Patent Application
20250213001
Traditional articles of footwear, including those with uppers, may include sole structures that are secured to the upper by way of applied adhesives or other applied bonding agents. The application of the adhesive during the manufacturing process as well as the securement of the sole structures to the upper using the adhesive or bonding agent may increase the number of manufacturing steps as well as increase the production time associated with the article of footwear. Additionally, the use of adhesives or other types of bonding methods may increase the carbon footprint associated with the manufacturing process and may potentially limit the recyclability of the article of footwear.
In some instances, with traditional articles of footwear, a sole structure, such as a midsole, is positioned within a foot-receiving void of an upper. Typically, due to the materials incorporated into the upper that provide the upper with the structure and stability desired for wear and repeated use, the midsole, or any other component positioned within or adjacent to the foot-receiving void of the upper, is generally not visible or viewable when viewing the article of footwear from an external viewpoint. This may limit the visual impact of the midsole and/or any visual indicators associated with the midsole or other components/structures positioned within the foot-receiving void of the upper.
Examples of aspects herein are described in detail below with reference to the attached drawing figures, wherein:
Aspects herein are directed to an article of footwear having an upper, an upper for an article of footwear, and methods of manufacturing an upper for an article of footwear. In example aspects, the upper includes yarns and knit structures that, after processing, form, at least in part, a translucent or transparent thermoplastic polymer layer, which may be made by thermoforming the upper, that facilitates visibility of a first sole structure, such as a midsole, that is removably positioned within a foot-receiving void of the upper. In another example aspect, the upper may include yarns and knit structures along with a translucent or transparent thermoplastic polymer film that, after processing, forms a translucent or transparent thermoplastic polymer layer that facilitates visibility of the first sole structure. Use of the translucent or transparent thermoplastic polymer layer to provide visibility of the first sole structure enhances the visual appeal of the article of footwear. It may also act as a visual indicator of the functional features of the particular midsole that is removably positioned within the foot-receiving void of the upper. For example, a wearer may have a number of different midsoles, with each having a different functional feature such as increased arch support, increased heel support, and the like. The functional feature associated with a particular midsole may be visually indicated by, for example, a color of the midsole (e.g., a red midsole may indicate increased arch support). When the wearer wishes to wear the article of footwear, they can easily view the midsole that is positioned within the foot-receiving void through the translucent or transparent polymer layer and make a determination of whether the midsole meets the particular needs of the activity in which the wearer is intending to engage.
In additional examples, the polymer layer may also secure a second sole structure to an underfoot portion of the upper. For example, when heat and/or pressure are applied to the upper, some of the material forming the yarn(s) of the upper may melt and flow. Upon cooling, the melted material hardens and forms a thermoformed layer that acts as the thermoplastic polymer layer. In another aspect, when a translucent or transparent thermoplastic polymer film is utilized, and when heat and/or pressure are applied to the upper, the thermoplastic polymer film may melt and flow to form the thermoplastic polymer layer. When the material is in a melted state, a second sole structure may be directly secured to the melted material such that the second sole structure is positioned at an outer-facing surface of the underfoot portion of the upper. Securing the second sole structure in this way eliminates and/or reduces the need for applied adhesives or bonding agents. In examples, this may reduce the number of processing steps associated with making the article of footwear, reduce the carbon footprint associated with making the article of footwear, and potentially enhance the recyclability of the article of footwear. In some aspects, an adhesive and/or bonding agent is used but the melted polymer from the upper may help strengthen the bond between the upper and the sole structure. In one embodiment, the upper may be thermoformed and molded to form one or more three-dimensional shapes complementary to one or more three-dimensional shapes of the second sole structure. The molded upper may then be secured to the second sole structure via an adhesive, for example.
In some examples, during the processing step of the upper, a last may be positioned within the foot-receiving void of the upper where the last includes an underfoot portion having a plurality of last supports or ridges and a plurality of last recesses disposed between adjacent last supports. After the application of heat and/or pressure to at least the underfoot portion of the upper and subsequent cooling, the resulting thermoplastic polymer layer in the underfoot portion is molded to include a plurality of supports and a plurality of recesses having a shape corresponding to the plurality of last supports and the plurality of last recesses. The upper may have a knitted structure that enables the supports of the upper to be molded into a more precise shape as described herein. In some examples, each of the plurality of supports may terminate in a support surface that, in example aspects, may be non-planar (i.e., not smooth or flat).
In examples, the second sole structure, which may be in the form of a fluid-filled bladder, includes one or more bulbs that are secured to the support surfaces of the one or more of the supports of the underfoot portion of the upper. In example aspects, the bulbs of the second sole structure may also include a non-planar surface. Having a non-planar surface for the support surfaces of the supports of the underfoot portion of the upper as well as having a non-planar surface for the bulbs of the second sole structure may increase the surface area of each of the supports and bulbs. Having a greater surface area at the points of securement between the second sole structure and the underfoot portion of the upper may improve or enhance the securement of these structures to each other.
After the second sole structure is secured to the upper by way of the polymer layer, the upper is spaced apart from the second sole structure at the plurality of recesses of the upper. This configuration may create a shock-absorbing system where the bulbs of the second sole structure absorb forces transmitted by way of the supports of the underfoot portion of the upper. Additionally, the spaces located between the recesses of the upper and the second sole structure may help to localize the forces transmitted by way of the supports of the underfoot portion of the upper to just the bulbs of the second sole structure, which may increase the number of flexion points of the second sole structure. This, in turn, may improve wearer comfort and reduce foot fatigue. Also, the spaces between the recesses of the upper and the second sole structure may resiliently compress under a load, which may further enhance the cushioning features of the article of footwear.
In examples, the upper may include a first knit zone that, after processing, includes the translucent or transparent thermoplastic polymer layer. In some examples, the first knit zone comprises a first knit layer having a knitted mesh structure with a first set of yarns. The first set of yarns may include, in one example, a core/sheath yarn comprising a core of a high-melting material surrounded by a sheath of a thermoplastic material having a relatively low melting point (i.e., a melting point lower than the melting point of the high-melting core). In a second example, the first set of yarns may include one or more of a single high-melting material such as a polyamide (e.g., nylon) monofilament and/or a bicomponent monofilament yarn (e.g., a co-extruded yarn with a first high-melting material and a second high-melting material). In examples, the first set of yarns is opaque.
In some aspects, the knit structure of the first knit zone is a single-layer structure comprising the first knit layer. Further, a film comprising a thermoplastic polymer material may be applied over at least a portion of a surface of the first knit layer. The thermoplastic polymer material of the film has a melting temperature that is less than the melting temperature of the sheath of the first set of yarns (when a core/sheath yarn is used). Further, in some examples, the film comprises two layers of two thermoplastic polymer materials where at least one of the thermoplastic polymer materials of the film has a lower melting temperature than the sheath of the first set of yarns. As such, heat may be applied that is sufficient to cause the lower melting thermoplastic material of the film to melt but not sufficient to melt the thermoplastic material forming the sheath of the first set of yarns, though it may be sufficient to soften the thermoplastic material of the first set of yarns. The melted thermoplastic material of the polymer film flows via, for example, the application of pressure such that it at least partially encapsulates the first set of yarns. In examples, the melted thermoplastic polymer film does not fully encapsulate the first set of yarns such that it may encapsulate a portion of the first set of yarns on what will form an outer-facing surface of the first knit layer when it is formed into an upper but not yarn portions forming an inner-facing surface. Stated differently, the first knit layer may be partially embedded within the melted thermoplastic polymer film such that the film extends through the outer-facing surface of the first knit layer but does not extend to the inner-facing surface of the first knit layer.
Once cooled, the melted thermoplastic film forms the transparent and/or translucent polymer layer over at least a portion of the first knit layer. Because the polymer layer is at least translucent, objects, such as a midsole, positioned within the foot-receiving void of the upper may be at least partially visible through the knitted mesh structure of the first knit layer. References herein are made to a translucent or transparent polymer layer, and it should be understood that unless otherwise indicated, some embodiments of the examples described herein include the polymer layer being translucent and other embodiments include the polymer layer being transparent. As previously described, when the thermoplastic material is in a melted state, it may be used to directly secure a second sole structure to an underfoot portion of the upper.
In other examples, the translucent or transparent polymer layer may be formed from thermoplastic material melted from a yarn of the knit structure. In particular, alternative aspects herein include the first knit zone comprising a double-knit construction and including a second knit layer comprising a second set of yarns. The second set of yarns may include a core/sheath yarn comprising a core of a high-melting material surrounded by a sheath of a thermoplastic material having a melting point that is lower than the melting point of the sheath of the first set of yarns (when a core/sheath yarn is used). In examples, the sheath of the second set of yarns may have transparent and/or translucent properties. In examples, the core of the second set of yarns is opaque. In some examples, the second knit layer is integrally knit with the first knit material and may be formed in the same knitting event.
After being formed into a knit textile and/or the upper, heat and/or pressure are applied to the first knit zone that comprises the first knit layer and the second knit layer. In these examples, the heat is sufficient to cause the thermoplastic material forming the sheath of the second set of yarns to melt (i.e., the heat has a temperature greater than the melting point of the thermoplastic material forming the sheath of the second set of yarns), but, in example aspects, the heat is not sufficient to melt the thermoplastic material forming the sheath of the first set of yarns (i.e., the heat has a temperature less than the melting point of the thermoplastic material forming the sheath of the first set of yarns), though it may be sufficient to soften the thermoplastic material of the first set of yarns. The melted thermoplastic material flows via, for example, the application of pressure such that it at least partially encapsulates the first set of yarns and the core of the second set of yarns. Once cooled, the melted thermoplastic material forms a transparent and/or translucent polymer layer similar to that described above. That is, because the polymer layer is at least translucent, objects, such as a midsole, positioned within the foot-receiving void of the upper, may be at least partially visible through the knitted mesh structure of the first knit layer, and/or when the thermoplastic material is in a melted state, it may be used to directly secure a second sole structure to an underfoot portion of the upper.
In yet another example, the first knit zone may comprise the first knit layer as described herein; a second knit layer, which may include the second set of yarns with the lower melting thermoplastic material or may have a higher melting material; and a thermoplastic polymer film applied to the first knit layer. In this example, the polymer of the film may be melted in the same manner as described above to create the transparent and/or translucent polymer layer.
In some aspects, the first knit zone is secured to one or more additional textiles, including additional knit textiles, to form the upper. In another example, the upper may further include a second knit zone that is integrally knitted with the first knit zone. The second knit zone may comprise a single-knit jersey structure having a plurality of rib structures that longitudinally extend in a direction from a toe end to a heel end of the article of footwear. The plurality of rib structures may include knit courses that longitudinally extend in a direction from the toe end of the article of footwear toward a heel end of the article of footwear. In examples, the second knit zone may be located in at least a tongue region. In this example, the longitudinal orientation of the rib structures facilitates medial-to-lateral stretching of the second knit zone. This may be advantageous in the tongue region to accommodate the insertion of a wearer's foot into the article of footwear.
The article of footwear described herein may comprise a running shoe, a baseball shoe, a basketball shoe, a skateboarding shoe, a cycling shoe, an American football shoe, a tennis shoe, a global football shoe, a training shoe, a walking shoe, a hiking shoe, and 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. As used herein, the 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; the forefoot region terminates in a toe end of the article of footwear. 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 heel region terminates in a heel end of the article of footwear. The article of footwear described herein may include a lateral side which corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot) and a medial side which corresponds with an inside area of the foot (i.e., 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 upper, and to sole structures.
The article of footwear described herein generally includes one or more sole structures. The sole structures may include a midsole, known as a first sole structure herein that is positioned within a foot-receiving void of the upper. The sole structures may also include a cushioning element, such as a fluid-filled bladder that is directly secured to an outer-facing surface of an underfoot portion of the upper. The cushioning element may be known herein as a second sole structure. The sole structures may additionally include an outsole structure or third sole structure that is secured to a ground-facing surface of the cushioning element. Additional or fewer sole structures are contemplated herein. The different sole structures described herein may provide cushioning, support, force attenuation, and the like.
The term “outer-facing surface” as used herein means a surface of the upper or article of footwear that faces the external environment. In some aspects, the outer-facing surface may mean the outermost-facing surface of the upper or article of footwear. The term “inner-facing surface” as used herein means a surface of the upper or article of footwear that faces a void for receiving the wearer's foot. In some aspects, the inner-facing surface may mean the innermost-facing surface of the upper or article of footwear. The terms “external” and “internal” as used herein are relative terms such that a layer that is external is positioned external to one or more internal layers, and a layer that is internal is positioned internal to one or more external layers.
The term “fluid-filled bladder” as used herein refers to, for example, the second sole structure, generally denotes a bladder formed from two barrier layers of polymer material that are sealed or bonded together. The fluid-filled bladder is pressurized with a fluid such as air, and may incorporate tensile members within the bladder to retain the shape of the bladder when compressed resiliently under applied loads, such as during athletic movements. Generally, bladders are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the bladder resiliently compresses under an applied load.
The term “knit” such as is used herein to describe the some or all portions of the upper 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 held 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 “double-knit construction” as used herein refers to a knit construction that is generally formed on at least two needle beds of a knitting machine (i.e., a multi-bed construction). Such multi-bed knit constructions may be characterized by two opposing faces or layers of knit loops and/or tucks, e.g., one face/layer of loops formed on a first needle bed (e.g., a first knit layer), and a second face/layer of loops formed on a second needle bed (e.g., a second knit layer). In example aspects, the two faces/layers may be joined by yarns that interloop with yarns in both the first face/layer and the second face/layer of the double-knit construction (e.g., transfer yarns). However, aspects herein contemplate that the two faces/layers may not be joined such that a space or potential space is formed between the two faces/layers. Common double-knit constructions include double jersey, rib, interlock, cardigan, other “double-bed” knit structures initially formed on at least two needle beds, and other knit structures having two opposing faces/layers of knit loops or tucks, including full-gauge and less-than-full-gauge variations of those structures. The term “single-knit construction” as used herein refers to a single-layer knit construction generally formed on a single needle bed (i.e., a single-bed construction). In some examples, a single-knit construction may be formed on a multi-bed knitting machine by knitting a number of knit courses on a first needle bed of the knitting machine and then transferring all of the loops to a second needle bed of the knitting machine where a number of knit courses are then knit. This knitting sequence may be repeated any number of times, as further described below. Common single-knit constructions include single jersey.
The term “knitted mesh structure” to describe the first knit layer describes a knit structure having a plurality of openings intentionally created using a combination of tuck stitches (or similar types of stitches such as held stitches) and knit stitches that may be knitted on every other needle, every third needle, and the like, of the needle bed. Thus, a knit stitch of a knit course may be spaced apart from an adjacent knit stitch by one wale, two wales, three wales, and the like to create the intentional or engineered openings in the knit structure. These engineered openings help to create the mesh structure. This may be contrasted with the inherent openings within a knit loop or between adjacent knit loops where the inherent openings are generally not spaced apart by a wale, two wales, and the like. In example aspects, the knitted mesh structure of the first knit layer has a lower knit stitch density (i.e., the number of knit stitches per inch or centimeter) than the knit structure used to form the second knit layer.
The term “integrally knit,” as used herein, may mean a knit textile having a yarn from one or more knit courses in a first knit layer or zone being interlooped with one or more knit courses of another knit layer or zone. 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, zones that are integrally knit together have a seamless transition such that they seamlessly extend from one another.
Forming some or all portions of the 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, or a relatively elastic material such as elasticated yarns, which is a thermoplastic material), 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, 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 uppers may have different properties as described herein.
The yarns, in accordance with aspects herein, may include monofilament yarns and multifilament yarns formed from, for example, synthetic materials. In example aspects, yarns used to knit the first knit layer and the second knit layer may include high-melting polymer yarns (e.g., yarns that melt at about 175 degrees Celsius or higher) including polyethylene terephthalate (PET) yarns (commonly known as polyester), recycled PET yarns, polyamide yarns (commonly known as nylon), elastane yarns, and other high-melting synthetic yarns. In example aspects, the high-melting yarns may form the core of a core/sheath yarn in the first knit layer (when a core/sheath yarn is used) and the core of a core/sheath yarn in the second knit layer. The high-melting synthetic yarns may also be used to knit the second knit zone.
In example aspects, the sheath of the core/sheath yarns in the first knit layer (when a core/sheath yarn is used) and the second knit layer (in aspects having a second knit layer) may comprise a synthetic polymeric material formed from a polymer that melts at relatively low temperatures (e.g., less than about 175 degrees Celsius). In example aspects, the sheath may comprise a thermoplastic material that is capable of melting upon the application of heat at a temperature greater or equal to the melting temperature of the thermoplastic material. The thermoplastic material hardens upon cooling and is capable of remelting when heat having a temperature greater than the temperature of the thermoplastic material is reapplied. In example aspects, the melting point of the thermoplastic material forming the sheath of the first set of yarns is greater than the melting point of the thermoplastic material forming at least part of an additional layer (e.g., a thermoplastic film and/or the sheath of the second set of yarns in a second knit layer). When heat having a temperature greater than the melting point of the thermoplastic material forming at least part of the additional layer but less than the melting point of the thermoplastic material forming the sheath of the first set of yarns is applied to the upper, the thermoplastic material of the additional layer melts (i.e., the sheath of the second set of yarns melts and/or the film melts), but the thermoplastic material of the first set of yarns does not melt, though it may soften (i.e., the sheath of the first set of yarns softens but does not melt). The melting temperature of the thermoplastic material forming the sheath of the first set of yarns and the additional material (e.g., the film and/or the sheath of the second set of yarns) may be sufficiently different from the melting temperature of the yarns used to form the core of the first set of yarns (when a core/sheath yarn is used). Such a melting temperature may also be sufficiently different from the melting temperature of the yarn used to form the core of the second set of yarns where a second knit layer is present. As such, the yarns forming the core of the first set of yarns (and in some aspects, the second set of yarns) are not adversely affected (e.g., burning, charring, or singeing) when heat is applied to the first knit zone of the upper during processing.
The term “thermoplastic polymer layer” refers to a generally unitary structure that includes a solidified thermoplastic polymer that at least partially encapsulates a yarn(s) of a knit structure. It may also be referred to herein as a composite layer that comprises one or more knit layers and a thermoplastic polymer material, which may form a film. The thermoplastic polymer layer may be a thermoformed layer formed from the knitted yarns, as further described herein, or may be a thermoplastic polymer film bonded to the knit structure by partially melting the polymer film and fusing it with the knit structure or by an adhesive, or may be a polymer solution that is sprayed to coat at least a portion of the knit structure. In examples, the thermoplastic polymer film may comprise a thermoplastic polyurethane film having a thickness, in some aspects, from about 0.3 millimeter (mm) to about 0.8 mm, from about 0.45 mm to about 0.7 mm, or about 0.6 mm, and in other aspects, from about 0.15 mm to about 0.45 mm, from about 0.2 mm to about 0.4 mm, or about 0.25 mm.
The term “thermoformed layer” refers to a generally unitary structure formed after heat and/or pressure is applied to the melted thermoplastic material of the second set of yarns and/or to the melted thermoplastic polymer film causing it to flow and after the melted thermoplastic material has solidified upon cooling. As such, the thermoformed layer may comprise the same polymeric material as the thermoplastic material used to form the sheath of the second set of yarns and/or the polymer film.
The term “translucency” as used herein relates to a transmission of light, and “translucent” refers to a physical property of an object when a light strikes its surface in which some of the light is passed or transmitted through the object and some of the light is diffused, reflected, and/or absorbed. Generally, the transmission of light is categorized as transparency, translucency, or opacity, each of which corresponds to a different interaction between an object and a light striking a surface thereof. As such, “transparent” refers to a physical property of an object when a light strikes its surface in which all of the light is passed or transmitted through the object and none of the light is diffused and/or absorbed. “Opaque” refers to a physical property of an object (e.g., a yarn) when a light strikes its surface in which none of the light is passed or transmitted through the object and all of the light is diffused and/or absorbed. In accordance with aspects herein, an object may be determined to be either transparent, translucent, or opaque by using instruments and/or methods known by those skilled in the art to measure and/or calculate a transmittance of an object. Thus, the term “translucent” when describing, for example, the thermoplastic polymer layer, means that the layer has physical properties such that light that strikes a first surface (e.g., an outer-facing surface) of the thermoplastic polymer layer partially passes through the layer, enabling at least partial visualization of any objects that are positioned adjacent the opposite surface (e.g., an inner-facing surface) of the thermoplastic polymer layer. Aspects herein also contemplate that the thermoplastic polymer layer may be transparent. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
In aspects, the uppers described herein can incorporate and/or be formed of different types of textiles. For example, optionally, an upper can incorporate or be formed of a knitted textile. In aspects, optionally, an upper can incorporate or be formed of a woven textile. In aspects, optionally, an upper can incorporate or be formed of a braided textile. In aspects, optionally, an upper can incorporate or be formed of a non-woven textile. In aspects, optionally, an upper can be formed substantially entirely from one type of textile, e.g., knitted, woven, non-woven, or the like. In aspects, optionally, an upper can be formed from multiple types of textiles (e.g., knitted and woven textiles combined together) and/or can be formed of multiple textile pieces of the same or different type (e.g., being assembled together to form a composite construction). The aspects described herein may frequently reference examples of knitted structures or knitted textiles, but it should be understood that the aspects described throughout this disclosure may also incorporate these other types of textiles and materials.
In aspects, an upper as described herein can be formed using knitting, weaving, braiding, or non-woven textile formation techniques and methods. Textiles used to form an upper can be selected based on the desired properties of an associated footwear article. For example, when an upper with greater stretch, comfort, and/or breathability is desired, a knitted textile may be used in an upper, and when an upper with greater durability, strength, and/or water resistance is desired, a woven textile may be used in an upper. These are examples, and other textiles or combinations of textiles with desired properties can optionally, additionally, or alternatively be used.
In some aspects, uppers described herein can incorporate or be formed of woven textiles or fabrics, non-woven textiles or fabrics, or combinations thereof. In some aspects, optionally, uppers described herein can incorporate mesh structures and/or translucent and/or transparent materials, e.g., including thermoplastic materials, e.g., thermoplastic polymer layers, skins, sheets, films, and/or adhesives, among other things. These materials may cover and/or enclose and/or encapsulate underlying yarns and textile structures. In aspects, woven constructions may utilize warp and weft yarn arrangements to achieve mesh or other patterned configurations to facilitate breathability, flexibility, and/or aesthetic appeal. Non-woven constructions, e.g., those that include felted or bonded materials, may similarly be enhanced with translucent and/or transparent thermoplastic materials, e.g., polymer layers, sheets, skins, or glues that cover and/or enclose and/or encapsulate underlying fibers or strands or other textile structures. In aspects, an internal component of the article of footwear may be at least partially visible through the mesh structures and/or translucent and/or transparent materials of the article of footwear. In aspects, the internal component that is at least partially visible may comprise a midsole, outsole, material layers, inserts inside the article of footwear, cushioning, cavities, air pockets, or other textile structures included in the article of footwear. These alternative textile constructions are contemplated to provide desired structural, functional, and visual benefits. The aforementioned materials and techniques can be incorporated into any of the uppers described herein, e.g., in addition to, or in the alternative to, knitted structures and associated constructions.
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 term “about” means within +10% of an indicated value.
The upper 110 includes an outer-facing surface 111 and an inner-facing surface (not readily seen in the views but should be understood to be opposite the outer-facing surface 111). The upper 110 may be partially or entirely formed from a knit textile. 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 118 having a toe end 119, a midfoot region 120, and a heel region 122 having a heel end 123, a medial side 124, and a lateral side 126. The article of footwear 100 includes an ankle collar 128 defining an opening to a void 129 for receiving a wearer's foot, a throat region 130, and a tongue 132. In example aspects, the tongue 132 may be integrally formed with the upper 110 as shown, or the tongue 132 may comprise a separate element that is secured to the upper 110 in, for example, a post-knitting manufacturing step. 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, the toe end 119 (e.g., a toe cap), the heel end 123 (e.g., a heel counter), and the like.
The upper 110 further includes a knitted underfoot portion 134. The underfoot portion 134 extends under a wearer's foot when the article of footwear 100 is worn and may include a plurality of supports 136 (better seen in
The first sole structure 112, in example aspects, may comprise a midsole that is positioned within the void 129. An upper extent or edge of the first sole structure 112 is demarcated by line 113. This is an illustrative shape for the first sole structure 112, and other shapes are contemplated herein. As will be described in additional detail, the first sole structure 112 may be at least partially visible through a translucent thermoplastic polymer layer (as indicated by the translucent/transparent markings in
The second sole structure 114 is secured to the knitted underfoot portion 134 of the upper 110. In examples, the second sole structure 114 may comprise a fluid-filled bladder or other type of cushioning or force-absorbing element having a plurality of bulbs 140 (better seen in
The shape of the bulbs 140 of the second sole structure 114 may complement the shape of the supports 136 of the underfoot portion 134 of the upper 110 so that each support 136 may be configured to be coupled to a corresponding bulb 140. In this way, the upper 110 may be molded to a particular shape to correspond to the second sole structure 114. In some examples, the underfoot portion 134 of the upper 110 has a knitted structure with a thermoplastic polymer layer. The knitted structure within the thermoplastic polymer layer may act as a scaffolding to enable the thermoplastic polymer layer to be bent and retain a particular shape during molding. When compared to other textile structures, such as a woven textile, the knit loops of the underfoot portion 134 further may better enable the underfoot portion 134 to be molded according to the desired shapes to complement the bulbs 140 of the second sole structure 114 for a secure coupling of the upper 110 and the second sole structure 114.
In example aspects, the article of footwear 100 further includes a third sole structure, which may comprise the outsole structure 116. The outsole structure 116 may be secured to a ground-facing surface of the second sole structure 114. The outsole structure 116 may come into contact with a ground surface and thus be formed of materials suitable for this function.
The upper 110 includes a first knit zone 142 and may further include a second textile zone. In some examples, the second textile zone is also knit and may be referred to herein as the second knit zone 144. The first and second knit zones 142 and 144 are depicted schematically and are provided to illustrate the general locations of the knit zones on the upper 110. Additional macroscopic features of various aspects of the first and second knit zones 142 and 144 are shown in subsequent figures. In examples, the first knit zone 142 is generally located along the medial side 124 and the lateral side 126 of the upper 110 and extends from the forefoot region 118, through the midfoot region 120, and the heel region 122. The first knit zone 142 may extend through the underfoot portion 134 of the upper 110. As will be described in additional detail, in aspects the first knit zone 142 includes the translucent or transparent thermoplastic polymer layer.
In the example shown in
The second knit zone 144 is adjacent the first knit zone 142. In both examples, the second knit zone 144 is generally superior to the first knit zone 142 and forms at least a portion of the throat region 130. The second knit zone 144 has a different knit construction as the first knit zone 142 and may comprise different material (e.g., yarns). In example aspects, the thermoplastic polymer layer may be absent from the second knit zone 144. Additionally, the first sole structure 112 may be absent from the second knit zone 144. Further examples of the second knit zone may be described further herein.
The first knit zone 142 and the second knit zone 144 may be formed separately and joined together via stitching, for example. For example, boundary line 145 in
The first knit layer 410 comprises a knit mesh construction, which has a grid or net-like pattern with visible openings between interlooped yarns. The openings are not inherent spacing between any adjacent loops of yarn; rather, the openings in the mesh construction of the first knit layer 410 are intentionally integrally formed during knitting by floating over needles between tuck stitches and/or loop stitches. In this way, the first knit layer 410 has a relatively lower stitch density and is more porous than a textile with a plain stitch pattern.
The second knit layer 412 is formed from a second set of yarns 413. Before the upper 110 is processed, the second set of yarns 413 may comprise a core/sheath yarn having a core of a high-melting material (e.g., PET yarns, recycled PET yarns, polyamide yarns, elastane yarns, and other high-melting synthetic yarns) and a sheath of a low-melting material (a TPU material, a TPE material, and other synthetic polymeric materials having a low melting point). After processing and as shown in
As further depicted in
After cooling the upper 110, the translucent thermoplastic polymer layer 612 is formed. In example aspects, the translucent thermoplastic polymer layer 612 may at least partially cover and/or enclose and/or encapsulate the first set of yarns 411. As further shown, the translucent thermoplastic polymer layer 612 may fully encapsulate portions of the first set of yarns 411 on the outer-facing surface 650 of the first knit layer but may not encapsulate the portions of the first set of yarns 411 on the inner-facing surface 652 of the first knit layer 410. To state this differently, in example aspects, the translucent thermoplastic polymer layer 612 does not fully extend through the first knit layer 410 to the inner-facing surface 652 such that the first knit layer 410 may be partially embedded within the translucent thermoplastic polymer layer 612. As such, the thermoplastic polymer material may be present on the outer-facing surface 650 and within the first knit layer 410, but may be absent from the inner-facing surface 652 of the first knit layer 410. In aspects, a thermoplastic polymer material may be applied to a textile layer, e.g., knit layer and/or woven layer and/or non-woven layer, in the form of a skin, film, sheet, or applied adhesive, such that a layer of thermoplastic polymer material is formed, e.g., similar to the layer 612 shown in
The translucent thermoplastic polymer layer 612 comprises the first surface 614 that forms, at least in part, an outermost-facing surface of the upper 110, and the opposite second surface 616. In this aspect, the first surface 614 is generally smooth in texture such that the outermost-facing surface of the upper 110 in the first knit zone 142 is generally smooth in texture. Because the thermoplastic polymer layer 612 in this aspect does not extend to the inner-facing surface 652 of the first knit layer 410, the inner-facing surface 652 of the first knit layer 410 retains a knit structure comprising loops and generally comprises a rougher texture relative to the outer-facing surface 650 of the first knit layer 410.
As depicted in
The thermoplastic polymer layer 612 may provide a waterproof barrier to prevent moisture from leaking into the interior of the upper 110, which protects not only a wearer's foot but also the first sole structure 112. The thermoplastic polymer layer 612 may also provide increased resistance to abrasion within the first knit zone 142.
Due to the translucent and/or transparent properties of the thermoplastic polymer layer 612, light that strikes the first surface 614 of the thermoplastic polymer layer 612 passes through at least the openings 414 in the first knit layer 410 before striking the first sole structure 112 such that the first sole structure 112 is at least partially visible when viewing the first surface 614 of the thermoplastic polymer layer 612. As described, this may enhance the aesthetic appeal of the article of footwear 100. It may also serve as a visual indicator of a particular functionality associated with the first sole structure 112. By way of illustrative example, a first sole structure that is red in color may visually indicate to a wearer a functionality of increased arch support. A first sole structure that is blue in color may visually indicate to a wearer a functionality of increased or enhanced heel support. By viewing the outer-facing surface 111 of the article of footwear 100, the wearer can make a decision as to whether the first sole structure 112 that is removably positioned within the article of footwear 100 is appropriate for a desired athletic activity. In some aspects, the first sole structure 112 may be a different color than the yarn of the first knit zone 142.
The first layer 654A and the second layer 654B of the thermoplastic polymer film 654 may have different material compositions with different melting temperatures. In example aspects, the second layer 654B has a lower melting temperature than the first layer 654A. In this way, an amount of heat sufficient to melt the second layer 654B may be applied without melting or at least completely melting the first layer 654A.
Regardless of whether the first layer 654A softens, partially melts, or is not changed by the heat, the first layer 654A and the second layer 654B may generally form a composite structure with the first set of yarns 411 such that the two layers 654A and 654B are not separable and may be considered as jointly forming the translucent thermoplastic polymer layer 612. In this example, the thermoplastic polymer layer 612 may have a first sublayer 612A corresponding to the first layer 654A and a second sublayer 612B. The application of heat, in some aspects, may also be sufficient to cause softening, but not melting, of the thermoplastic material of the first set of yarns 411 and/or the thermoplastic material of the first layer 654A of the polymer film 654. Thus, after processing, the first set of yarns 411 may still comprise a core/sheath configuration.
The first knit layer 410 is formed using the first set of yarns 411. As described, the first set of yarns 411 may comprise a core/sheath yarn having a core of a high-melting material and a sheath of a low-melting material, although aspects herein also contemplate that the first set of yarns 411 may comprise a single high-melting material (e.g., a high-melting polyamide monofilament). The second knit layer 412 is formed using the second set of yarns 413. Because the upper 110 has not yet been processed, the second set of yarns 413 comprises a core of high-melting material and a sheath of low-melting material. In example aspects, the sheath of the second set of yarns 413 comprises a first thermoplastic material having a first melting point, and the sheath of the first set of yarns 411 comprises a second thermoplastic material having a second melting point greater than the first melting point. The first thermoplastic material, in example aspects, may be transparent and/or translucent. In example aspects, both the first thermoplastic material and the second thermoplastic material have melting points less than the melting points of the high-melting cores of the first set of yarns 411 (when a core/sheath yarn is used) and the second set of yarns 413.
Before processing and as shown in
After cooling the upper 110, a translucent thermoplastic polymer layer 612 is formed. Although the thermoplastic polymer layer 612 is further described herein as translucent, it should be understood that the description may also apply to the thermoplastic polymer layer 612 that is transparent unless otherwise indicated. In example aspects, the translucent thermoplastic polymer layer 612 may at least partially encapsulate, and may fully encapsulate, both the first set of yarns 411 and the second set of yarns 413, thus helping to secure the first knit layer 410 and the second knit layer 412 together. The translucent thermoplastic polymer layer 612 comprises a first surface 614 that forms, at least in part, an outermost-facing surface of the upper 110, and an opposite second surface 616 that forms, at least in part, an innermost-facing surface of the upper 110. In some aspects, the second surface 616 forms an inner-facing surface while another component, such as a lining, may be secured to the upper 110 to form the innermost-facing surface.
As depicted in
Aspects herein further contemplate that the thermoplastic polymer layer 612 may be a solution sprayed and dried onto the first knit layer 410. The different ways of forming the thermoplastic polymer layer 612 may serve to secure the first and second knit layers 410 and 412 together as described with respect to
Knitting the knit textile 700 from the medial side 124 to the lateral side 126 or vice versa helps to reduce the knitting time compared to knitting the knit textile 700 from the toe end 119 to the heel end 123 or vice versa. For example, all the transfers that join the first knit layer 410 to the second knit layer 412 at the transfer area 710 on the medial side 124 and the transfer area 712 on the lateral side 126 may be executed during one or more passes of the knitting carriage. In examples where the first knit layer 410 and the second knit layer 412 are joined by transfer yarns before transitioning to the single-layer throat region 130, tongue 132, and the ankle collar 128, all these transfers may be executed during one or more passes of the knitting carriage. This may be contrasted with knitting the knit textile 700 in a toe-to-heel direction or a heel-to-toe direction. In this knitting aspect, each pass of the knitting carriage would require executing transfer stitches at the transfer area 710 on the medial side 124, executing transfer stitches and/or changing the knitting construction to a single-layer knit construction at the throat region 130, the tongue 132, and the ankle collar 128, and executing transfer stitches at the transfer area 712 on the lateral side 126, which would increase knitting time.
Starting with
At a step 912, one or more of heat and pressure 914 are applied to the knit textile 900 and the thermoplastic polymer film 654 while the knit textile 900 is positioned flat on a surface (e.g., flat or two-dimensional pressing). In example aspects where the film 654 is a single-layered film, the heat is sufficient to melt the thermoplastic polymer film 654 without melting the first set of yarns 411, and in example aspects where the film 654 is a two-layered film, the heat is sufficient to melt one layer (e.g., the layer directly contacting the knit textile 900) without melting the first set of yarns 411 or the second layer of the film 654. Further, for either example, the heat may be sufficient to soften, but not melt, at least a portion of the first set of yarns 411 (e.g., a sheath when a core/sheath yarn is used).
Heat and/or pressure causes the melted thermoplastic polymer material to reflow so that it at least partially encapsulates the first set of yarns 411. The melted thermoplastic polymer material may be melted and reflowed enough to become partially embedded in the first knit layer 410 but not to fully extend to the inner-facing surface 652 of the first knit layer 410. After heat and pressure 914 are removed, the thermoplastic polymer material may cool and solidify to form the thermoplastic polymer layer 612, which may be considered a thermoformed layer.
After the application of the heat and/or pressure 914, the knit textile 900 includes the translucent thermoplastic polymer layer 612. In example aspects, the thermoplastic polymer layer 612 provides structural stability (i.e., stiffness) to the knit textile 900 such that it can readily be positioned for cutting and/or the application of additional elements such as overlays to the knit textile 700. Step 918 depicts a portion of the upper 110 after being cut from the knit textile 900 but before being formed into a three-dimensional shape suitable for the article of footwear 100. The portion of the upper 110 cut in step 918 may be a bottom or underfoot portion of the upper 110. In other aspects, the knit textile 900 may be at least partially knit to the desired shape such that the cutting step is eliminated or reduced.
Step 920 depicts the upper 110 in a three-dimensional shape suitable for the article of footwear 100. In this example of step 920, the upper 110 is formed after the knit textile 900 is joined to one or more additional upper components 902, such as additional textile (e.g., knit, woven, or non-woven) pieces. In this configuration, the knit textile 900 may be folded to primarily include the underfoot portion 134 with the knit textile 900 extending partially up the medial and lateral sides 124 and 126 of the article of footwear 100 (e.g., similar to how a taco shell is folded). In this example, the underfoot portion 134 would not include a seam along the bottom. This process of joining the knit textile 900 that forms an underfoot portion 134 to other textile pieces forming the overfoot portion may be done via stitching, adhesives, and/or thermal bonding, etc.
At a step 922, the upper 110 undergoes a three-dimensional press process. In particular, a shoe last 924 is positioned within the upper 110. In example aspects, the last 924 may be hinged at one or more regions of the last 924 to facilitate insertion and removal of the last 924 from the upper 110. The last 924 includes an underfoot portion having a plurality of last supports 926 and a plurality of last recesses 928 disposed between adjacent last supports 926. Once the last 924 is positioned within the upper 110, the combination of the last 924 and the upper 110 may be positioned in a bottom mold piece 923, which may have the inverse geometry as the bottom of the last 924 so that the last supports 926 (covered with the upper 110) may be seated within recesses of the bottom mold piece 923 while the last recesses 928 may receive projections in the bottom mold piece 923. The heat and/or pressure is applied to the last 924 within the upper 110 while being positioned on the bottom mold piece 923, where the heat and/or pressure is sufficient to remelt the thermoplastic polymer layer 612 and mold the thermoplastic polymer layer 612 and knit textile 900 to a three-dimensional shape corresponding to the underfoot portion of the last 924. In some aspects, the heat is not sufficient to melt the first set of yarns 411 (or at least the sheath of the first set of yarns 411 when a core/sheath yarn is used) or to alter the physical properties of the other yarns forming the upper 110.
The knit textile 900 (as well as knit textile 700 in
As depicted in step 925, after the upper 110 is at least partially cooled, the second sole structure 114 is secured to the underfoot portion 134 of the upper 110. In some aspects, this may be done while the thermoplastic polymer layer 612 is in a melted or partially melted state such that the second sole structure 114 is directly secured without the use of adhesives to the underfoot portion 134 of the upper 110 by way of the thermoplastic polymer layer 612. This securement may occur after the thermoplastic polymer layer 612 is softened through another application of heat at some point after removal of the last 924, and the second sole structure 114 may be secured to the underfoot portion 134 prior to the thermoplastic polymer layer 612 rehardening. The thermoplastic polymer composition within the thermoplastic polymer layer 612, which may be thermoplastic polyurethane, may be compatible with the material of the second sole structure 114 to allow a secure attachment between the two uppers 110 and the second sole structure 114. In other aspects, adhesive may be used as an alternative or additional method of securing the underfoot portion 134 to the second sole structure 114.
Additionally, after the three-dimensional processing in step 922, the underfoot portion 134 of the upper 110 comprises the plurality of supports 136 and the plurality of recesses 138, where the plurality of supports 136 and the plurality of recesses 138 have a shape corresponding to the plurality of last supports 926 and the plurality of last recesses 928. The shape of the supports 136 that are molded into the upper 110 may complement the shape of bulbs 140 on the second sole structure 114 that are secured to one or more of the plurality of supports 136 of the underfoot portion 134 of the upper 110 at step 925.
At step 929, the outsole structure 116 is secured to a ground-facing surface of the second sole structure 114. The outsole structure 116 may be secured to the second sole structure 114 using an adhesive, in some examples.
At step 930, the first sole structure 112 is inserted into the void 129 of the upper 110. In example aspects, the first sole structure 112 is removably positioned within the upper 110. In other example aspects, the first sole structure 112 is permanently positioned within the upper 110 and may be directly secured to the upper 110. In some aspects, an adhesive may be used to secure the first sole structure 112 within the upper 110. In other aspects, the first sole structure 112 is secured to the upper 110 without adhesives by way of the thermoplastic polymer layer 612. In this example, the thermoplastic polymer layer 612 may be soften, through application of heat, after the last 924 is removed, and the first sole structure 112 may be placed within the upper 110 prior to the thermoplastic polymer layer 612 rehardening.
Turning to
At a step 912, one or more of heat and pressure 914 are applied to the knit textile 700 while the knit textile 700 is positioned flat on a surface (e.g., flat or two-dimensional pressing). The example step 912 in
Heat and/or pressure causes the melted thermoplastic polymer material to reflow so that it at least partially encapsulates the first set of yarns 411 and a remaining knitted core from the second set of yarns 413 when the knit textile 700 includes the first knit layer 410 and the second knit layer 412. After heat and pressure 914 are removed, the thermoplastic polymer material may cool and solidify to form the thermoplastic polymer layer 612, which may be considered a thermoformed layer.
Step 916 depicts the knit textile 700 after the application of the heat and/or pressure 914. The knit textile 700 now includes the translucent thermoplastic polymer layer 612. In example aspects, the thermoplastic polymer layer 612 provides structural stability (i.e., stiffness) to the knit textile 700 such that it can readily be positioned for cutting and/or the application of additional elements such as overlays to the knit textile 700. Step 918 depicts the upper 110 after being cut from the knit textile 700 but before being formed into a three-dimensional shape suitable for the article of footwear 100. The cutting step may involve trimming the edges such that the upper 110 includes one or more cut edges. In other aspects, the knit textile 700 may be knit to the shape of the upper 110 such that the cutting step is eliminated or reduced.
Step 920 depicts the upper 110 after being formed into a three-dimensional shape suitable for the article of footwear 100. In this aspect, the medial and lateral side edges may be secured to each other in the underfoot portion 134 of the upper 110. Alternatively, the knit textile 700 may be cut in a similar shape as knit textile 900 in step 920 in
At a step 922, the upper 110 undergoes a three-dimensional press process similar to step 922 in
Steps 925, 929, and 930 depicted in
The orders of the steps depicted in
As depicted in
In the heel region 122 of the underfoot portion 134, the supports 136 may comprise one or more discrete supports that are spaced apart from one another in both the medial-to-lateral direction and the toe-to-heel direction, such as supports 1020, 1022, and 1024. In this aspect, the recesses 138 in the heel region 122 that space apart the supports 136 may extend generally continuously in the medial-to-lateral direction and the toe-to-heel direction. This shape configuration may facilitate toe-to-heel flexion in the heel region 122 of the underfoot portion 134 in addition to medial-to-lateral flexion. This shape configuration may reflect a wearer's motion of both transferring weight from the ball of the foot to the heel, or vice versa, as well as the wearer's motion of transferring weight from the medial side to the lateral side, or vice versa, such as when executing side-to-side movements. Further having smaller but a greater number of discrete supports 136 in the heel region 122 may provide more points for increased point loading and, therefore, may increase the ability to attenuate ground forces (i.e., cushioning) in the heel region 122.
In example aspects, a knitting sequence used to form at least one or more portions of the second knit zone 144 may comprise a repeating pattern of knitting a first number of knit courses on a first needle bed of a knitting machine using a set of yarns, transferring loops of the set of yarns held on the first needle bed to a second needle bed of the knitting machine, knitting a second number of knit courses on the second needle bed using the set of yarns, and transferring loops of the set of yarns back to the first needle bed to repeat the pattern. Because the yarns are knit on only one needle bed at a time, a single-knit jersey structure is achieved. In example aspects, the first number of knit courses that are knit on the first needle bed is different from the second number of knit courses that are knit on the second needle bed. In one example, the first number of knit courses is two knit courses, and the second number of knit courses is four knit courses. This is an illustrative example, and other combinations of knit courses are contemplated herein. The uneven distribution of knit courses on the first and second needle beds combined with the inherent tendency of single-knit jersey construction to curl creates the rib structures 146.
The longitudinal orientation of the plurality of rib structures 146 facilitates medial-to-lateral stretching of the second knit zone 144, as indicated by arrow 1112 in
The underfoot portion 134 also includes a longitudinal seam 1304 extending from the toe end 119 to the heel end 123. The longitudinal seam 1304 may extend continuously through the forefoot region 118, the midfoot region 120, and the heel region 122, joining the lateral side 126 and the medial side 124. In this example, the longitudinal seam 1304 is substantially centered along a center midline of the underfoot portion 134 between the lateral side 126 and the medial side 124, but in other examples, the longitudinal seam 1304 may be off-centered and/or extend diagonally.
Turning to
The upper 110 may also include a second heel-end seam 1308 extending up the overfoot portion 135 of the heel end 123. The second heel-end seam 1308 may extend from the first heel-end seam 1306 to the ankle collar 128. The second heel-end seam 1308 may join the medial side 124 and the lateral side 126 of the overfoot portion 135 in the heel region 122. In some aspects, the second heel-end seam 1308 is substantially centered along a center midline of the overfoot portion135 between the lateral side 126 and the medial side 124 at the heel end 123, but in other examples, the second heel-end seam 1308 may be off-centered and/or extend diagonally.
The heel counter 1310 may also extend over at least part of the first heel-end seam 1306 (shown in a dashed line). When the first sole structure (e.g., first sole structure 112) is positioned within the void of the upper 110, the underfoot portion 134 of the upper 110 may be shaped so that at least part of it appears along the sides of the upper 110, such that at least a portion of the first heel-end seam 1306 may be visible above an exterior sole structure, such as the second sole structure 114. A first portion 1307 of the first heel-end seam 1306 on the medial side 124 may extend upward on a diagonal, while a second portion 1309 of the first heel-end seam 1306 on the lateral side 126 may extend upward on a diagonal to meet the first portion 1307 of the first heel-end seam 1306. As such, the heel counter 1310 may have a first bottom portion 1311 that extends upwards on a diagonal and meets with a second bottom portion 1313 that extends upward on a diagonal. The first bottom portion 1311 of the heel counter 1310 may cover the second portion 1309 of the first heel-end seam 1306, and the second bottom portion 1313 of the heel counter 1310 may cover the first portion 1307 of the first heel-end seam 1306. From where the first and second bottom portions 1311 and 1313 meet, the heel counter 1310 may extend at least partially up the overfoot portion 135 in the heel region 122. Further, the heel counter 1310 may cover at least part of the second heel-end seam 1308. In the example shown, the top of the heel counter 1310 may also extend out further away from the second heel-end seam 1308 (shown in a dashed line), but the heel counter 1310 may have other shapes in other examples. Further, the heel counter 1310 may extend continuously from the upper 110 over part of the second sole structure 114.
Additionally, the upper 110 may include a heel tab 1312. The heel tab 1312 may comprise a textile strip, which may have a loop at the top, that extends to the ankle collar 128 and provides a structure onto which a wearer can grasp when pulling the upper 110 up the wearer's heel. The heel tab 1312 may be positioned over and cover the second heel-end seam 1308. Further, the heel tab 1312 may extend from the heel counter 1310.
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: an upper having a void for receiving a wearer's foot, the upper comprising: a first knit layer comprising a knitted mesh structure comprising a first set of yarns; a translucent or transparent thermoplastic polymer layer that at least partially encapsulates the first set of yarns; and a first sole structure positioned within the void of the upper, the first sole structure being at least partially visible through the knitted mesh structure of the first knit layer.
Clause 2. The article of footwear of clause 1, wherein the first set of yarns comprises a sheath of a first type of material surrounding a core of a second type of material different from the first type of material.
Clause 3. The article of footwear of clause 1, wherein the first set of yarns comprises a mono-component monofilament yarn, a bicomponent monofilament yarn, a coated monofilament yarn, or a multifilament yarn.
Clause 4. The article of footwear of any of clauses 1-3, wherein the first set of yarns is opaque.
Clause 5. The article of footwear of any of clauses 1-4, wherein the translucent or transparent thermoplastic polymer layer forms, at least in part, an outermost-facing surface of the upper.
Clause 6. The article of footwear of any of clauses 1-4, wherein the translucent or transparent thermoplastic polymer layer forms, at least in part, an innermost-facing surface of the upper.
Clause 7. The article of footwear of any of clauses 1-6, wherein the first sole structure is positioned interior to the first knit layer.
Clause 8. The article of footwear of any of clauses 1-7, wherein the first sole structure is removably disposed within the upper.
Clause 9. The article of footwear of any of clauses 1-8, wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer and the translucent or transparent thermoplastic polymer layer.
Clause 10. The article of footwear of clause 9, further comprising a second sole structure secured to the underfoot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer secures the second sole structure to the upper.
Clause 11. The article of footwear of clause 10, wherein the second sole structure is positioned exterior to the first knit layer.
Clause 12. The article of footwear of any of clauses 9-10, wherein the second sole structure comprises a fluid-filled bladder.
Clause 13. The article of footwear of any of clauses 9-12, wherein the underfoot portion of the upper comprises one or more supports, and wherein a plurality of recesses are disposed between adjacent ones of the one or more supports, wherein each of the one or more supports terminates distally to form one or more support surfaces.
Clause 14. The article of footwear of clause 13, wherein at least a portion of the one or more support surfaces are non-planar.
Clause 15. The article of footwear of clause 13, further comprising a second sole structure secured to the underfoot portion of the upper and comprising one or more bulbs, each of the one or more bulbs secured to a corresponding support of the underfoot portion, wherein the underfoot portion of the upper is spaced apart from the second sole structure at the plurality of recesses.
Clause 16. The article of footwear of any of clauses 1-15, wherein the first set of yarns are partially embedded within the translucent or transparent thermoplastic polymer layer.
Clause 17. The article of footwear of any of clauses 1-16, wherein the translucent or transparent thermoplastic polymer layer does not fully extend to an inner-facing surface of the first knit layer.
Clause 18. The article of footwear of any of clauses 1-17, wherein the translucent or transparent thermoplastic polymer layer comprises a first sublayer having a first thermoplastic polymer composition and a second sublayer having a second thermoplastic polymer composition, the second sublayer being positioned between the first knit layer and the first sublayer.
Clause 19. The article of footwear of clause 18, wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition.
Clause 20. The article of footwear of any of clauses 18-19, wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.
Clause 21. The article of footwear of any of clauses 1-20, wherein the upper comprises a second knit layer comprising a second set of yarns and positioned interior to the first knit layer.
Clause 22. The article of footwear of clause 21, wherein the translucent or transparent thermoplastic polymer layer at least partially encapsulates the second set of yarns.
Clause 23. The article of footwear of clause 21 or 22, wherein the first sole structure is positioned interior to the second knit layer, where the second knit layer is positioned between the first knit layer and the first sole structure.
Clause 24. The article of footwear of any of clauses 21-23, wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer, the second knit layer, and the translucent or transparent thermoplastic polymer layer.
Clause 25. The article of footwear of clause 24, further comprising a second sole structure secured to the underfoot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer secures the second sole structure to the upper.
Clause 26. The article of footwear of clauses 24 or 25, wherein the underfoot portion of the upper comprises one or more supports, and wherein a plurality of recesses are disposed between adjacent ones of the one or more supports.
Clause 27. The article of footwear of clause 26, wherein the underfoot portion is secured to a second sole structure that comprises one or more bulbs, each of the one or more bulbs secured to a corresponding support of the underfoot portion, wherein the underfoot portion of the upper is spaced apart from the second sole structure at the plurality of recesses.
Clause 28. The article of footwear of clause 21, wherein a diameter of the second set of yarns is smaller than a diameter of the first set of yarns.
Clause 29. An article of footwear comprising: an upper having a void for receiving a wearer's foot, the upper comprising: a composite layer comprising one or more knit layers and a thermoplastic polymer material forming a film structure, wherein the one or more knit layers are positioned to form at least part of an inner-facing surface of the upper, wherein the thermoplastic polymer material forms at least part of an outer-facing surface of the upper and being translucent or transparent, and a first sole structure positioned within the void of the upper, the first sole structure being at least partially visible through the composite layer.
Clause 30. The article of footwear of clause 29, wherein the composite layer comprises a first surface defined by the thermoplastic polymer material and a second surface comprising the at least part of the one or more knit layers, wherein the first surface has a smooth texture and the second surface has a non-smooth texture.
Clause 31. The article of footwear of clause 30, wherein the first sole structure directly abuts the second surface.
Clause 32. The article of footwear of any of clauses 29-31, wherein the one or more knit layers comprise a single-knit layer.
Clause 33. The article of footwear of any of clauses 29-31, wherein the one or more knit layers comprise a first knit layer and a second knit layer, the second knit layer being interior to the first knit layer.
Clause 34. The article of footwear of clause 33, wherein the first knit layer comprises a first set of yarns and the second knit layer comprises a second set of yarns having a smaller diameter than the first set of yarns.
Clause 35. The article of footwear of any of clauses 29-34, wherein the one or more knit layers comprise a knitted mesh structure.
Clause 36. The article of footwear of any of clauses 29-35, wherein the upper comprises an underfoot portion comprising the composite layer.
Clause 37. The article of footwear of clause 36, further comprising a second sole structure secured to the underfoot portion of the upper, wherein the film structure secures the second sole structure to the upper.
Clause 38. The article of footwear of clause 37, wherein the second sole structure comprises a fluid-filled bladder.
Clause 39. The article of footwear of any of clauses 36-38, wherein the underfoot portion of the upper comprises one or more supports, and wherein a plurality of recesses are disposed between adjacent ones of the one or more supports, wherein each of the one or more supports terminates distally to form one or more support surfaces.
Clause 40. The article of footwear of clauses 39, wherein at least a portion of the one or more support surfaces are non-planar.
Clause 41. The article of footwear of any of clauses 39-40, further comprising a second sole structure secured to the underfoot portion of the upper and comprising one or more bulbs, each of the one or more bulbs secured to a corresponding support of the underfoot portion, wherein the underfoot portion of the upper is spaced apart from the second sole structure at the plurality of recesses.
Clause 42. The article of footwear of any of clauses 29-41, wherein the thermoplastic polymer material of the composite structure includes a first thermoplastic polymer material forming a first sublayer of the film structure and a second thermoplastic polymer material forming a second sublayer of the film structure, the second sublayer being positioned between the one or more knit layers and the first sublayer.
Clause 43. The article of footwear of clause 42, wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition.
Clause 44. The article of footwear of any of clauses 42-43, wherein the one or more knit layers comprise a first set of yarn, and wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.
Clause 45. A method of manufacturing an article of footwear having a toe end and a heel end, the method comprising: forming a first knit zone of an upper of the article of footwear, wherein forming the first knit zone comprises: knitting, on a knitting machine, a first knit layer having a knitted mesh structure using a first set of yarns; applying a translucent or transparent thermoplastic polymer film to a first surface of the first knit layer; applying one or more of heat and pressure to at least a portion of the first knit zone such that the translucent or transparent thermoplastic polymer film melts to form a translucent or transparent thermoplastic polymer layer; forming the upper from at least the first knit zone such that the upper includes a void for receiving a wearer's foot; and positioning a first sole structure within the void of the upper and interior to the first knit layer, the first sole structure being at least partially visible through the knitted mesh structure of the first knit layer.
Clause 46. The method of manufacturing the article of footwear of clause 45, wherein the first surface of the first knit layer comprises an outer-facing surface of the first knit layer after being formed into the upper, and wherein the translucent or transparent thermoplastic polymer layer at least partially encapsulates the first set of yarns forming the outer-facing surface of the first knit layer.
Clause 47. The method of manufacturing the article of footwear of any of clauses 45-46, wherein the translucent or transparent thermoplastic polymer layer does not partially encapsulate the first set of yarns at an inner-facing surface of the first knit layer after the first knit layer is formed into the upper.
Clause 48. The method of manufacturing the article of footwear of any of clauses 45-47, wherein the first knit layer is at least partially embedded within the translucent or transparent thermoplastic polymer layer.
Clause 49. The method of manufacturing the article of footwear of any of clauses 45-48, wherein the translucent or transparent thermoplastic polymer layer does not extend to an inner-facing surface of the first knit layer after the first knit layer is formed into the upper.
Clause 50. The method of manufacturing the article of footwear of any of clauses 45-49, wherein the first set of yarns comprises a sheath of a first type of material surrounding a core of a second type of material different from the first type of material.
Clause 51. The method of manufacturing the article of footwear of any of clauses 45-50, wherein the first set of yarns is opaque.
Clause 52. The method of manufacturing the article of footwear of any of clauses 45-51, wherein the translucent or transparent thermoplastic polymer layer forms, at least in part, an outer-facing surface of the upper.
Clause 53. The method of manufacturing the article of footwear of any of clauses 45-52, wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer and the translucent or transparent thermoplastic polymer layer.
Clause 54. The method of manufacturing the article of footwear of clause 53, further comprising securing a second sole structure to the underfoot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer directly secures the second sole structure to the upper.
Clause 55. The method of manufacturing the article of footwear of clause 54, wherein the second sole structure is positioned exterior to the first knit layer.
Clause 56. The method of manufacturing the article of footwear of any of clauses 54-55, wherein the second sole structure comprises a fluid-filled bladder.
Clause 57. The method of manufacturing the article of footwear of any of clauses 54-55, wherein the underfoot portion of the upper comprises one or more supports, and wherein a plurality of recesses are disposed between adjacent ones of the one or more supports.
Clause 58. The method of manufacturing the article of footwear of clause 57, wherein each of the one or more supports terminates distally to form one or more support surfaces.
Clause 59. The method of manufacturing the article of footwear of any of clauses 57-58, wherein at least a portion of the one or more support surfaces are non-planar.
Clause 60. The method of manufacturing the article of footwear of clause 59, wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer, the second knit layer, and the translucent or transparent thermoplastic polymer layer.
Clause 61. A method of manufacturing an article of footwear having a toe end and a heel end, the method comprising: securing an upper having an underfoot portion comprising a first thermoplastic material having a first melting point around a last, wherein the last comprises an underfoot portion having a plurality of last supports and a plurality of last recesses disposed between adjacent last supports, the underfoot portion of the upper covering the underfoot portion of the last when the upper is secured around the last; applying one or more of heat and pressure to at least the underfoot portion of the upper while the upper is secured on the last such that the first thermoplastic material melts; and after the upper has cooled, removing the last from the upper, wherein after removal of the last from the upper, the underfoot portion of the upper includes a plurality of supports and a plurality of recesses having a shape corresponding to the plurality of last supports and the plurality of last recesses.
Clause 62. The method of manufacturing the article of footwear of clause 61, wherein the upper comprises one or more cut edges.
Clause 63. The method of manufacturing the article of footwear of any of clauses 61-62, further comprising, prior to securing the upper around a last, applying a film over a first knit layer, the film comprising the first thermoplastic material; wherein after applying one or more of heat and pressure, the underfoot portion of the upper comprises the first knit layer at least partially embedded within the thermoplastic layer comprising the melted first thermoplastic material.
Clause 64. The method of manufacturing the article of footwear of clause 63, wherein the first knit layer is positioned interior to the thermoplastic layer.
Clause 65. The method of manufacturing the article of footwear of any of clauses 63-64, wherein the first knit layer comprises a second thermoplastic polymer material having a higher melting temperature than the first thermoplastic polymer material.
Clause 66. The method of manufacturing the article of footwear of any of clauses 63-65, wherein the first knit layer comprises a knitted mesh structure and the thermoplastic layer is translucent or transparent.
Clause 67. The method of manufacturing the article of footwear of any of clauses 61-66, further comprising inserting a first sole structure into a void defined by the upper such that the first sole structure is positioned interior to the first knit layer, the first sole structure being at least partially visible through the knitted mesh structure of the first knit layer and the thermoplastic layer.
Clause 68. The method of manufacturing the article of footwear of any of clauses 61-67, comprising inserting a first sole structure into a void defined by the upper.
Clause 69. The method of manufacturing the article of footwear of clause 68, further comprising securing a second sole structure to an exterior of the underfoot portion of the upper, wherein the second sole structure comprises one or more bulbs each secured to a support of the plurality of supports of the underfoot portion, wherein the underfoot portion of the upper is spaced apart from the second sole structure at the plurality of recesses of the upper.
Clause 70. The method of manufacturing the article of footwear of clause 69, wherein an outsole structure is secured to a ground-facing surface of the second sole structure.
Clause 71. The method of manufacturing the article of footwear of any of clauses 61-70, wherein the underfoot portion is seamless.
Clause 72. The method of manufacturing the article of footwear of any of clauses 61-71, wherein prior to the application of one or more of heat and pressure, the underfoot portion of the upper comprises: a first knit layer knit using a first set of yarns; and a second knit layer knit using a second set of yarns, the second set of yarns comprising a first high-melting material and the first thermoplastic material.
Clause 73. The method of manufacturing the article of footwear of clause 72, wherein the first knit layer is integrally knit with the second knit layer.
Clause 74. The method of manufacturing the article of footwear of any of clauses 72-73, wherein prior to the application of one or more of heat and pressure, the upper comprises an unsecured area where the first knit layer and the second knit layer are unsecured to one another.
Clause 75. The method of manufacturing the article of footwear of clause 74, further comprising, prior to securing the upper around the last, applying one or more of heat and pressure to at least the underfoot portion of the upper such that the first thermoplastic material melts and forms a thermoformed layer at least partially encapsulating the first set of yarns and the first high-melting material of the second set of yarns, wherein the application of one or more of heat and pressure to at least the underfoot portion of the upper while secured on the last remelts the first thermoplastic material.
Clause 76. The method of manufacturing the article of footwear of any of clauses 72-75, wherein the first set of yarns comprises a core of a second high-melting material and a sheath of a second thermoplastic material having a second melting point greater than the first melting point of the first thermoplastic material, and wherein the sheath of the second thermoplastic material surrounds the core of the second high-melting material.
Clause 77. The method of manufacturing the article of footwear of clause 76, wherein the sheath of the second thermoplastic material of the first set of yarns softens during application of the one or more of heat and pressure to at least the underfoot portion of the upper while secured on the last.
Clause 78. The method of manufacturing the article of footwear of any of clauses 72-77, wherein the first knit layer comprises a knitted mesh structure.
Clause 79. An article of footwear having a medial side, a lateral side, a toe end, and a heel end, the article of footwear comprising: an upper having a void for receiving a wearer's foot, the upper comprising a first knit zone integrally knit with a second knit zone, the first knit zone comprising: a first knit layer comprising a knitted mesh structure comprising a first set of yarns; a second knit layer comprising a second set of yarns, the second knit layer positioned interior to the first knit layer; a translucent or transparent thermoplastic polymer layer that at least partially encapsulates each of the first set of yarns and the second set of yarns; and the second knit zone, wherein the translucent or transparent thermoplastic polymer layer is absent from the second knit zone.
Clause 80. The article of footwear of clause 79, wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.
Clause 81. The article of footwear of any of clauses 79-80, wherein the first set of yarns is opaque.
Clause 82. The article of footwear of any of clauses 80-81, wherein the first sole structure is located in the first knit zone.
Clause 83. The article of footwear of any of clauses 80-82, wherein the first sole structure is absent from the second knit zone.
Clause 84. The article of footwear of any of clauses 80-83, wherein the first sole structure is positioned interior to the second knit layer.
Clause 85. The article of footwear of any of clauses 80-84, wherein the first sole structure is removably disposed within the upper.
Clause 86. The article of footwear of any of clauses 79-85, wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit zone.
Clause 87. The article of footwear of clause 86, further comprising a second sole structure secured to the underfoot portion of the upper, wherein the translucent or transparent thermoplastic polymer layer directly secures the second sole structure to the upper.
Clause 88. The article of footwear of clause 87, wherein the second sole structure is positioned exterior to the first knit layer.
Clause 89. The article of footwear of any of clauses 87-88, wherein the second sole structure comprises a fluid-filled bladder.
Clause 90. The article of footwear of any of clauses 79-89, wherein the translucent or transparent thermoplastic polymer layer forms an outermost-facing surface of the upper in the first knit zone.
Clause 91. The article of footwear of any of clauses 79-89, wherein the translucent or transparent thermoplastic polymer layer forms, at least in part, an innermost-facing surface of the upper in the first knit zone.
Clause 92. The article of footwear of any of clauses 79-91, wherein the second knit zone comprises a single jersey knit structure.
Clause 93. The article of footwear of clause 92, wherein the second knit zone comprises at least a tongue region of the upper, the tongue region comprising a plurality of rib structures.
Clause 94. The article of footwear of clause 93, wherein the plurality of rib structures have knit courses that longitudinally extend in a direction from the toe end of the article of footwear to the heel end of the article of footwear.
Clause 95. A method of manufacturing an article of footwear having a toe end and a heel end, the method comprising: forming a first knit zone of an upper of the article of footwear, wherein forming the first knit zone comprises: knitting, on a knitting machine, a first knit layer having a knitted mesh structure using a first set of yarns; knitting, on the knitting machine, a second knit layer using a second set of yarns, the second set of yarns comprising a first high-melting material and a first thermoplastic material having a first melting point; forming the upper from at least the first knit zone such that the upper includes a void for receiving a wearer's foot, wherein the second knit layer is positioned interior to the first knit layer; applying one or more of heat and pressure to at least a portion of the first knit zone such that the first thermoplastic material melts and a thermoformed layer is formed that at least partially encapsulates the first set of yarns and the first high-melting material of the second set of yarns, wherein the thermoformed layer is translucent or transparent; and positioning a first sole structure within the void of the upper and interior to the second knit layer, the first sole structure being at least partially visible through the knitted mesh structure of the first knit layer.
Clause 96. The method of manufacturing the article of footwear of clause 95, wherein the first thermoplastic material of the second set of yarns comprises a sheath, wherein the first high-melting material of the second set of yarns comprises a core, and wherein the sheath surrounds the core.
Clause 97. The method of manufacturing the article of footwear of any of clauses 95-96, wherein the core of the second set of yarns is opaque.
Clause 98. The method of manufacturing the article of footwear of any of clauses 95-97, wherein the first set of yarns comprises a core of a second high-melting material and a sheath of a second thermoplastic material having a second melting point greater than the first melting point of the first thermoplastic material, and wherein the sheath of the second thermoplastic material surrounds the core of the second high-melting material.
Clause 99. The method of manufacturing the article of footwear of any of clauses 95-98, wherein the heat applied to the at least a portion of the first knit zone comprises a temperature equal to or greater than the first melting point of the first thermoplastic material and less than the second melting point of the second thermoplastic material.
Clause 100. The method of manufacturing the article of footwear of any of clauses 95-99, wherein the first set of yarns comprises a mono-component monofilament yarn, a bicomponent monofilament yarn, a coated monofilament yarn, or a multifilament yarn.
Clause 101. The method of manufacturing the article of footwear of any of clauses 95-100, wherein the first set of yarns is opaque.
Clause 102. The method of manufacturing the article of footwear of any of clauses 95-101, wherein the thermoformed layer forms an outermost-facing surface of the first knit zone of the upper.
Clause 103. The method of manufacturing the article of footwear of any of clauses 95-101, wherein the thermoformed layer forms, at least in part, an innermost-facing surface of the first knit zone of the upper when the upper is formed.
Clause 104. The method of manufacturing the article of footwear of any of clauses 95-103, wherein the first sole structure is removably disposed within the upper.
Clause 105. The method of manufacturing the article of footwear of any of clauses 95-104, wherein the first knit zone forms an underfoot portion of the upper.
Clause 106. The method of manufacturing the article of footwear of clause 97, further comprising securing a second sole structure to the underfoot portion of the upper, wherein the thermoformed layer directly secures the second sole structure to the upper.
Clause 107. The method of manufacturing the article of footwear of clause 106, wherein the second sole structure is positioned exterior to the first knit layer.
Clause 108. The method of manufacturing the article of footwear of any of clauses 106-107, wherein the second sole structure comprises a fluid-filled bladder.
Clause 109. The method of manufacturing the article of footwear of clause 95, further comprising: forming a second knit zone of the upper of the article of footwear, forming the second knit zone comprising: knitting on the knitting machine a single-knit jersey structure having a plurality of rib structures.
Clause 110. The method of manufacturing the article of footwear of clause 109, wherein the second knit zone is integrally knit with the first knit zone.
Clause 111. The method of manufacturing the article of footwear of clause 109, wherein the plurality of rib structures comprise knit courses that longitudinally extend in a direction from the toe end to the heel end.
Clause 112. The method of manufacturing the article of footwear of clause 111, wherein the second knit zone forms, at least in part, a tongue region of the upper.
Clause 113. The method of manufacturing the article of footwear of any of clauses 109-112, wherein the thermoformed layer is absent from the second knit zone.
Clause 114. The method of manufacturing the article of footwear of any of clauses 109-113, wherein a knitting sequence used to knit the plurality of rib structures comprises a repeating pattern of knitting a first number of knit courses on a first needle bed of the knitting machine using a set of yarns; transferring loops of the set of yarns held on the first needle bed to a second needle bed of the knitting machine; knitting a second number of knit courses on the second needle bed using the set of yarns; and transferring loops of the set of yarns back to the first needle bed to repeat the pattern.
Clause 115. The method of manufacturing the article of footwear of clause 114, wherein the first number of knit courses is different from the second number of knit courses.
Clause 116. The method of manufacturing the article of footwear of clause 115, wherein the first number of knit courses is two knit courses, and wherein the second number of knit courses is four knit courses.
Clause 117. The article of footwear of any of clauses 1-44 and 79-94, wherein the upper comprises an underfoot portion having one or more seams.
Clause 118. The article of footwear of clause 117, wherein the one or more seams comprise a longitudinal seam extending from a toe end to a heel end of the upper.
Clause 119. The article of footwear of clauses 117 or 118, wherein the one or more seams comprise a first heel-end seam having a first portion at least partially extending diagonally up a side of the first sole structure on a diagonal and a second portion at least partially extending diagonally up the side of the first sole structure and meeting the first portion of the first heel-end seam.
Clause 120. The article of footwear of clause 119, further comprising a heel counter secured to the upper and having a first portion covering the first portion of the first heel-end seam and a second portion covering the second portion of the first heel-end seam.
Clause 121. The article of footwear of clause 120, wherein the upper comprises a second heel-end seam extending from the first heel-end seam to an ankle opening, wherein the heel counter covers part of the second heel-end seam.
Clause 122. An article of footwear, comprising: an upper, comprising: a first knit layer comprising a knitted mesh structure comprising a first set of yarns; a thermoplastic polymer layer that at least partially covers and/or encapsulates the first set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and at least one internal component of the article of footwear that is at least partially visible through the thermoplastic polymer layer.
Clause 123. The article of footwear of clause 122, wherein the knitted mesh structure of the first knit layer is at least partially visible through the thermoplastic polymer layer.
Clause 124. The article of footwear of any of clauses 122-123, wherein the at least one internal component is a midsole or a sole structure that is at least partially visible through both of the thermoplastic polymer layer and the knitted mesh structure of the first knit layer.
Clause 125. The article of footwear of any of clauses 122-124, wherein the thermoplastic polymer layer forms, at least in part, an outermost-facing surface of the upper.
Clause 126. The article of footwear of any of clauses 122-125, wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer and the thermoplastic polymer layer.
Clause 127. The article of footwear of any of clauses 122-126, wherein the first set of yarns are partially embedded within the thermoplastic polymer layer.
Clause 128. The article of footwear of any of clauses 122-127, wherein the thermoplastic polymer layer does not fully extend to an inner-facing surface of the first knit layer.
Clause 129. The article of footwear of any of clauses 122-128, wherein the thermoplastic polymer layer comprises a first sub-layer having a first thermoplastic polymer composition and a second sub-layer having a second thermoplastic polymer composition, the second sub-layer being positioned between the first knit layer and the first sub-layer.
Clause 130. The article of footwear of clause 129, wherein the second thermoplastic polymer composition has a lower melting temperature than the first thermoplastic polymer composition.
Clause 131. The article of footwear of any of clauses 129-130, wherein the second thermoplastic polymer composition has a lower melting temperature than the first set of yarns.
Clause 132. The article of footwear of any of clauses 122-131, wherein the upper comprises a second knit layer comprising a second set of yarns and positioned interior to the first knit layer.
Clause 133. The article of footwear of clause 132, wherein the upper comprises an underfoot portion, the underfoot portion comprising the first knit layer, the second knit layer, and the thermoplastic polymer layer.
Clause 134. An article of footwear, comprising: an upper, comprising: a composite layer comprising one or more knit layers and a thermoplastic polymer material forming a skin and/or a film structure, wherein the one or more knit layers are positioned to form at least part of an inner-facing surface of the upper, wherein the thermoplastic polymer material forms at least part of an outer-facing surface of the upper and is translucent or transparent, and wherein at least one internal component of the article of footwear is at least partially visible through the composite layer.
Clause 135. The article of footwear of clause 134, wherein the composite layer comprises a first surface comprising the thermoplastic polymer material and a second surface comprising the at least part of the one or more knit layers, wherein the first surface has a smoother texture than the second surface.
Clause 136. The article of footwear of clause 135, wherein a sole structure directly abuts the second surface.
Clause 137. The article of footwear of clause 136, wherein the one or more knit layers comprise a first knit layer and a second knit layer, the second knit layer being interior to the first knit layer.
Clause 138. An article of footwear comprising a medial side, a lateral side, a toe end, and a heel end, the article of footwear comprising: an upper comprising a first knit zone integrally knit with a second knit zone, the first knit zone comprising: a first knit layer comprising a knitted mesh structure comprising a first set of yarns; a second knit layer comprising a second set of yarns, the second knit layer positioned interior to the first knit layer; and a thermoplastic polymer layer that is translucent or transparent and that at least partially covers and/or encapsulates the first set of yarns and/or the second set of yarns, wherein the thermoplastic polymer layer is absent from the second knit zone.
Clause 139. The article of footwear of clause 138, wherein the polymer layer forms an outermost-facing surface of the upper in the first knit zone.
Clause 140. The article of footwear of any of clauses 138-139, wherein the second knit zone comprises a single jersey knit structure.
Clause 141. The article of footwear of any of clauses 138-140, wherein the second knit zone comprises at least a tongue region of the upper, the tongue region comprising a plurality of rib structures.
Clause 142. An article of footwear, comprising: an upper, comprising: a textile layer comprising a first set of yarns; and a thermoplastic polymer layer that at least partially covers and/or encapsulates the first set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and a sole structure incorporated into the upper and being at least partially visible through the thermoplastic polymer layer.
Clause 143. The article of footwear of clause 142, wherein the textile layer comprises a knitted textile.
Clause 144. The article of footwear of clause 142, wherein the textile layer comprises a woven textile.
Clause 145. The article of footwear of clause 142, wherein the textile layer comprises a non-woven textile.
Clause 146. The article of footwear of clause 142, wherein the textile layer comprises a mesh structure.
Clause 147. An article of footwear, comprising: an upper, comprising: a composite layer comprising one or more textile layers and a thermoplastic polymer material forming a skin and/or a film structure, wherein the thermoplastic polymer material forms at least part of an outer-facing surface of the upper and is translucent or transparent, and a sole structure incorporated into the upper and being at least partially visible through the composite layer.
Clause 148. The article of footwear of clause 147, wherein at least one textile layer comprises a knitted textile.
Clause 149. The article of footwear of clause 147, wherein at least one textile layer comprises a woven textile.
Clause 150. The article of footwear of clause 147, wherein at least one textile layer comprises a non-woven textile.
Clause 151. The article of footwear of clause 147, wherein at least one textile layer comprises a mesh structure.
Clause 152. An article of footwear, comprising: an upper, comprising: a first textile zone that is integrally formed with a second textile zone, the first textile zone comprising: a first textile layer comprising a first set of yarns; a second textile layer comprising a second set of yarns, the second textile layer positioned interior to the first textile layer; a thermoplastic polymer layer that at least partially covers and/or encapsulates the first set of yarns and/or the second set of yarns, wherein the thermoplastic polymer layer is translucent or transparent; and wherein the thermoplastic polymer layer is absent from the second textile zone.
Clause 153. The article of footwear of clause 152, wherein the first textile layer and/or the second textile layer comprises a knitted textile.
Clause 154. The article of footwear of clause 152, wherein the first textile layer and/or the second textile layer comprises a woven textile.
Clause 155. The article of footwear of clause 152, wherein the first textile layer and/or the second textile layer comprises a non-woven textile.
Clause 156. The article of footwear of clause 152, wherein the first textile layer and/or the second textile layer comprises a mesh structure.
This application claims priority to co-pending U.S. provisional app. No. 63/615,109 (filed Dec. 27, 2023) and claims priority to co-pending U.S. provisional app. No. 63/642,342 (filed May 3, 2024). The entireties of the aforementioned applications are incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63615109 | Dec 2023 | US | |
| 63642342 | May 2024 | US |
