitted net layer 150 that overlays at least part of the knitted base layer 140 such that the knitted base layer 140 and the knitted net layer 150 may be at least partially coextensive. The knitted component 130 may have a unitary knit construction and may be formed in a single knitting process. In other words, the knitted base layer 140 and the knitted net layer 150 may be integrated as a single piece during the knitting process. In other aspects, the knitted base layer 140 and the knitted net layer 150 may be separately formed (e.g., formed in separate knitting processes) and subsequently joined through stitching or bonding to form the knitted component 130. Additionally, examples of the knitted component 130 may be weft knit such that the knitted base layer 140 and/or the knitted net layer 150 may be formed on a weft-knitting machine, such as a flat v-bed knitting machine or a circular weft-knitting machine; in other aspects, the knitted component 130 may be warp-knitted.

The knitted base layer 140 may have a first side forming an inner-facing surface of the upper 110 (e.g., facing towards a foot-receiving void of the article of footwear 100) and a second side forming at least part of an outer-facing surface of the upper 110. The knitted base layer 140 has a first knit density, defined by a number of knitted stitches per square area. In some aspects, the knitted base layer 140 may be formed of courses having any one or more stitches. For example, at least a portion of the knitted base layer 140 may be knit with repeating knit stiches, and one or more tuck stitches may be inserted (e.g., every seven stitches, every five knit stitches, every three stitches, every other stitch) to create apertures within the knitted base layer 140, enhancing breathability, moisture permeability, and/or transparency of the knitted component 130.

The knitted net layer 150 has a second knit density that is less than the first knit density of the knitted base layer 140. In aspects, the knitted net layer 150 can include yarns that are knit through a repeating pattern of float stitches in between tuck stitches and/or knitted stitches. The yarn of the knitted net layer 150 can be knit so as to define a plurality of cells 156, such as polygon cells, having multiple sides joined by vertices. Adjacent cells 156 of the knitted net layer 150 share at least one common vertex. The cells 156 may be referred to as polygonal cells. Polygonal, as used herein, can encompass any substantially polygonal shape, such as a figure formed by a sequence of connected edges and vertices, where the edges are not limited to straight line segments but may include imperfectly straight lines and/or curved segments. Further, vertices of polygonal cells represent a point where two edges of a polygonal cell meet, and these points may be sharp intersections or may be curved and/or rounded junctions.

The knitted base layer 140 and the knitted net layer 150 are in a layered arrangement such that at least part of each layer 140 and 150 are in contact. For example, the knitted net layer 150 may overlay the knitted base layer 140 such that the knitted net layer 150 may form at least part of the outer-facing surface of the upper 110 (e.g., the second side forming the outer-facing surface). Because the knitted net layer 150 has a lower knit density than the knitted base layer 140, the knitted base layer 140 may be exposed through the open area (e.g., openings 310 in FIG. 3) within each cell 156 of the knitted net layer 150 such that the knitted base layer 140 may also form part of the outer-facing surface of the upper 110. While the knitted net layer 150 is shown as extending continuously over the knitted base layer 140, in aspects, the knitted net layer 150 may be discontinuous in one or more areas such that the knitted net layer 150 provides a unique visual appearance and/or forms one or more patterns on the upper 110, e.g., identifying areas having different functional characteristics.

The knitted base layer 140 is secured to the knitted net layer 150 at one or more locations, such as through knitting, bonding, and/or stitching, examples of which are further described herein. The more open knit structure of the knitted net layer 150 results in less stretch than the knitted base layer 140. When secured to the knitted base layer 140, the knitted net layer 150 may inhibit the stretch of the knitted component 130. For example, areas of the knitted component 130 where the knitted base layer 140 is secured to the knitted net layer 150 may elongate less than the knitted base layer 140 would elongate if it were on its own. Reducing the stretch using the knitted net layer 150 may be advantageous to provide containment, strength, and durability to the upper 110 without the use of other structures that would increase the weight and/or reduce breathability of the upper 110.

Example aspects of the knitted component 130 also include one or more inlaid strands 160 arranged to at least partially extend between the knitted base layer 140 and the knitted net layer 150. FIGS. 1A and 1B show the inlaid strands 160 incorporated into the knitted component 130 and the upper 110; however, in aspects, such inlaid strands can be omitted partially or entirely. The inlaid strands 160 may generally be inlaid within the structure of the knitted component 130 such that the inlaid strands 160 generally extend in an unlooped state along a course formed by knitted loops of one or more other yarns (e.g., yarns of the knitted base layer 140 and/or yarns of the knitted net layer 150). The inlaid strands 160 may include one or more loops at each end of the inlaid strands 160 to anchor the inlaid strands 160 to the knitted structure of the knitted component 130 and the inlaid strands 160 may generally otherwise extend through or along a course without being interlooped with another yarn strand. The inlaid strands 160 may further provide containment by reducing stretch and providing structure to the upper 110. Further details of integration of the inlaid strand 160 into the knitted component 130 are described further with respect to FIG. 2.

Although the various rows of inlaid strands 160 shown in FIGS. 1A and 1B are referred to herein as in the plurality, it should be understood that these inlaid strands 160 may be sections of a continuous strand. For example, the knitted component 130 may include one inlaid strand that forms a continuous serpentine pattern such that, after being inlayed across one course of the knitted component 130, the inlaid strand 160 may exit the knitted structure of the knitted component 130 and curve back to enter back into the knitted structure of the knitted component 130 to extend through another course in the opposite direction. Further, as described below, the inlaid strands 160 may include multiple ends of strands extending in parallel as a single inlaid strand 160.

The inlaid strands 160 may have the configuration of a multifilament yarn, a filament (e.g., a monofilament yarn), thread, rope, webbing, cable, or chain, for example. The inlaid strands 160 may comprise a material having a property to increase the strength of the knitted component 130 in areas with the inlaid strands 160. In some aspects, the inlaid strands 160 include a low-melting thermoplastic polymer that has a lower melting temperature than the yarns forming the knitted base layer 140. In some aspects, the inlaid strands 160 may be the same type of yarn forming the knitted net layer 150, but it should be understood that other types of yarn, including other types of yarn with a low-melting polymer, may be used for the inlaid strand 160. In one example, the inlaid strands 160 have a core-sheath configuration where a low-melting thermoplastic polymer material (such as any described above for the yarn of the knitted net layer) may surround a core with a higher melting temperature of the thermoplastic polymer sheath. Further, in some aspects, the inlaid strands 160 may comprise a yarn with a greater diameter, at least prior to melting as described further herein with respect to some aspects, than the yarn of the knitted base layer 140. In some aspects, the inlaid strands 160 may be yarn with a greater melting or decomposition temperature than yarn forming the knitted net layer 150. In some examples, the inlaid strands 160 are formed by a high-tenacity (e.g., having a tenacity greater than 5 grams/denier) polyester or nylon yarn. Further, in some examples, the inlaid strands 160 may exhibit greater stretch resistance than the rest of the knitted component 130 and may be formed from a variety of engineering filaments that are utilized for high-tensile-strength applications, including glass, aramids (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene, and liquid crystal polymer.

The inlaid strands 160 may be located in one or more areas of the upper 110. For example, the inlaid strands 160 may be located in the forefoot region 114, the midfoot region 116, and the heel region 118. In other examples, the inlaid strands 160 may be localized to one or more of these regions. For instance, the inlaid strands 160 may be arranged generally only in the midfoot region 116, which is an area where increased containment is desired, in one example. Inlaid strands 160 in the midfoot region 116 may further disperse tension applied to a tensioning system of the upper 110, such as laces 128. In other examples, the inlaid strands 160 may be located in the forefoot region 114 only or in addition to the midfoot region 116 to provide further containment and support around the wearer's forefoot.

In FIGS. 1A and 1B, the inlaid strands 160 are depicted as extending width-wise across the upper 110 such that they extend in a medial-lateral direction. Some inlaid strands 160 extend from the biteline 115 on the medial side 120 to the throat area 126, and other inlaid strands 160 extend from the biteline 115 on the lateral side 122 to the throat area 126. Some inlaid strands, such as the inlaid strands 160 in the forefoot region 114, extend from the biteline 115 on the medial side 120, over the top of the upper 110, and to the biteline 115 on the lateral side 122. In other aspects, the inlaid strands 160 may be oriented to extend in a different direction, such as a heel-toe direction. While inlaid strands 160 illustrated in the upper 110 extend generally parallel to one another, other examples include inlaid strands 160 within the same upper 110 extending in different directions.

FIG. 2 depicts the knitted component 130 in the shape of the upper 110 of FIGS. 1A-1B before being secured to the sole structure 112. In example aspects, the knitted component 130 may have a generally U-shaped configuration that is outlined by an outer perimeter edge 210, a pair of heel edges 212, and an inner edge 214. In some aspects, the knitted component 130 (specifically, the knitted base layer 140 and the knitted net layer 150) are knit as larger textile pieces from which a U-shaped portion is cut for formation of the upper 110. In other aspects, the knitted base layer 140 and the knitted net layer 150 are each knitted into the U-shaped configuration shown in FIG. 2. Although the knitted base layer 140 and the knitted net layer 150 are shown as generally having the same size and shape, it should be understood that these layers 140 and 150 may have different sizes and shapes. For example, the knitted base layer 140 may have a larger area than the knitted net layer 150 such that the knitted component 130 includes a region of the knitted base layer 140 that is not covered by the knitted net layer 150. Further, the U-shaped configuration depicted in FIG. 2 is just one example shape of the knitted component 130, and other example shapes are contemplated herein.

When incorporated into the article of footwear 100, the outer perimeter edge 210 may be positioned against the upper surface of the sole structure 112 and may be joined to a strobel in example aspects. In other aspects, the upper 110 may include an underfoot portion also formed of the knitted component 130. In this example, the article of footwear 100 may not include a strobel. In example aspects, the pair of heel edges 212 are joined to each other and extend generally vertically in the heel region 118 of the article of footwear 100. The inner edge 214 forms the ankle collar 124 and extends forward to define the throat area 126.

FIG. 3 depicts a close-up view of a portion of the knitted component 130 (circled in FIG. 2) having the knitted net layer 150 overlaying the knitted base layer 140. The knitted base layer 140 is formed by one or more first yarns, such as a first yarn 302. In this example, only one first yarn 302 forms the knitted base layer 140, but it is understood that there may be multiple yarn strands having the same or different yarn type forming the knitted base layer 140. For example, in one aspect, the first yarn 302 may include a coated nylon yarn and another yarn (e.g., elastic yarn) plated with the coated nylon yarn. In some aspects, the first yarn 302 can be transparent, translucent, and/or a lighter color (e.g., white, off-white, light gray), such that other yarns and/or components forming the knitted component 130 may contrast with the knitted base layer 140. In aspects, the first yarn 302 can be a contrasting color compared to other components and/or yarns forming the knitted component 130.

The knitted net layer 150 is formed by one or more second yarns, such as the second yarn 304. In this example, there are two ends or strands of yarn 304A and 304B forming the second yarn 304. Strands of the second yarn 304A and 304B are the same yarn type in some aspects but may be different yarn types. In some example aspects, the second yarn 304 comprises a first component and a second component (e.g., the first component is a core and the second component is a sheath, the first component is the first strand of yarn 304A and the second component is the second strand of yarn 304B). In some aspects, at least some of the strand(s) forming the second yarns 304A, 304B can be transparent, translucent, and/or a lighter color (e.g., white, off-white, light gray) such that other yarns and/or components forming the knitted component (e.g., the first yarn 302 and/or the inlaid strands 160) may contrast with the knitted net layer 150. In other aspects, the second yarn 304 can be a contrasting color compared to other components and/or yarns forming the knitted component (e.g., the first yarn 302 and/or the inlaid strands 160).

In accordance with aspects herein, a yarn forming a knitted net layer, e.g., the knitted net layer 150, can be transparent, translucent, or a lighter color or shade comparatively speaking, e.g., to allow parts of a knitted base layer thereunder, e.g., the knitted base layer 140, to be more visible or provide a more pronounced visual or color contrast. For example, in an aspect, a second yarn 304 forming the knitted net layer 150 can be transparent, translucent, or a lighter color (e.g., white, off-white, light gray), and the first yarn 302 can be a non-transparent, darker, and/or highly contrasting color to produce an enhanced visual appearance on the surface of the upper 110 and/or allow the colors of the knitted base layer 140 to have a more opaque visual appearance.

The second yarn 304 of the knitted net layer 150 is knitted to form a plurality of adjoining cells 156. The second yarn 304 defines a perimeter of the cells 156, and the center of the cells 156 are open. In other words, the cells 156 may be considered to be openings 310 defined by the second yarn 304. In example aspects, the cells 156 of the knitted net layer 150 are polygon cells with the perimeter defined by floating sections 306 of the second yarn 304 that meet at vertices 308. The floating sections 306 are unlooped segments of the second yarn of the knitted net layer 150. Adjacent cells 156 may share one or more common vertices 308. In the example illustrated, the knitted net layer 150 is divided into four-sided polygons (e.g., quadrilaterals), but the cells 156 of the knitted net layer 150 may be triangular, pentagonal, hexagonal, etc. Additionally, the floating sections 306 forming the sides of each cell 156 may be equal lengths; for example, the knitted component 130 depicts generally square-shaped cells 156. In example aspects, only these unlooped floating sections 306 of separate openings 310 of adjacent cells 156 are not attached to the knitted base layer 140.

The underlying knitted base layer 140 is exposed through the openings 310 of the cells 156. The size of the cells 156 of the knitted net layer 150 determine how much of the knitted base layer 140 is exposed in each opening. Each cell 156 may have a width 322 in the course-wise direction 320 between two opposing vertices 308. In some examples, the width 322 is at least one wale of the knitted base layer 140, at least three wales of the knitted base layer 140, or at least five wales of the knitted base layer 140. In one example, the width 322 is seven wales of the knitted base layer 140. In another example, the width may be five wales of the knitted base layer 140. As described further with respect to FIG. 5, the size of the cells 156 may be determined based on the number of needle positions the second yarn 304 is floated between adjacent stitches (e.g., tuck stitches) on the needle bed and the number of courses of the knitted base layer 140 that are knit while the second yarn 304 is being held on a needle.

As described herein, the knitted base layer 140 and the knitted net layer 150 are secured together at one or more locations. The knitted base layer 140 and the knitted net layer 150 may be secured together at each of the vertices 308 of the knitted net layer 150. For example, the knitted base layer 140 and the knitted net layer 150 may be secured together at the vertices 308 by tuck stitches. In aspects, securing the knitted base layer 140 to the knitted net layer 150 using one or more tuck stitches may advantageously create openings within the knitted base layer 140 such that additional breathability or moisture permeability is achieved. In one example, the second yarn 304 of the knitted net layer 150 tucks with a knitted loop of the first yarn 302 of the knitted base layer 140 at the vertices 308. In another example, the first yarn 302 may tuck with a loop of the second yarn 304 at the vertices 308. In yet another example, another yarn may tuck with loops of the first yarn 302 and loops of the second yarn 304 to create a connection between the knitted base layer 140 and the knitted net layer 150. In other examples, another strand may connect the knitted base layer 140 to the knitted net layer 150 at one or more locations of the knitted component 130, which may be done in a post-knitting process, such as stitching or embroidering. In such examples, the other strand used to connect the knitted base layer 140 to the knitted net layer 150 may have a contrasting color compared to the first yarn 302 and/or the second yarn 304. In some examples, the other strand may connect the knitted base layer 140 to the knitted net layer 150 at one or more vertices 308, offset from one or more vertices 308, or a combination thereof.

In some aspects, the knitted base layer 140 may be secured to the knitted net layer 150 through fusing a thermoplastic polymer material. At least the first yarn 302 or the second yarn 304 may have a low-melting thermoplastic polymer material. Any of the examples previously described may be used. In some example aspects, the knitted base layer 140 is secured to the knitted net layer 150 by forming one or more composite structures. For example, the second yarn 304 may have a thermoplastic polymer sheath surrounding a core, such as a polyester core, where the thermoplastic polymer sheath has a lower melting temperature than the melting temperature or decomposition temperature of the core. In this way, heat, and in some aspects pressure, may be applied to the knitted component 130 so that the thermoplastic polymer of sheath of the second yarn 304 may at least partially melt (i.e., reflow) and, when cooled (i.e., resolidified), fuses or bonds the remaining unmelted portion of the second yarn 304 with the first yarn 302, forming the one or more composite structures. Further, the first yarn 302 of the knitted base layer 140 may be formed with materials having a greater melting or decomposition temperature of the second yarn 304 such that the first yarn 302 does not melt when the knitted component 130 is heated to a temperature that melts the second yarn 304. In one example, the first yarn 302 is nylon core with a thermoplastic polyurethane sheath that has a higher melting temperature than the thermoplastic polyurethane of the second yarn 304.

In one example, the sheath of the second yarn 304 does not completely melt and reflow, such that a portion of the sheath may remain around the unmelted core of the second yarn 304 after melting. Alternatively, the sheath of the second yarn 304 may completely melt and reflow to form a film over parts of the knitted component 130 after cooling, which may further enhance durability and water resistance. The remaining core, and in some aspects part of the sheath of the second yarn 304, helps maintain structure to the knitted net layer 150 while still bonding with the first yarn 302 to secure the knitted net layer 150 to the knitted base layer 140.

In some aspects, the first yarn 302 may have the low-melting thermoplastic polymer having a lower melting temperature than that of the second yarn 304 so that at least part of the first yarn 302 melts during heating and fuses with an unmelted second yarn 304. In some aspects, both the first yarn 302 and the second yarn 304 have a low-melting thermoplastic polymer, which may be the same polymer or different, and are heated to a temperature above the melting temperature(s) of the polymer(s) so that each yarn 302 and 304 at least partially melts to fuse together.

In some aspects, at least a sheath portion (and in some aspects, both a sheath and a core) of the first yarn 302 and/or the second yarn 304 can be translucent, transparent, and/or a lighter color (white, off-white, light gray), such that other components and/or yarns forming the knitted component 130 provide a contrasting appearance. In a fused state, the translucent, transparent, and/or lighter color yarns (the first yarn 302 and/or the second yarn 304) may form a layer of translucent, transparent, and/or lighter color re-solidified thermoplastic material. For example, the second yarn 302 may be formed of a core of high-melting colorful yarn (e.g., red, blue, yellow, green) surrounded by a sheath of low-melting translucent, transparent, and/or lighter color yarn. In this example, when the sheath is exposed to a temperature above the melting temperature of the sheath, the sheath reflows and solidifies to reveal the colorful core yarn. Further, in such an example, the inlaid strands 160 may have a second color to provide additional contrast and aesthetic appeal to the knitted component 130.

While tuck stitches described above may generally secure the knitted base layer 140 to the vertices 308 of the knitted net layer 150, fusing the second yarn 304 to the first yarn 302 (and vice versa) secures the knitted base layer 140 to the floating sections 306 of the cells 156, as well as to the vertices 308. In this way, fusing provides more points of securement between the knitted base layer 140 and the knitted net layer 150.

In one example, the knitted net layer 150 is secured to the knitted base layer 140 through knitting (e.g., intermittent tuck stitches) as well as through fusing. In other examples, the knitted net layer 150 is secured to the knitted base layer 140 only through knitting and not through fusing. Further examples include the knitted net layer 150 and the knitted base layer 140 being formed separately such that they are not secured through knitting and are only secured through at least partially fusing the first and second yarns 302 and 304 together.

FIG. 3 also depicts the inlaid strands 160 that are at least partially positioned between the knitted base layer 140 and the knitted net layer 150. That is, the inlaid strands 160 extend between the first yarn 302 of the knitted base layer 140 and the second yarn 304 of the knitted net layer 150, but the inlaid strands 160 are at least partially exposed through the openings 310 of the cells 156 forming the knitted net layer 150. Sections of the inlaid strands 160 that extend across the openings 310 of the cells 156 of the knitted net layer 150 are woven in front of and behind wales of the knitted base layer 140, which may help to secure the inlaid strands 160 in place and prevent snagging. In one example, the inlaid strands 160 extends in front of three wales of the first yarn 302 of the knitted base layer 140 then behind one wale of the first yarn 302, in a repeating pattern; however, other patterns may be used.

In example aspects, the inlaid strands 160 intersect floating sections 306 of the second yarn 304 of the knitted net layer 150 and not the vertices 308. By not intersecting at the vertices 308, the knitted component 130 may have a smoother surface and be less prone to knit defects. However, in other aspects, the inlaid strands 160 may intersect the vertices 308 of the knitted net layer 150.

The inlaid strands 160 may extend in a course-wise direction 320. In other aspects, the inlaid strands 160 may extend in a wale-wise direction 325. Further, the inlaid strands 160 may alternate between the course-wise direction 320 and the wale-wise direction 325.

The inlaid strands 160 may extend generally parallel to one another. Further, the inlaid strands 160 may be spaced apart by a quantity of courses of the knitted base layer 140. In one example, the inlaid strands 160 are inserted at every eight courses of the knitted base layer 140. In other examples, the inlaid strands are inserted at every six courses or every four courses of the knitted base layer 140. However, other arrangements of the inlaid strands 160 may be used.

In one example, at least two spaced-apart inlaid strands 160 extend through the opening 310 of each cell 156 of the knitted net layer 150. FIG. 3, for example, shows a first inlaid strand 160A and a second inlaid strand 160B extending through the openings 310. As shown in FIG. 3, the first inlaid strand 160A and the second inlaid strand 160B may be asymmetrically positioned such that they are not equidistant from the vertices 308. For example, each cell 156 in FIG. 3 includes a first vertex 308A opposite a second vertex 308B in a wale-wise direction 325. The first inlaid strand 160A is positioned closer to the first vertex 308A than the second vertex 308B, while the second inlaid strand 160B is positioned closer to the second vertex 308B than the first vertex 308A. The distance 312 between the first inlaid strand 160A and the first vertex 308A may be different than the distance 314 between the second inlaid strand 160B and the second vertex 308B. For example, the distance 312 may be less than the distance 314.

In some aspects, the inlaid strands 160 may be secured to the knitted base layer 140 and/or the knitted net layer 150 through fusing a thermoplastic polymer material. In one example, the second yarn 304 of the knitted net layer 150 may have a low-melting thermoplastic polymer material that at least partially melts to fuse with the inlaid strands 160 where the inlaid strands 160 intersect with the second yarn 304 in a similar manner described with respect to fusing the first and second yarns 302 and 304. In some aspects, the inlaid strand 160 also includes a low-melting thermoplastic polymer material, which may be the same or different from the low-melting thermoplastic polymer material of the second yarn 304, and the knitted component 130 may be heated to a temperature sufficient to at least partially melt both the second yarn 304 and the inlaid strands 160. As such, the inlaid strands 160 may be fused not only to the second yarn 304 (and in some aspects the first yarn 302) where the inlaid strands 160 intersect the second yarn 304 but may also be fused to the first yarn 302 in areas of the knitted base layer 140 extending across the openings 310 of the knitted net layer 150. In an example aspect, the second yarn 304 and the inlaid strands 160 are of the same yarn type, which may be a thermoplastic polyurethane sheath surrounding a polyester core.

Alternatively or additionally, the first yarn 302 may include a low-melting thermoplastic polymer. For example, the first yarn 302 may have a low-melting thermoplastic polymer with a lower melting temperature than materials of the second yarn 304 and the inlaid strands 160, such that only the first yarn 302 is melted. In another example, each of the first yarn 302 and the second yarn 304 may have a low-melting thermoplastic polymer (that is either the same or different) having a lower melting temperature than that of the inlaid strand 160. In yet another example, each of the first yarn 302, the second yarn 304, and the inlaid strands 160 may have thermoplastic polymer materials (which may be the same or different) that are all at least partially melted during heating. In yet another aspect, the inlaid strand 160 may have a low-melting thermoplastic polymer material that has a lower melting temperature than the melting or decomposition temperatures of the first and second yarns 302 and 304, such that the knitted base layer 140 and the knitted net layer 150 may be fused together only through the inlaid strands 160.

FIG. 4 depicts another knitted component 430, which may be used for forming at least part of an upper for an article of footwear, such as the upper 110. The knitted component 430 includes a knitted base layer 440 and a knitted net layer 450. Features of any of the aspects described with respect to the knitted component 130, knitted base layer 140, and the knitted net layer 150 may be present in aspects of the knitted component 430, the knitted base layer 440, and the knitted net layer 450, respectively, without repeating such details here. The knitted component 430 of FIG. 4, however, does not include the inlaid strands.

FIGS. 5A and 5B depict an example stitch notation diagram 500. Due to the size of the stitch notation diagram 500, the diagram 500 is split between FIGS. 5A and 5B. The stitch notation diagram 500 includes rows 501-528 that include representations of needles on front and back needle beds of a knitting machine. Each of these rows may represent a pass of a feeder of the knitting machine. Some of these rows may be formed together such that they represent courses of multiple yarns knit to form the same course, either on a single bed or both beds. It should be understood that the stitch notation diagram 500 illustrates only a portion of the actions used to form the knitted component 130 and that additional rows and needle positions may be utilized. Additionally, references to a back needle bed and a front needle bed should be understood to be illustrative for relative positioning and that courses described on the back needle bed may be formed on the front needle bed while courses on the front needle bed may be formed on the back needle bed.

Rows 501, 503-506, 509, 513-515, 517-520, 523, and 527-528 may represent a first yarn 532 (which may include aspects of the first yarn 302) knit to form a knitted base layer, such as the knitted base layer 140 or 440. These rows include the first yarn 532 being knit into knitted loop stitches on the back needle bed. In this example, the first yarn 532 is knit on all available needles (i.e., full-gauge).

Rows 502, 508, 516 and 522 represent a second yarn 534 (which may include aspects of the second yarn 304) knit to form a knitted net layer, such as the knitted net layer 150 or 450. Note that stitch notation diagram 500 depicts an example in which two ends of the second yarn 534 are knit to run in parallel. Rows 502 and 508, for example, may together form the same floating sections of the second yarn 534 but may be shown separately in the stitch notation diagram 500 to indicate that they are fed through different feeders of the knitting machine. However, in other aspects, multiple ends of the second yarn 534 may be knit through the same feeder. In yet another example, there may be a single end of the second yarn 534 forming the knitted net layer.

The second yarn 534 is knit using tuck stitches, such as tuck stitch 536, and floats, such as float 538. The tuck stitches 536 of the second yarn 534 may alternate between tucking on a front bed and tucking on a back bed, as shown in the example stitch notation diagram 500. (Note that rows 502 and 516 depict stitches on the front bed as being looped, but these may be tuck stitches similar to rows 508 and 522.) Each tuck stitch 536 of the second yarn 534 may represent where the second yarn 534 forms a vertex of cells forming the knitted net layer (e.g., vertices 308), and each float 538 represents a floating section defining a side of the cell (e.g., floating section 306). As such, every other tuck stitch 536 of the second yarn 534 shown in one of the rows (e.g., row 508) represents two vertices opposite each other in a cell in a course-wise direction. The number of needles positioned between these tuck stitches determines the width of the cell in the course-wise direction. For example, tuck stitch 536A and tuck stitch 536B in row 508 are separated by seven needle positions. Where the knitted base layer is knit on every needle, as shown in the example stitch notation diagram 500, seven wales of the knitted base layer 140 would be exposed across the width of the cell between the vertices formed at tuck stitch 536A and tuck stitch 536B. The tuck stitch between tuck stitch 536A and tuck stitch 536B may help to form either a top or bottom vertex of that cell.

Rows 507 and 521 include arrows 552 representing transfers from a needle on the front bed to a needle on the back bed. Specifically, the transfers in rows 507 and 521 are transfers of tuck stitches 536 of the second yarn 534 to the back needle bed, where a corresponding needle is knitting the first yarn 532 of the knitted base layer. As such, the tuck stitches 536 of the second yarn 534 are tucked with the first yarn 532, which secures the knitted net layer with the knitted base layer.

Rows 511 and 525 depict inlaying an inlaid strand 535, which may be any of the examples of the inlaid strand 160. The inlaid strand 535 may be inlaid between front and back needle beds using a combination feeder. Prior to inlaying the inlaid strand 535 in rows 511 and 525, some knitted loops of the first yarn 532 of the knitted base layer are transferred from the back needle bed to the front needle bed. The arrows 554 in rows 510 and 524 represent these transfers from the back bed to the front bed. After the inlaid strand 535 is inlaid, the loops of the first yarn 532 on the front bed are transferred back to the back bed, which are represented by arrows 556 in rows 512 and 526. By transferring some loops but not all loops of the first yarn 532 to another needle bed only during inlaying of the inlaid strand 535, the inlaid strand 535 moves between extending in front of and extending behind the loops of the first yarn 532 forming the knitted base layer, which helps maintain the position of the inlaid strand 535. In this example, every fourth knitted loop is transferred to the front bed in rows 510 and 524 so that the inlaid strand 535 extends in front of three wales of the knitted base layer, then extends behind one wale of the knitted base layer in a repeating manner. Other patterns may be used.

Some example knitted components disclosed herein have courses extending generally parallel, at least in the forefoot region, and in some aspects, the midfoot region. For example, the knitted component 130 has knit courses in the knitted base layer 140 and the knitted net layer 150 extending laterally across the upper 110. In FIG. 2, for example, the forefoot region 114 may include courses that generally extend parallel from the outer perimeter edge 210 on the medial side 120 to the outer perimeter edge 210 on the lateral side 122, and the midfoot region 116 may include courses that generally extend parallel from the inner perimeter edge 214 to the outer perimeter edge 210 on the medial side 120 or lateral side 122. In other constructions without an opening in the throat area 126, courses in the midfoot region 116 may generally extend parallel between the outer perimeter edge 210 on the medial and lateral sides 120 and 122. This orientation of the courses may result from knitting the knitted component 130 in a toe-to-heel direction or a heel-to-toe direction. Alternatively, courses may extend generally parallel longitudinally along the upper 110 when the knitted component 130 is knit in a medial-to-lateral direction or lateral-to-medial direction.

FIGS. 6A and 6B depict a portion of another knitted component 630 with an alternative course orientation. In particular, at least some courses within the knitted component 630 may extend radially as described herein. While only a portion of the knitted component 630 is depicted for illustrative purposes, it should be understood that the knitted component 630 may have a similar shape and configuration as the knitted component 130 in FIGS. 1A-2 and may be used to form at least part of an upper for an article of footwear, similar to the upper 110 for the footwear 100. FIG. 6B depicts at least a portion of the knitted component 630 being formed into an upper. Additionally, only some features of the knitted component 630 are described for purposes of discussion of the radially extending courses in FIGS. 6A-B, but it should be understood that any of the features, including alternatives, described with respect to the knitted component 130 may apply to the knitted component 630 unless otherwise indicated.

The knitted component 630 includes a knitted base layer 640 and a knitted net layer 650 overlaying at least part of the knitted base layer 640. The knitted net layer 650 may be integrally formed with the knitted base layer 640 at a plurality of locations through a knit structure, such as a tuck stitch, and/or through the fusing of a low-melt material, as previously described. Further, in some aspects, the knitted component 630 also includes one or more inlaid strands 660 arranged to at least partially extend between the knitted base layer 640 and the knitted net layer 650. Further structural and functional details of the knitted base layer 640, knitted net layer 650, and inlaid strands 660 may be the same as described for the knitted base layer 140, the knitted net layer 150, and the inlaid strands 160, and need not be repeated here.

FIGS. 6A-B depict courses in the knitted component 630 extending radially such that the knit courses extend from an outer perimeter 610 of the knitted component 630 towards a common portion or region. Particularly, the courses of the knitted component 630 may extend from the outer perimeter 610 to the throat area 626 (e.g., the inner perimeter 612 at the throat area 626), which may be referred to as the common portion. In this way, knit courses of the knitted component 630 may extend diagonally to each other, rather than parallel. Courses in both the knitted base layer 640 and the knitted net layer 650 may extend radially. Further, the one or more inlaid strands 660 may also extend radially from the outer perimeter to a common region, such as the throat area 626. As previously described, the one or more inlaid strands 660 may help to disperse tension applied through laces (such as laces 128), which prevents wear and tear in the throat area 626. Extending the inlaid strands 660 radially along the knitted component 630 creates additional angles at which tension can be distributed around the knitted component 630 and, thereby, result in more effective redistribution of tension forces. The inlaid strands 660 may also help provide strength and stretch resistance to the knitted component 630, which provides containment around a wearer's foot when an upper with the knitted component 630 is worn. Extending the inlaid strands 660 radially creates additional angles of containment around a wearer's foot compared to inlaid strands extending generally parallel to each other. Further, even in aspects without inlaid strands, extending courses within the knitted base layer 640 and the knitted net layer 650 may also improve distribution of tension forces and provide additional angles of containment.

The knitted component 630 with radially extending courses may be formed by knitting one side (e.g., medial side 620 or lateral side 622) in the midfoot region 616 (and in some aspects, a heel region) before knitting the forefoot region 614 and the opposite side in the midfoot region 616 (and in some aspects, the heel region). For example, arrow 670 in FIG. 6A is intended to represent the direction in which the knitted component 630 may be knit. The midfoot region 616 on the medial side 620 is knit, then the forefoot region 614 on the medial side 620, then the forefoot region 614 on the lateral side 622, and then the midfoot region 616 on the lateral side 622. In some aspects, the heel region on the medial side 620 is knit prior to knitting the midfoot region 616 on the medial side 620, and/or a heel region on the lateral side 622 is knit after the midfoot region 616 on the lateral side 622. In other examples, the knitted component 630 is knit in the opposite direction of arrow 670. While only part of a midfoot region 616 is depicted in FIGS. 6A-B, it should be understood that additional portions of the knitted component 630 may form additional aspects of the midfoot region 616.

In some aspects, the radially extending courses may form wedge-shaped portions that include full-length and partial-length courses, where the partial-length courses may help fill in additional area between the full-length courses adjacent the outer perimeter 610 in certain areas. Further details of wedge-shaped portions are described further below with respect to FIG. 7. In some aspects, the knitted base layer 640 includes the wedge-shaped portions while the knitted net layer 650 does not include wedge-shaped portions. In this way, the knitted net layer 650 may not include partial-length courses, at least in the forefoot region 614. In some aspects, the knitted net layer 650 also does not include partial-length courses in the midfoot region 616 and, where present, the heel region. In this way, the knitted net layer 650 may include only full-length courses in these regions 614 and 616. At the same time, the knitted net layer 650 may be integrally knit with the knitted base layer 640 that may include wedge-shaped portions with partial-length courses. As described with respect to FIGS. 5A and 5B, the knitted base layer 640 and the knitted net layer 650 may be knit on separate needle beds. While the partial-length courses are being formed in the knitted base layer 640 on one needle bed, the knitted net layer 650 may be held on needles on the other needle bed until the two layers are ready to be joined, such as through tuck stitches. The inlaid strands 660 may be inlaid between a full-length course in the knitted base layer 640 and a course in the knitted net layer 650. If inlaid strands 660 are inlaid in full-length courses in the knitted base layer 640, the inlaid strands 660 may extend between the outer perimeter 610 (which may be secured to a sole beyond a biteline when the knitted component 630 is incorporated in an article of footwear) and the throat area 626, which may include eye stay areas. By extending along full-length courses instead of partial-length courses, the inlaid strands 660 may better help redistribute tension applied to the eye stays, as previous described.

While the knitted net layer 650 does not include partial-length courses to help fill in space adjacent the outer perimeter 610, portions of the knitted net layer 650 may be stretched to accommodate the additional area created at the outer perimeter 610 of the wedge-shaped portions of the knitted base layer 640, which is integrally knit with the knitted net layer 650. As a result, the knitted net layer 650 may be stretched more at the outer perimeter 610 than the common portion, or the inner perimeter 612.

As described further with respect to the knitted net layer 150, the knitted net layer 650 may have yarn that is knitted to form a plurality of adjoining cells 656 with a perimeter defined by floating sections 606 of the yarn that meet at vertices 608, where adjacent cells 656 share at least one common vertex 608. Each cell 656 may have a width in the course-wise direction (which extends radially in the knitted component 630) between two opposing vertices 608. Example widths may be similar to width 322 of the cells 156. However, the width of the cells 656 of the knitted net layer 650 may vary across a row of cells 656 arranged from the common region (throat area 626) to the outer perimeter 610. For example, a cell 656 closer to the throat area 626 may have a first width 652A and a cell 656 in the same row (which may be formed by one or more adjacent courses) that is closer to the outer perimeter 610 may have a second width 652B that is greater than the first width 652A. Further, a cell 656 within the same row but located somewhere between cells adjacent the throat area 626 and cells adjacent the outer perimeter 610 may have an intermediate width 652C. In this way, the width of the cells 656 in the knitted net layer 650 and/or the area of the cells 656 may generally increase from cells 656 closer to the throat area 626 to cells 656 closer to the outer perimeter 610.

In some aspects, the inlaid strands 660 are secured to the knitted net layer 650 via one or more tuck stitches. As some cells 656 within the knitted net layer 650 may stretch to accommodate the partial-length courses in the knitted base layer 640, the inlaid strands 660 may change angles of extension as the inlaid strands 660 extend towards the outer perimeter 610. In other words, at least some of the inlaid strands 660 may not extend completely straight, as seen in FIG. 6B. However, in other aspects, the inlaid strands 660 may extend generally straight while inlaid.

FIG. 7 depicts a schematic representation of some example knit courses within the portion of the knitted base layer 640 of the knitted component 630 of FIGS. 6A-B in accordance with aspects herein. The radially extending courses within the knitted base layer 640 may divide the knitted base layer 640 into wedge-shaped portions. For example, looking at the close-up view of the knitted base layer 640 in FIG. 7, a wedge-shaped portion 710 is marked by dashed boundary lines, and similar wedge-shaped portions can be positioned throughout at least the forefoot region 614 and a portion of the midfoot region 616 of the knitted base layer 640, although it should be understood that wedge-shaped portions may also be present in other portions of the midfoot region 616 and, in some examples, a heel region.

The courses forming the wedge-shaped portion 710 may be formed by knitting full-length, radially extending courses and partial-length, radially extending courses. The wedge-shaped portion 710 includes at least two full-length knit courses with partial-length knit courses in between. It should be understood that the full-length knit courses and partial-length knit courses in FIG. 7 are intended to be schematic representations only and do not depict every feature of these courses, such as the yarn extending between ends of adjacent courses; rather, the schematic representation of FIG. 7 is intended to show how radially extending full-length and partial-length courses may form a wedge-shaped portion.

A full-length knit course, such as course 712, may extend from one edge of the knitted base layer 640 (e.g., at the outer perimeter 610) to another edge of the knitted base layer 640 (e.g., in a throat area 626). Partial-length knit courses, such as course 714, may not fully extend between two edges of the knitted base layer 640. One or both ends of a partial-length knit course may end before the edge of the knitted base layer 640. However, the partial-length knit courses, such as course 714, may still be considered to be radially extending as they extend in a direction from the outer perimeter 610 towards the common portion (e.g., the throat area 626). For simplicity, the partial-length knit courses are only depicted in FIG. 7 within the wedge-shaped portion 710, but it should be understood that the knitted base layer 640 would include additional partial-length courses forming other wedge-shaped portions not illustrated. Forming partial-length knit courses distributed between full-length knit courses may create shape and dimension in the knitted base layer 640 while also enabling the courses to extend radially.

Also depicted in FIG. 7 are selective example full-length courses radially extending in the midfoot region 616 and forefoot region 614 on the medial and lateral sides 620 and 622. As illustrated, the angle of radially knit courses varies such that courses at least in the forefoot region 614 generally do not extend parallel to one another and, in some aspects, courses in at least an anterior portion of the midfoot region 616 also do not extend parallel to each other.

FIG. 8 depicts an exploded close-up view of a portion of another example knitted component 830 in accordance with aspects herein. While only a portion of the knitted component 830 is depicted for illustrative purposes, it should be understood that the knitted component 830 may have a similar shape and configuration as the knitted component 130 in FIGS. 1A-2 and may be used to form at least part of an upper for an article of footwear, similar to the upper 110 for the footwear 100. Additionally, only some features of the knitted component 830 are described for purposes of discussion of FIG. 8, but it should be understood that any of the features, including alternatives, described with respect to the knitted component 130 may apply to the knitted component 830 unless otherwise indicated.

Similar to the knitted component 130, the knitted component 830 includes a knitted base layer 840 comprising one or more first yarns 802 and a knitted net layer 850 overlaying at least part of the knitted base layer 840 and comprising one or more second yarns 804. Further structural and functional details of the knitted base layer 840 and the knitted net layer 850 may be the same as described for the knitted base layer 140 and the knitted net layer 150, and need not be repeated here.

The knitted component 830 also includes a second knitted base layer 820 overlaying at least a portion of the knitted net layer 850 and comprising one or more third yarns 805. In this way, the knitted net layer 850 may be positioned between the knitted base layer 840 (which may also be referred to as a first knitted base layer 840) and the second knitted base layer 820.

The first yarn 802 in the first knitted base layer 840 and the third yarn 805 in the second knitted base layer 820 may be any of the yarn types disclosed for the first yarn 302. In some examples, the first yarn 802 in the first knitted base layer 840 and the third yarn 805 in the second knitted base layer 820 may be the same type of yarn. For example, if the knitted net layer 850 is formed of one or more colorful yarns, the first yarn 802 and the third yarn 805 may each be translucent, transparent, and/or a lighter color, such that the knitted net layer 850 provides an overall contrasting and visually striking appearance and pattern. In other examples, the first yarn 802 and the third yarn 805 can be different types of yarns. For example, the first yarn 802 may be formed of one or more colors, and the third yarn 805 may be translucent, transparent, and/or a lighter color, such that the colors of the first yarn 802 are visible and provide an aesthetically appealing or striking appearance. The second yarn 804 of the knitted net layer 850 may be any of the yarn types, as described for second yarn 304.

The first knitted base layer 840 has a first knit density, defined by a number of knitted stitches per square area. The knitted net layer 850 has a second knit density that is less than the first knit density of the knitted base layer 840. Specifically, the knitted net layer 850 may include yarn(s) (e.g., second yarn 804) that are knit through a repeating pattern of float stitches in between tuck stitches and/or knitted stitches. The second yarn 804 of the knitted net layer 850 is knit so as to define a plurality of cells 856, such as polygon cells, having multiple sides formed by floating sections 806 of the second yarn 804 joined by vertices 808. Adjacent cells 856 of the knitted net layer 850 share at least one common vertex. The perimeter of the cells 856 are formed by the floating section 806 of the second yarn 804 and define an opening 810 in the knitted net layer 850.

The second knitted base layer 820 may have a third knit density, which may be at least greater than the second knit density of the knitted net layer 850. In some aspects, the third knit density of the second knitted base layer 820 is less than the first knit density of the first knitted base layer 840. In one example, the third knit density of the second knitted base layer 820 is half of the first knit density of the first knitted base layer 840. For example, the first knitted base layer 840 may be a full-gauge knit, meaning that every needle on a section of a needle bed is used to knit the first knitted base layer 840, while the second knitted base layer 820 may be a half-gauge knit, meaning that every other needle on a section of the needle bed is used to the knit the second knitted base layer 820.

The first knitted base layer 840, the knitted net layer 850, and the second knitted base layer 820 are arranged in a layered arrangement. For example, second knitted base layer 820 may overlay at least part of the knitted net layer 850, which may overlay at least part of the first knitted base layer 840. Because the knitted net layer 850 has a lower knit density than the first knitted base layer 840 and the second knitted base layer 820, the first knitted base layer 840 may be exposed through the opening 810 within each cell 856 of the knitted net layer 850 so that the first knitted base layer 840 may be in contact with the second knitted base layer 820. The addition of the second knitted base layer 820 may provide further structure to the knitted component 830 (and any resulting upper), provide increased abrasion resistance, and prevent possible snagging of the knitted net layer 850.

The knitted net layer 850 may be integrally formed with the first knitted base layer 840 at a plurality of locations through a knit structure, such as a tuck stitch, and/or through fusing of a low-melt material, as previously described with respect to the knitted component 130. Similarly, the second knitted base layer 820 may be integrally formed with the knitted net layer 850. In some examples, the knitted net layer 850 and the second knitted base layer 820 are formed on the same needle bed within the same section of needles but not on overlapping needles. For example, the third yarn 805 of the second knitted base layer 820 may be knit on every other needle within a section of needles on a needle bed, while the second yarn 804 of the knitted net layer 850 may be knit on at least some of the needles within the section of needles that is skipped by the third yarn 805. In this way, the second yarn 804 of the knitted net layer 850 and the third yarn 805 of the second knitted base layer 820 are interwoven together such that the two layers are not entirely separable but are not necessarily being interlooped together. In some aspects, the second yarn 804 and the third yarn 805 may be interlooped in some areas of the knitted component 830, such as areas that form a perimeter of an upper.

Additionally or alternatively, the second knitted base layer 820 may be secured in at least select portions to the knitted net layer 850 (and in some aspects to the first knitted base layer 840) through fusing (e.g., softening, partial melting, or fully melting and subsequent cooling) of a thermoplastic polymer material. Various examples of this fusing, including example materials, are described with respect to the knitted component 130 and apply here without repetition.

In some aspects, when the knitted component 830 is formed in an upper (such as upper 110), the second knitted base layer 820 forms an outer-facing surface of the upper, and the first knitted base layer 840 forms an inner-facing surface of the upper. In other examples, the second knitted base layer 820 forms an inner-facing surface of the upper, and the first knitted base layer 840 forms an outer-facing surface of the upper.

FIG. 9 depicts a partially exploded close-up view of a portion of another example knitted component 930 in accordance with aspects herein. While only a portion of the knitted component 930 is depicted for illustrative purposes, it should be understood that the knitted component 930 may have a similar shape and configuration as the knitted component 130 in FIGS. 1A-2 and may be used to form at least part of an upper for an article of footwear, similar to the upper 110 for the footwear 100. Additionally, only some features of the knitted component 930 are described for purposes of discussion of FIG. 9, but it should be understood that any of the features, including alternatives, described with respect to the knitted component 130 and the knitted component 830 may apply to the knitted component 930 unless otherwise indicated.

The knitted component 930 includes a first knitted base layer 940, a knitted net layer 950 overlaying at least part of the knitted base layer 940, and a second knitted base layer 920 overlaying at least part of the knitted net layer 950. These layers 940, 950, and 920 may have any of the properties of layers 840, 850, and 820, respectively.

Unlike the knitted component 830, the knitted component 930 may also include inlaid strands 960, which may be any of the materials described for inlaid strands 160. The inlaid strands 960 may be at least partially arranged between the first knitted base layer 940 and the knitted net layer 950. In some examples, as described with respect to the knitted component 830, the knitted net layer 950 may be intertwined with the second knitted base layer 920, such as where yarn forming the knitted net layer 950 is knit on needles interspersed with needles on which the yarn forming the second knitted base layer 920 is formed without being knit on the same needles. In this example, the inlaid strands 960 may be arranged between the first knitted base layer 940 and the combination of the knitted net layer 950 intertwined with the second knitted base layer 920. Further, the inlaid strands 960 may be secured within the knitted component 930 through mechanical structures of the strands 960 and/or the yarn of the layers 940, 950, or 920, and/or through fusing of a thermoplastic polymer material through any of the examples given for the knitted component 130.

FIG. 10 depicts another example of a knitted component 1030, in accordance with aspects herein. While only a portion of the knitted component 1030 is depicted for illustrative purposes, it should be understood that the knitted component 1030 may have a similar shape and configuration as the knitted component 130 in FIGS. 1A-2 and may be used to form at least part of an upper for an article of footwear, similar to the upper 110 for the article of footwear 100 shown in FIGS. 1A and 1B. Additionally, only some features of the knitted component 1030 are described for the purposes of discussion of FIG. 10, but it should be understood that any of the features, including alternatives, described with respect to the knitted component 130 and/or the knitted component 630 and/or the knitted component 830 may apply to the knitted component 1030 unless otherwise indicated. Further, the features of the knitted component 1030 may likewise apply to the knitted component 130, 630, and/or 830 unless otherwise indicated.

Similar to the knitted component 130, the knitted component 1030 includes a knitted base layer 1040 comprising one or more first yarns 1002 and a knitted net layer 1050 overlaying at least part of the knitted base layer 1040 and comprising one or more second yarns 1004. In some aspects, optionally, the knitted component 1030 can include one or more inlaid strands 1060, as shown in FIG. 10. While not shown, the knitted component 1030 may further include a second knitted base layer overlaying at least a portion of the knitted net layer 1050 and including one or more third yarns, e.g., as described with respect to FIGS. 8-9. The first yarn 1002 in the knitted base layer 1040 and the third yarn 805 in the second knitted base layer 820 can be any of the yarn types disclosed for the first yarn 302. The second yarn 1004 of the knitted net layer 1050 may be any of the yarn types described for the second yarn 304.

Similar to the knitted component 630, the knitted component 1030 is shown as extending radially such that the knit courses extend from an outer perimeter 1010 of the knitted component 1030 towards a common portion or region, and it should be understood that the knitted component 1030 may be knitted and/or stitched in a course-wise direction. Further, the one or more inlaid strands 1060 may also extend radially from the outer perimeter 1010 to a common region, such as the throat area 626, and it should be understood that the inlaid strands 1060 may extend in a course-wise direction and/or in a wale-wise direction in accordance with different aspects. Further, in some aspects, the inlaid strands 1060 may not be present in the knitted component 1030 or may be present in a smaller quantity, e.g., with greater radial spacing.

In contrast to the knitted component 130, the knitted component 1030 (e.g., including the knitted base layer 1040, the knitted net layer 1050, a second knitted base layer, or any combination thereof) can include distinct zones. The zones can have distinct features or characteristics of one or more of the knitted base layer 1040, the knitted net layer 1050, a second knitted base layer, or a combination of these. It should be understood that each of these features or characteristics may be incorporated alone or in combination with other features or characteristics and/or with one or more other aspects described herein. In aspects, the knitted component 1030 has one or more zones configured to provide one or more functions and/or benefits. For example, some zones may have larger or smaller cells 1056 of the knitted net layer 1050 than other zones; some zones may have differently shaped cells 1056 forming part of the knitted net layer 1050; and/or some zones may be positioned at different areas of the knitted net layer 1050 (e.g., a forefoot region, a heel region, a lateral side, a medial side, a throat region, a combination of these). For example, some zones may have apertures in the knitted base layer 1040; and/or some zones may be positioned at different areas of the knitted base layer 1040 (e.g., a forefoot region, a heel region, a lateral side, a medial side, a throat region, a combination of these).

In a first zone 1072 of the knitted component 1030, the knitted net layer 1050 includes a variety of overlapping cells 1056A near a throat region 1026 of the knitted component 1030. In the first zone 1072, the overlapping cells form pentagonal shapes and overlap one another such that a unique pattern and/or containment configuration is created. In aspects, the overlapping cells 1056A may provide additional containment in the area of the first zone 1072 based on their comparatively smaller size. In other examples, the overlapping cells 1056A may have one or more other shapes, including a combination thereof, such as triangular shapes, quadrilateral shapes, hexagonal shapes, and the like. The overlapping cells 1056A may form one or more secondary shapes through overlapping. For example, the overlapping cells 1056A are primarily pentagonal in FIG. 10, and the overlapping of these pentagonal shapes may create triangular shapes at one or more overlapping sections 1058 of the overlapping cells 1056A. While the first zone 1072 is shown adjacent to the throat area 1026, the first zone 1072 may be positioned in any one or more areas of the knitted component 1030 (e.g., a forefoot region, a heel region, a lateral side, a medial side, a combination of these), including substantially throughout the knitted component 1030.

In a second zone 1074 of the knitted component 1030, the knitted net layer 1050 includes a number of extended cells 1056B. In the second zone 1074, the extended cells 1056B form hexagonal shapes. In other examples, the extended cells 1056B may take other shapes, such as extended quadrilateral shapes, extended triangular shapes, extended pentagonal shapes, and the like. The incorporation of extended cells 1056B may provide an additional unique containment function, and the extended cells 1056B may provide similar benefits as inlaid strands 1060 (e.g., provide containment by reducing stretch and providing structure). In aspects, the extended cells 1056B may have a first length 1090A, which may vary at various locations of the second zone 1074, while adjacent cells 1056 have a second length 1090B. The first length 1090A may be larger than the second length 1090B (e.g., at least double, at least 1.5 times, at least triple the second length 1090B). While the second zone 1074 is shown adjacent to the first zone 1072, the second zone 1074 may be positioned in any one or more areas of the knitted component 1030 (e.g., a forefoot region, a heel region, a lateral side, a medial side, a throat region, a combination of these), including substantially throughout the knitted component 1030.

In a third zone 1076 of the knitted component 1030, the knitted base layer 1040 includes apertures 1080. In aspects, the knitted net layer 1050 includes one or more quadrilateral cells 1056C exposing the apertures 1080 in the knitted base layer 1040. In some aspects, e.g., the aspect shown in FIG. 10, the knitted base layer 1040 includes apertures 1080 that can provide additional breathability and moisture permeability in a forefoot region of the knitted component 1030. In some aspects, the apertures 1080 are formed by transfer stitches (e.g., a stitch that is moved to a different needle or needle bed) in the knitted net layer 1040 to thereby create an opening in the knitted base layer 1040, as shown generically in FIG. 10. While one aperture 1080 is shown within each quadrilateral cell 1056C of the third zone 1076 in FIG. 10, each quadrilateral cell 1056C may include additional apertures 1080 and/or one or more quadrilateral cell 1056C may be offset from the apertures, which may further enhance breathability, moisture permeability, and the visual appearance of transparency through the knitted net layer 1050 and knitted base layer 1040. The apertures may also vary in the area occupied inside the corresponding cell, e.g., being between about 10-80% of the total cell area, in aspects. In accordance with aspects herein, apertures can also be provided as one or multiple apertures and the apertures can be located in different areas of a knitted base layer, e.g., forefoot, midfoot, later side, medial side, tongue, heel, vamp, or any combination thereof. While the third zone 1076 is shown in the forefoot region of the knitted component 1030 in FIG. 10, the third zone 1076 (e.g., the apertures 1080 in the knitted base layer 1040) may be positioned in any one or more areas of the knitted component 1030 (e.g., a heel region, a lateral side, a medial side, a throat region, a combination of these), including substantially throughout the knitted component 1030.

While the knitted net layer 1050 in each of the first zone 1072, the second zone 1074, and the third zone 1076 are shown as a continuous knitted net layer 1050, the knitted net layer 1050 in each of the zones 1072, 1074, and 1076 may in aspects be discontinuous such that the cells 1056 are not all connected to each other. In aspects, a discontinuous knitted net layer 1050 may provide a unique, dynamic, and/or striking visual pattern and/or aesthetic to the exterior of the knitted component 1030 (e.g., camouflage-like pattern, pixel shapes, splatters, florals, plaids, among others). In such aspects, the discontinuous knitted net layer 1050 may be at least partially formed of one or more incomplete cells 1056, such that some cells 1056 are not entirely enclosed by edges. In aspects, the visual pattern and/or striking appearance and/or containment may be enhanced by incorporating the inlaid strands 1060 at one or more areas of the knitted component 1030 (e.g., in one or more of the first zone 1072, second zone 1074, third zone 1076, a forefoot region, a medial side, a lateral side, a heel area) in one or more orientations (e.g., course-wise, wale-wise, radially extending toward a common portion).

Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.

It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.

• • Clause 1. An article of footwear comprising a knitted component, the knitted component comprising: a knitted base layer; a knitted net layer integrally knitted with the knitted base layer; and one or more inlaid strands extending between the knitted base layer and the knitted net layer.
  • Clause 2. The article of footwear clause 1, wherein one or more yarns forming the knitted net layer form a plurality of polygon cells, wherein adjacent polygon cells share at least one common vertex.
  • Clause 3. The article of footwear of clause 2, wherein each polygon cell has a width between a first vertex and a second vertex, wherein the width is at least a width of five wales of the knitted base layer.
  • Clause 4. The article of footwear of clause 3, wherein the width between the first vertex and the second vertex is seven wales of the knitted base layer.
  • Clause 5. The article of footwear of any of clauses 2 through 4, wherein each of the plurality of polygon cells are quadrilaterals.
  • Clause 6. The article of footwear of any of clauses 2 through 5, wherein each polygon cell includes at least one inlaid strand extending across the polygon cell.
  • Clause 7. The article of footwear of any of clauses 2 through 6, wherein each polygon cell includes at least two inlaid strands spaced apart from each other.
  • Clause 8. The article of footwear of clause 7, wherein the at least two inlaid strands are asymmetrically positioned within the polygon cell.
  • Clause 9. The article of footwear of any of clauses 2 through 8, wherein each polygon cell is defined by floating sections of yarn of the knitted net layer extending between one or more vertices, wherein the one or more inlaid strands intersect the floating sections.
  • Clause 10. The article of footwear of any of clauses 1 through 9, wherein the knitted base layer comprises one or more first yarns and the knitted net layer comprises one or more second yarns, and wherein the one or more first yarns are intermittently joined with the one or more second yarns by a tuck stitch.
  • Clause 11. The article of footwear of any of clauses 1 through 10, wherein the knitted base layer is formed with one or more first yarns, and the knitted net layer is formed with one or more second yarns, and wherein the one or more second yarns have a lower melting temperature than the one or more first yarns.
  • Clause 12. The article of footwear of any of clauses 7 through 11, wherein the one or more inlaid strands have a lower melting temperature than the one or more first yarns.
  • Clause 13. The article of footwear of any of clauses 2 through 12, wherein each side of the plurality of polygon cells of the knitted net layer is formed with multiple ends of a yarn.
  • Clause 14. The article of footwear of any of clauses 1 through 13, wherein the knitted base layer forms an inner-facing surface of an upper of the article of footwear, and the knitted net layer at least partially forms an outer-facing surface of the upper.
  • Clause 15. The article of footwear of any of clauses 1 through 14, wherein the knitted component forms at least part of an upper having a medial side and a lateral side, wherein the one or more inlaid strands extend from the medial side to the lateral side of the upper.
  • Clause 16. An article of footwear comprising a knitted component, the knitted component comprising: a knitted base layer formed with one or more first yarns; and a knitted net layer formed with one or more second yarns that at least partially overlay the one or more first yarns of the knitted base layer, wherein a thermoplastic polymer material at least partially fuses the one or more second yarns of the knitted net layer and the one or more first yarns of the knitted base layer.
  • Clause 17. The article of footwear of clause 16, wherein the one or more second yarns each comprise a core yarn, the thermoplastic polymer material having a lower melting temperature than the core yarn.
  • Clause 18. The article of footwear of clause 17, wherein the core yarn is at least partially covered by a sheath of the thermoplastic polymer material.
  • Clause 19. The article of footwear of any of clauses 16 through 18, wherein the thermoplastic polymer material has a melting temperature that is lower than a melting temperature or decomposition temperature of the one or more first yarns.
  • Clause 20. The article of footwear of any of clauses 16 through 19, wherein the knitted base layer is integrally knit with the knitted net layer.
  • Clause 21. The article of footwear of any of clauses 16 through 20, wherein the knitted component further includes one or more inlaid strands positioned between the knitted base layer and the knitted net layer, wherein the thermoplastic polymer material at least partially fuses the one or more inlaid strands to the one or more second yarns of the knitted net layer.
  • Clause 22. The article of footwear of clause 21, wherein the thermoplastic polymer material further fuses the one or more inlaid strands to a portion of the knitted base layer that extends across an opening of a cell of the knitted net layer.
  • Clause 23. A method forming a knitted component, the method comprising: forming a knitted base layer having one or more first yarns forming a plurality of courses of knitted loops; forming a knitted net layer having one or more second yarns forming a net of polygon cells; and inlaying one or more inlaid strands within the knitted component so that the one or more inlaid strands are at least partially arranged between the knitted base layer and the knitted net layer.
  • Clause 24. The method of clause 23, wherein the knitted base layer and the knitted net layer are secured together.
  • Clause 25. The method of clauses 23 or 24, wherein the knitted base layer and the knitted net layer are integrally knit.
  • Clause 26. The method of any of clauses 23 through 25, wherein the knitted base layer and the knitted net layer are secured together by a plurality of tuck stitches.
  • Clause 27. The method of any of clauses 23 through 26, wherein the one or more second yarns of the knitted net layer are tucked with a knitted loop stitch of the one or more first yarns of the knitted base layer.
  • Clause 28. The method of any of clauses 23 through 27, wherein the one or more first yarns and the one or more second yarns are fused together.
  • Clause 29. The method of any of clauses 23 through 27, wherein the one or more second yarns comprise a core surrounded by a sheath of a thermoplastic polymer material having a lower melting temperature than the core.
  • Clause 30. The method of any of clauses 23 through 28, further comprising: applying heat to the knitted component so that a sheath of the one or more second yarns is at least partially melted; and cooling the knitted component so that the thermoplastic polymer material fuses the one or more second yarns with the one or more first yarns.
  • Clause 31. The method of clauses 29 or 30, wherein the one or more first yarns have a higher melting temperature than the thermoplastic polymer material of the one or more second yarns, wherein the one or more first yarns are not melted when heat is applied to the knitted component.
  • Clause 32. The method of any of clauses 23 through 28, wherein the one or more inlaid strands comprise a core surrounded by a sheath of a thermoplastic polymer material.
  • Clause 33. The method of any of clauses 23 through 28, wherein the knitted component is formed into an upper and secured to a sole structure.
  • Clause 34. An article of footwear comprising a knitted component, the knitted component comprising: a knitted base layer formed with one or more first yarns; a knitted net layer formed with one or more second yarns that at least partially overlay the one or more first yarns of the knitted base layer, the one or more second yarns comprising a first component and a second component having a lower melting temperature than the first component and the one or more first yarns; and one or more composite structures where the knitted base layer is secured to the knitted net layer, the one or more composite structures each comprising the one or more first yarns, the first component of the one or more second yarns, and the second component of the one or more second yarns in a reflowed and resolidified state at least partially surrounding the one or more first yarns and the first component of the one or more second yarns within the one or more composite structures.
  • Clause 35. The article of footwear of clause 34, wherein the knitted component further comprises one or more inlaid strands, wherein at least a subset of the one or more composite structures further includes the one or more inlaid strands.
  • Clause 36. The article of footwear of clause 35, wherein the one or more inlaid strands comprises a first component and a second component having a lower melting temperature than the first component of the one or more inlaid strands, wherein the subset of the one or more composite structures further comprises the second component of the one or more inlaid strands in a reflowed and resolidified state.
  • Clause 37. The article of footwear of clauses 35 or 36, wherein the one or more inlaid strands comprises a first component and a second component having a lower melting temperature than the first component of the one or more inlaid strands, wherein the second component of the one or more inlaid strands is the same material as the second component of the one or more second yarns, wherein within the subset of the one or more composite structures, the second component of the one or more second yarns and the second component of the one or more inlaid strands are each in a reflowed and resolidified state at least partially surrounding the one or more first yarns, the first component of the one or more second yarns, and the first component of the one or more inlaid strands.
  • Clause 38. The article of footwear of any of clauses 34 through 37, wherein the one or more composite structures include a plurality of composite structures that are spaced apart and separated from one another by portions of the knitted base layer that are not part of composite structures.
  • Clause 39. The article of footwear of any of clauses 34 through 38, wherein the knitted base layer has radially extending courses.
  • Clause 40. A knitted component comprising: a knitted base layer having a first portion comprising full-length courses and partial-length courses; and a knitted net layer integrally knitted with the knitted base layer, a first portion of the knitted net layer overlaying the first portion of the knitted base layer, the knitted net layer having no partial-length courses.
  • Clause 41. The knitted component of clause 40, wherein the knitted base layer comprises one or more first yarns, and the knitted net layer comprises one or more second yarns that each comprise a first component and a second component having a lower melting temperature of the first component.
  • Clause 42. The knitted component of clause 41, wherein the knitted component comprises one or more composite structures each comprising the one or more first yarns, the first component of the one or more second yarns, and the second component of the one or more second yarns in a reflowed and resolidified state at least partially surrounding the one or more first yarns and the first component within the one or more composite structures.
  • Clause 43. The knitted component of any of clauses 40 through 42, further comprising one or more inlaid strands at least partially positioned between the knitted base layer and the knitted net layer.
  • Clause 44. The knitted component of any of clauses 40 through 42, further comprising one or more inlaid strands, wherein the one or more inlaid strands are radially extending from an outer perimeter to a throat area when the knitted component is incorporated into an upper for an article of footwear.
  • Clause 45. The knitted component of clauses 43 or 44, wherein the knitted base layer comprises one or more first yarns, the knitted net layer comprises one or more second yarns that each comprise a first component and a second component having a lower melting temperature than the first component of the one or more second yarns, and the one or more inlaid strands comprising a first component and a second component having a lower melting temperature than the first component of the one or more inlaid strands.
  • Clause 46. The knitted component of clause 45, wherein the second component of the one or more second yarns and the second component of the one or more inlaid strands have a lower melting temperature than the one or more first yarns.
  • Clause 47. The knitted component of any of clauses 40 through 46, wherein the knitted base layer and the knitted net layer are secured together by a plurality of tuck stitches.
  • Clause 48. An article of footwear comprising an upper with the knitted component of claim 40.
  • Clause 49. The article of footwear of clause 48, wherein the knitted net layer comprises one or more yarns forming a plurality of polygon cells, wherein adjacent polygon cells share at least one common vertex.
  • Clause 50. The article of footwear of clause 49, wherein the plurality of polygon cells form a row extending from a biteline of the article of footwear to an inner perimeter, wherein an area of each polygon cell decreases in a pattern from the biteline to the inner perimeter.
  • Clause 51. The knitted component of any of clauses 44 through 50, wherein the one or more inlaid strands are radially extending in a forefoot region of the upper when the knitted component is incorporated into the upper.
  • Clause 52. An article of footwear comprising a knitted component, the knitted component comprising: a first knitted base layer comprising one or more first yarns; a knitted net layer comprising one or more second yarns that at least partially overlay the one or more first yarns; and a second knitted base layer comprising one or more third yarns that at least partially overlay the one or more second yarns, wherein a thermoplastic polymer material at least partially fuses the one or more first yarns, the one or more second yarns, and the one or more third yarns.
  • Clause 53. The article of footwear of clause 52, wherein the one or more second yarns each comprise a core yarn, the thermoplastic polymer material having a lower melting temperature than the core yarn.
  • Clause 54. The article of footwear of clause 53, wherein the core yarn is at least partially covered by a sheath of the thermoplastic polymer material.
  • Clause 55. The article of footwear of any of clauses 52 through 54, wherein the thermoplastic polymer material has a melting temperature that is lower than a melting temperature or decomposition temperature of the one or more first yarns.
  • Clause 56. The article of footwear of any of clauses 52 through 55, wherein the one or more first yarns and the one or more third yarns have the same material composition.
  • Clause 57. The article of footwear of any of clauses 52 through 56, wherein the knitted net layer is integrally knit with the first knitted base layer and the second knitted base layer.
  • Clause 58. The article of footwear of any of clauses 52 through 57, wherein the knitted component further includes one or more inlaid strands positioned between the first knitted base layer and the knitted net layer, wherein the thermoplastic polymer material at least partially fuses the one or more inlaid strands to the one or more second yarns of the knitted net layer.
  • Clause 59. The article of footwear of clause 58, wherein the thermoplastic polymer material further fuses the one or more inlaid strands to portions of the first knitted base layer and the second knitted base layer that extend across an opening of a cell of the knitted net layer.
  • Clause 60. The article of footwear of any of clauses 52 through 59, wherein the first knitted base layer and the second knitted base layer have different knit densities.
  • Clause 61. The article of footwear of any of clauses 52 through 60, wherein the first knitted base layer has a greater knit density than the second knitted base layer.
  • Clause 62. The article of footwear of any of clauses 52 through 61, wherein the knitted component includes one or more inlaid strands at least partially arranged between the first knitted base layer and the knitted net layer.
  • Clause 63. The article of footwear of clause 62, wherein the one or more inlaid strands are at least partially fused to the first knitted base layer.
  • Clause 64. The article of footwear of clause 62 or 63, wherein the one or more inlaid strands are at least partially fused to the knitted net layer.
  • Clause 65. The article of footwear of any of clauses 62 through 64, wherein the one or more inlaid strands are at least partially fused to the second knitted base layer.
  • Clause 66. The article of footwear of any of clauses 62 through 65, wherein the one or more inlaid strands are secured to the knitted component by tuck stitches with at least one of the first knitted base layer, the knitted net layer, or the second knitted base layer.
  • Clause 67. An article of footwear comprising a knitted component, the knitted component comprising: a knitted base layer; and a knitted net layer.
  • Clause 68. The article of footwear of clause 67, wherein the knitted base layer comprises one or more first yarns and the knitted net layer comprises one or more second yarns.
  • Clause 69. The article of footwear of clauses 67 or 68, wherein one or more yarns forming the knitted net layer form a plurality of polygon cells, wherein adjacent polygon cells share at least one common vertex.
  • Clause 70. The article of footwear of clause 69, wherein each polygon cell has a width between a first vertex and a second vertex, wherein the width is at least a width of five wales of the knitted base layer.
  • Clause 71. The article of footwear of clause 70, wherein the width between the first vertex and the second vertex is seven wales of the knitted base layer.
  • Clause 72. The article of footwear of any of clauses 69 through 71, wherein each of the plurality of polygon cells are quadrilaterals.
  • Clause 73. The article of footwear of any of clauses 69 through 72, wherein each polygon cell includes at least one inlaid strand extending across the polygon cell.
  • Clause 74. The article of footwear of any of clauses 69 through 73, wherein each polygon cell includes at least two inlaid strands spaced apart from each other.
  • Clause 75. The article of footwear of clause 74, wherein the at least two inlaid strands are asymmetrically positioned within the polygon cell.
  • Clause 76. The article of footwear of any of clauses 69 through 75, wherein each polygon cell is defined by floating sections of yarn of the knitted net layer extending between one or more vertices, wherein the one or more inlaid strands intersect the floating sections.
  • Clause 77. The article of footwear of any of clauses 68 through 76, wherein the one or more second yarns have a lower melting temperature than the one or more first yarns, and wherein the knitted net layer is at least partially fused to the knitted base layer.
  • Clause 78. The article of footwear of any of clauses 73 through 77, wherein the one or more inlaid strands have a lower melting temperature than the one or more first yarns.
  • Clause 79. The article of footwear of any of clauses 69 through 78, wherein each side of the plurality of polygon cells of the knitted net layer is formed with multiple ends of a yarn.
  • Clause 80. The article of footwear of any of clauses 67 through 79, wherein the knitted base layer forms an inner-facing surface of an upper of the article of footwear, and the knitted net layer at least partially forms an outer-facing surface of the upper.
  • Clause 81. The article of footwear of any of clauses 67 through 80, wherein the knitted component forms at least part of an upper having a medial side and a lateral side, wherein the one or more inlaid strands extend from the medial side to the lateral side of the upper.
  • Clause 82. The article of footwear of any of clauses 68 through 81, wherein the one or more first yarns are intermittently joined with the one or more second yarns by a tuck stitch.
  • Clause 83. The article of footwear of any of clauses 67 through 82, further comprising a second knitted base layer positioned to overlap with at least a portion of the knitted net layer, wherein the second knitted base layer is formed of one or more third yarns.
  • Clause 84. The article of footwear of any of clauses 68 through 83, wherein the one or more first yarns are transparent, translucent, or a lighter color, wherein the one or more second yarns comprise one or more contrasting colors.
  • Clause 85. The article of footwear of any of clauses 68 through 83, wherein the one or more first yarns comprise one or more contrasting colors, wherein the one or more second yarns are transparent, translucent, or a lighter color.
  • Clause 86. The article of footwear of any of clauses 68 through 83, wherein the one or more first yarns comprise one or more contrasting colors, and wherein the one or more second yarns comprise one or more contrasting colors.
  • Clause 87. The article of footwear of any of clauses 83 through 86, wherein the one or more third yarns are transparent, translucent, or a lighter color.
  • Clause 88. The article of footwear of any of clauses 83 through 86, wherein the one or more third yarns comprise one or more contrasting colors.
  • Clause 89. The article of footwear of any of clauses 67 through 88, wherein the knitted component further comprises one or more inlaid strands positioned between the knitted base layer and the knitted net layer, wherein a thermoplastic polymer material of the one or more inlaid strands at least partially fuses the one or more inlaid strands to the one or more second yarns of the knitted net layer.
  • Clause 90. The article of footwear of any of clauses 67 through 88, wherein the knitted component further comprises one or more inlaid strands positioned between the knitted base layer and the knitted net layer, wherein a thermoplastic polymer material of the one or more second yarns at least partially fuses the one or more inlaid strands to the one or more second yarns of the knitted net layer.
  • Clause 89. The article of footwear of any of clauses 67 through 88, wherein the knitted component further comprises one or more inlaid strands positioned between the knitted base layer and the knitted net layer, wherein a thermoplastic polymer material of the one or more first yarns at least partially fuses the one or more inlaid strands to the one or more first yarns.
  • Clause 90. The article of footwear of any of clauses 68 through 89, wherein the one or more second yarns each comprise a high-melting core and a low-melting sheath, wherein the one or more second yarns are at least partially fused to the one or more first yarns.
  • Clause 91. The article of footwear of clause 90, wherein the core comprises one or more contrasting colors, and wherein the sheath comprises a transparent, translucent, or lighter color.
  • Clause 92. The article of footwear of any of clauses 83 through 91, wherein the one or more third yarns comprise a low-melting thermoplastic material, and wherein the one or more third yarns are fused to the knitted net layer.
  • Clause 93. The article of footwear of any of clauses 69 through 92, wherein at least a portion of the polygonal cells are overlapping cells, wherein the overlapping cells create a primary shape and a secondary shape.
  • Clause 94. The article of footwear of clause 93, wherein the primary shape is a pentagonal shape and the secondary shape is a triangular shape.
  • Clause 95. The article of footwear of any of clauses 69 through 94, wherein at least a portion of the polygonal cells are extended cells, wherein the extended cells have a length longer than a length associated with the one or more polygonal cells.
  • Clause 96. The article of footwear of any of clauses 69 through 95, wherein at least a portion of the knitted base layer includes a plurality of apertures extending through the knitted base layer.
  • Clause 97. The article of footwear of clause 96, wherein at least a portion of the polygonal cells expose the plurality of apertures of the knitted base layer.
  • Clause 98. The article of footwear of clauses 96 or 97, wherein the plurality of apertures are positioned in a forefoot region of the knitted base layer.
  • Clause 99. The article of footwear of any of clauses 67 through 98, wherein the knitted net layer is discontinuous in one or more areas of the knitted component.
  • Clause 100. The article of footwear of clause 99, wherein the knitted net layer is discontinuous to produce one or more patterns on the knitted component.
  • Clause 101. The article of footwear of any of clauses 67 through 100, wherein the knitted base layer and the knitted net layer are integrally knitted using one or more tuck stitches.
  • Clause 102. The article of footwear of any of clauses 67 through 100, wherein the knitted base layer and the knitted net layer are joined through stitching.
  • Clause 103. The article of footwear of any of clauses 67 through 100, wherein the knitted base layer and the knitted net layer are joined through bonding.
  • Clause 104. The article of footwear of any of clauses 67 through 103, wherein the knitted component comprises one or more zones within one or more of the knitted base layer or the knitted net layer.
  • Clause 105. The article of footwear of clause 104, wherein the one or more zones are within the knitted base layer and wherein the one or more zones comprise the plurality of apertures extending through the knitted base layer.
  • Clause 106. The article of footwear of clauses 104 or 105, wherein the one or more zones are within the knitted net layer and wherein the one or more zones comprise the overlapping cells creating the primary shape and the secondary shape.
  • Clause 107. The article of footwear of any of clauses 104 through 106, wherein the one or more zones are within the knitted net layer and wherein the one or more zones comprise the extended cells.
  • Clause 108. The article of footwear of any of clauses 93 through 103, wherein one or more zones of the knitted component comprises the overlapping cells creating the primary shape and the secondary shape.
  • Clause 109. The article of footwear of any of clauses 95 through 103, wherein one or more zones of the knitted component includes the extended cells.
  • Clause 110. The article of footwear of any of clauses 96 through 103, wherein one or more zones includes the plurality of apertures extending through the knitted base layer.
  • Clause 111. The article of footwear of any of clauses 108 through 110, wherein the one or more zones are discontinuous in one or more areas of the knitted component.
  • Clause 112. The article of footwear of any of clauses 104 through 111, wherein the one or more zones are positioned at a forefoot region of the knitted component.
  • Clause 113. The article of footwear of any of clauses 104 through 112, wherein the one or more zones are positioned at a lateral side of the knitted component.
  • Clause 114. The article of footwear of any of clauses 104 through 113, wherein the one or more zones are positioned at a medial side of the knitted component.
  • Clause 115. The article of footwear of any of clauses 104 through 114, wherein the one or more zones are positioned at a heel region of the knitted component.
  • Clause 116. The article of footwear of any of clauses 104 through 115, wherein the one or more zones are positioned at a throat region of the knitted component.
  • Clause 117. The article of footwear of any of clauses 104 through 116, wherein the one or more zones include the one or more inlaid strands.
  • Clause 118. An article of footwear comprising a knitted base layer and a knitted net layer coupled together and forming part of an upper, wherein the knitted base layer comprises one or more distinct zones and/or the knitted net layer comprises one or more distinct zones.

Claims

1. An article of footwear comprising a knitted component, the knitted component comprising: a knitted base layer;a knitted net layer integrally knitted with the knitted base layer; andone or more inlaid strands extending between the knitted base layer and the knitted net layer.

2. The article of footwear claim 1, wherein one or more yarns forming the knitted net layer form a plurality of polygon cells, wherein adjacent polygon cells share at least one common vertex.

3. The article of footwear of claim 2, wherein each polygon cell has a width between a first vertex and a second vertex, wherein the width is at least a width of five wales of the knitted base layer.

4. The article of footwear of claim 3, wherein the width between the first vertex and the second vertex is seven wales of the knitted base layer.

5. The article of footwear of claim 2, wherein each of the plurality of polygon cells are quadrilaterals.

6. The article of footwear of claim 2, wherein each polygon cell includes at least one inlaid strand extending across the polygon cell.

7. The article of footwear of claim 2, wherein each polygon cell includes at least two inlaid strands spaced apart from each other.

8. The article of footwear of claim 7, wherein the at least two inlaid strands are asymmetrically positioned within the polygon cell.

9. The article of footwear of claim 2, wherein each polygon cell is defined by floating sections of yarn of the knitted net layer extending between one or more vertices, wherein the one or more inlaid strands intersect the floating sections.

10. An article of footwear comprising a knitted component, the knitted component comprising: a knitted base layer formed with one or more first yarns; anda knitted net layer formed with one or more second yarns that at least partially overlay the one or more first yarns of the knitted base layer,wherein a thermoplastic polymer material at least partially fuses the one or more second yarns of the knitted net layer and the one or more first yarns of the knitted base layer.

11. The article of footwear of claim 10, wherein the one or more second yarns each comprise a core yarn, the thermoplastic polymer material having a lower melting temperature than the core yarn.

12. The article of footwear of claim 11, wherein the core yarn is at least partially covered by a sheath of the thermoplastic polymer material.

13. The article of footwear of claim 10, wherein the thermoplastic polymer material has a melting temperature that is lower than a melting temperature or decomposition temperature of the one or more first yarns.

14. The article of footwear of claim 10, wherein the knitted base layer is integrally knit with the knitted net layer.

15. The article of footwear of claim 10, wherein the knitted component further includes one or more inlaid strands positioned between the knitted base layer and the knitted net layer, wherein the thermoplastic polymer material at least partially fuses the one or more inlaid strands to the one or more second yarns of the knitted net layer.

16. The article of footwear of claim 10, wherein the knitted net layer is joined to the knitted base layer through stitching and/or bonding.

17. An article of footwear comprising a knitted component, the knitted component comprising: a first knitted base layer comprising one or more first yarns;a knitted net layer comprising one or more second yarns that at least partially overlay the one or more first yarns; anda second knitted base layer comprising one or more third yarns that at least partially overlay the one or more second yarns,wherein a thermoplastic polymer material at least partially fuses the one or more first yarns, the one or more second yarns, and the one or more third yarns.

18. The article of footwear of claim 17, wherein the one or more second yarns each comprise a core yarn, the thermoplastic polymer material having a lower melting temperature than the core yarn.

19. The article of footwear of claim 18, wherein the core yarn is at least partially covered by a sheath of the thermoplastic polymer material.

20. The article of footwear of claim 18, wherein the thermoplastic polymer material has a melting temperature that is lower than a melting temperature or decomposition temperature of the one or more first yarns.

21. The article of footwear of claim 17, wherein the one or more first yarns and the one or more third yarns have the same material composition.

22. The article of footwear of claim 17, wherein the knitted net layer is integrally knit with the first knitted base layer and the second knitted base layer.

23. The article of footwear of claim 17, wherein the knitted component further includes one or more inlaid strands positioned between the first knitted base layer and the knitted net layer, wherein the thermoplastic polymer material at least partially fuses the one or more inlaid strands to the one or more second yarns of the knitted net layer.

24. The article of footwear of claim 23, wherein the thermoplastic polymer material further fuses the one or more inlaid strands to portions of the first knitted base layer and the second knitted base layer that extend across an opening of a cell of the knitted net layer.

25. The article of footwear of claim 17, wherein the first knitted base layer and the second knitted base layer have different knit densities.

26. The article of footwear of claim 25, wherein the first knitted base layer has a greater knit density than the second knitted base layer.