INTERLACED KNITTED UPPER AND METHODS OF MANUFACTURE

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional patent application claims priority to U.S. provisional patent app. No. 63/609,661, filed Dec. 13, 2023, and titled “INTERLACED KNITTED UPPER AND METHODS OF MANUFACTURE”, the entire contents of which is incorporated herein by reference.

BACKGROUND

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the footwear for comfortably and securely receiving a foot. Uppers may be formed by a variety of materials, including knitted textiles. Uppers may be formed from one or more textiles, which may be knitted together or attached through other structures comprising the upper. These textiles are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines.

For certain activities, such as running, it may be advantageous to provide an upper that is lightweight, breathable, and durable and able to provide containment around a wearer's foot. Knitted textiles for uppers may include multiple knit structures, or layers, with each structure having different knit constructions and/or yarn types to provide desirable characteristics. Such layered constructions are often formed on two needle beds of a knitting machine, which allows for flexibility in adjusting the yarn and/or stitch types between structures knit on different needle beds. However, knitting on both needle beds is more likely to include additional knitted loops and, therefore, result in a less breathable and lightweight textile.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are described in detail herein with reference to the attached Figures, which are intended to be exemplary and non-limiting, wherein:

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

FIG. 1B illustrates a lateral view of an example article of footwear with inlaid strands in accordance with aspects herein;

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

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

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

FIG. 4A illustrates an example stich pattern that may be used to form a first side of a portion of a knitted component in accordance with aspects herein;

FIG. 4B illustrates an example stich pattern that may be used to form a second side of a portion of the knitted component of FIG. 4A in accordance with aspects herein; and

FIG. 5 illustrates an example close-up view of a single bed knitting machine manufacturing a portion of a knitted component in accordance with aspects herein.

DETAILED DESCRIPTION

Aspects hereof relate to a knitted component, which may be incorporated into an upper for an article of footwear, which includes knit structures formed with yarns of different tenacities with different knit stitch patterns. As described herein, various aspects incorporate yarn types, knit stitch patterns, and/or constructions between the two knit structures to provide a breathable and lightweight yet strong knitted component.

In some aspects, the knitted component includes a first knit structure comprising a first yarn and a second knit structure comprising a second yarn. The two yarns may have different tenacities. The yarns of the first and second knit structures may also follow different knit stitch patterns. For example, the first yarn of the first knit structure may be formed into a sequence of knit loops and floats, while the second yarn of the second knit structure may be formed into a sequence with knit loops, tuck stitches, held loops, and floats. The patterns of knit stitches of the first and second knit structures may result in different stretch properties.

Further, the first and second knit structures may be formed on a single needle bed, where the first yarn forms the first knit structure on a first set of needles and the second yarn forms the second knit structure on the second set of needles. These first and second sets of needles may be interspersed so that the first and second knit structures may be integrally formed together. This may result in the first knit structure being formed of knit loops on a first set of wales and floated across a second set of wales and the second knit structure being formed of knit loops, tucks, stiches, and held loops on the second set of wales and floated across the first set of wales. The first and second knit structures formed in this way may not be interlooped together, but instead, may be interlaced or interconnected by the first yarn alternatively passing in front of and behind the second yarn.

Further, some aspects of this disclosure include a knitted component with a first yarn and a second yarn having a different tenacity than the first yarn. Each yarn may be knit with different knit stitch patterns that both include floats but the floats may be extending in different directions. For example, the first yarn may be knitted into knit loops and floats extending in a first direction and the second yarn is knitted into knit loops and floats extending in a second direction. At least some of the floats formed by the second yarn also traverse at least two courses. In some examples, the first direction of the floats of the first yarn is in a course-wise direction, while the second direction of the floats of the second yarn may be in a direction other than a course-wise or wale-wise direction (e.g., diagonal). The first yarn and second yarn may both be knitted along the same courses and same wales, where each of the wales in a plurality of wales of the knitted component comprises at least one float formed by either the first yarn or the second yarn. For example, in any given course within a plurality of courses, one wale may include a float by the first yarn while an adjacent wale may include a float by the second yarn.

Another aspect of this disclosure relates to a method of forming or manufacturing a knitted component, which may form at least a part of an article of footwear. The method includes forming at least part of the knitted component on a single needle bed. For example, a plurality of courses may be knit on a single needle bed, where each course has a first yarn and a second yarn that has a different tenacity than the first yarn. The first yarn is knit to form knit loops on a first set of needles of the single needle bed and is floated over a second set of needles of the single needle bed, where the second set of needles are interspersed with the first set of needles on the single needle bed. For example, the first set of needles may be the even-numbered needles and the second set of needles may be the odd-numbered needles. Conversely, the second yarn is knit to form knit loops on the second set of needles and is floated over the first set of needles. In some aspects, the knit loops of the second yarn are held and later tucked with another loop of that yarn. As such, the method further includes that some of the knit loops of the second yarn are released from the respective needle and some of the knit loops of the second yarn are held on the respective needle to be released in a subsequent course. This may result in the second knit structure having with a lesser degree of stretch than the first knitted component.

The use of different yarns in a knitted component formed according to the knitting processes described herein can allow combinations of desired characteristics to be imparted into a knitted component or knitted structure or into portions thereof. For example, incorporation of different yarns can allow for combinations of characteristics, e.g., strength, containment, traction or grip, softness, texture, or the like, in a knitted component. For example, a knitted component as described herein may incorporate high-tenacity yarns (e.g., having a tenacity of at least 5 grams per denier (g/denier); to impart strength and stretch-resistance) in combination with yarns having other properties, e.g., softness (e.g., from a chenille or analogous yarn type), grip (e.g., from a yarn having thermoplastic materials), or that has different properties (e.g., color, texture, denier, stretch-resistance, elasticity, or the like). The aspects described herein can include any combination of the aforementioned yarn types based on desired properties and are not limited to any example combinations.

In aspects, because the yarns are knit on a single needle bed, instead of two needle beds, the resulting knitted component may be thinner than if the first and second yarns where knit on both needle beds. Further, having the two yarns looped onto different needles interspersed with each other creates two separate structures that are interwoven together. While knit structures formed on separate needle beds by separate yarns may be integrally formed by having at least one of the yarns or a third yarn form loops on both needle beds, forming the structure on a single bed in accordance with this disclosure reduces the amount of yarn (number of ends or length of ends) needed to interconnect the two layers, resulting in a knitted component that is lighter weight and may reduce knit time.

As used herein, an article of footwear generally includes a sole structure secured to an upper. 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. A midfoot region generally includes portions of the article of footwear corresponding with an arch area and an instep area of the foot. A heel region generally corresponds with rear portions of the foot including the calcaneus bone. The article of footwear described herein may include a lateral side which corresponds with an outside area of the foot (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 knitted upper, and to the sole structure.

The term “outer-facing surface” as used herein means a surface of the knitted 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 knitted upper or article of footwear. The term “inner-facing surface” as used herein means a surface of the knitted upper or article of footwear that faces a void for receiving the wearer's foot. In some aspects, the inner-facing surface may mean the innermost-facing surface of the knitted upper or article of footwear.

The term “knit” such as used herein to describe the knitted 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 (also referred to herein as a knit loop), a float, a tuck stitch, a held loop, 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 “single knit construction” as used herein refers to a knit construction generally formed on a single needle bed (i.e., a single-bed knit construction). A single knit construction may include multiple overlapping knit structures that are formed on the same, single needle bed. In contrast, 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 of knit loops and/or tucks, e.g., one face of loops formed on a first needle bed, and a second face of loops formed on a second needle bed. In contrast to a multi-bed knit construction, a single-bed knit construction may include two sets of loops, where the faces of loops are facing the same direction so that there is only a single side with the “face” of loops and the opposite side of the knit textile is the back of the loops.

The term “integrally knit,” as used herein, may mean a knit textile having a yarn from one or more knit courses in a first area or zone being interlooped with one or more knit courses of another area 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, areas or zones that are integrally knit together have a seamless transition such that they seamlessly extend from one another.

A knit stitch is the basic unit of interlooping (i.e., a loop) formed on a needle. The loop includes a head (top arc), two legs, and two feet (or bottom half arcs). It typically is formed as a part of three or more interlooped loops. A center loop has been drawn through the head of a lower previously-formed loop and is, in turn, interlooped through its head by the loop above it. When a knitting needle is raised sufficiently high by a camming action to obtain the yarn in a hooked portion of the knitting needle and the lower previously-formed loop is below the latch, a knit stitch will be formed as the needle descends. The term “knit loop,” as used herein may mean when a stitch is produced when the needle receives a new loop and knocks over the old loop that it held from the previous knitting cycle (i.e., the prior course). This knit loop has a height spanning a single course. The term “held loop,” as used herein may mean a loop from a previous course that the needle has retained in the subsequent knitting cycle (i.e., the next course). The held loop can be retained by the needle for a number of knit courses before it is interlooped with a new loop. The held loop has a height that spans more than one course, where the height depends on how many knit courses the loop is retained on the needle before being knocked over.

The term “tuck stitch,” as used herein, may mean a stich composed of a held loop, one or more tuck loops and knit loops. A tuck stitch is produced when a needle holding a held loop also receives a new loop, which becomes a tuck loop because it is not intermeshed through the old loop but, rather, tucked in with the old loop.

The term “float stitch,” (which may also be referred to as “float”) as used herein may mean a yarn that floats over at least one needle without interlooping, resulting in a yarn section that remains unlooped over at least one wale. The floating yarn may float freely on a reverse side of a held loop or, where may float within an opening where the loop on the needle from a previous knit cycle is transferred to a different needle position. As described herein, when a yarn is referred to as “floated” or “floating” it is forming a float stich.

The term “technical face,” as used herein may mean a side of a knitted textile that contains all face loops or weft knit loops. During loop formation, when the new loop passes from the face side to the back of the previous loop, then it is termed as back loop or purl loop. The term “technical back,” as used herein may mean a side of a knitted textile that contains all back loops or purl loops is known as technical back.

Forming the knitted 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, a thermoplastic material, a lightweight or ultra-lightweight monofilament, or another 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 knitted upper may have different properties as described herein.

Unless indicated otherwise, all measurements provided herein are taken when the upper and/or article of footwear is at standard ambient temperature and pressure (298.15 K and 100 kPa) and is in a resting (non-tensioned) state. As used herein, the terms “substantially” and “about” mean within ±5% of an indicated value.

FIG. 1A schematically depicts a lateral view of an example article of footwear 100 having an upper 110 and a sole structure 112 secured to the upper 110. A biteline 115 represents where the upper 110 meets the sole structure 112. Although not illustrated, in some aspects the article of footwear 100 may include plurality of sole structures, connected to the upper 110 at a plurality of bitelines. The article of footwear 100 is illustrated in the form of an athletic shoe but other types of shoes (e.g., running shoes, sandals, leisure shoes, and the like) are contemplated herein. The article of footwear 100 includes a forefoot region 114, midfoot region 116, and a heel region 118. The article of footwear 100 includes an ankle collar 124 having an opening 125 for receiving a wearer's foot, and a throat area 126.

The article of footwear 100 may include a tongue 127 and one or more fasteners, such as a set of laces (hereinafter “laces”) 128. The laces 128 may be engaged to the upper 110 by a plurality of looped fabric or holes in the upper 110 (hereinafter “eyelets”) 129. The eyelets 129 are depicted herein as a set of holes in the upper 110. The eyelets 129 may include a reinforced area around an opening in the upper 110 where the laces 128 are inserted. Although not shown, aspects herein contemplate that the article of footwear 100 may include additional elements attached to the upper 110 or sole structure 112 including, for example, leather materials, synthetic leather materials, knitted or woven textiles, polymer skins, and the like. The additional elements may be positioned at discrete locations of the upper 110 including, for example, a toe area (e.g., a toe cap), the heel area (e.g., a heel counter), and the like.

In some aspects, the upper 110 includes a knitted component 130 that forms at least part of the upper 110. For example, the knitted component 130 may form at least part of the midfoot region 116 and at least part of the forefoot region 114 of the upper 110. The knitted component 130 may form all or substantially all of the upper 110. The knitted component 130 may form the upper 110 with additional pieces applied on top of or underneath the knitted component 130. In the example shown, the knitted component 130 forms the forefoot region 114, the midfoot region 116, and the heel region 118. The tongue 127 may be formed by a portion of the knitted component 130 and be a contiguous piece of the upper 110. Alternatively, the tongue 127 may be formed from a second knitted component or by another material for example, leather materials, synthetic leather materials, knitted or woven textiles, polymer skins, and the like. The knitted component 130 may have a first side forming an inner-facing surface (not shown) of the upper 110 (e.g., facing towards a foot-receiving foot of the article of footwear 100) and a second side forming at least part of an outer-facing surface 111 of the upper 110.

The knitted component 130 includes a first knit structure 140 and a second knit structure 150. The first knit structure 140 and the second knit structure 150 are interconnected or interlaced, but not interlooped. As such, the knitted component 130 may comprise a unitary knit construction and may be formed in a single knitting process, as described below when describing FIG. 5. In other words, the first knit structure 140 and the second knit structure 150 may be integrated as a single piece during the knitting process. The first knit structure 140 may be formed from a first yarn (identified as first yarn 302 in FIG. 3) knitted into knit loops and floats. The second knit structure 150 may be formed from a second yarn knitted (identified as second yarn 304 in FIG. 3) into knit loops, tuck stitches, held loops, and floats. The first yarn may alternatively pass from the inner-facing surface to the outer-facing surface 111 across the second yarn to interlace the first knit structure 140 with the second knit structure 150. Correspondingly, the second yarn may be considered to alternatively pass from the inner-facing surface to the outer-facing surface 111 across the first yarn to interlace the first knit structure 140 with the second knit structure 150.

Generally, and as described in more details with respect to FIG. 3, the knitted component 130 is formed by alternating looping the first or the second yarn on a needled or set of needles while the other yarn floats. In this way, each wale of the knitted component 130 includes a float of one yarn and a loop (e.g., knit loop, held loop, and/or tuck loop) of the other yarn. Further, the types of loops formed by the first yarn in the first knit structure 140 may vary from the types of loops formed by the second yarn in the second knit structure 150 as a result of different knit stitch patterns. For example, the first knit structure 140 may be formed with a knit stitch pattern of one float followed by one knit stitch, whereas the second knit structure 150 may be formed with a knit stitch pattern of one float followed by one tuck stitch. As a result, the first knit structure 140 may include knit loops at the same wales where the second yarn floats, and the second knit structure 150 may include a knit loops, a held loop, and/or a tuck loop where the first yarn floats.

In further examples, the knitted component 130 also includes one or more inlaid strands 160 arranged between the first knit structure 140 and the second knit structure 150, as illustrated in FIG. 1B. The inlaid strands 160 may generally be inlaid between the first knit structure 140 and the second knit structure 150 of the knitted component 130 such that the inlaid strands 160 generally extend in an unlooped state along a course formed with knitted loops of one or more other yarns (e.g., the first yarn of the first knit structure 140 and the second yarn of the second knit structure 150). While other portions of the knitted component 130 may be a single knit construction, where, the first knit structure 140 and the second knit structure 150 are both knit on the same needle bed, the first and second knit structures 140 and 150 may be separated onto separate needle beds to create double knit construction in areas with the inlaid strands 160. In this way, a feeder (e.g., a combination feeder) of the knitted machine may insert one of the inlaid strands 160 between two needle beds, while the first yarn of the first knit structure 140 is knit on a separate needle bed as the second yarn of the second knit structure 150. The first and second knit structures 140 and 150 may, therefore, form a tunnel through which the inlaid strand 160 extends. Further, one or more additional yarns may be knit with the first yarn and/or the second yarn to form the tunnels for the inlaid strands 160.

The inlaid strands 160 may include one or more loops at each end of the inlaid strands 160 to anchor the inlaid strands 160 into one of the first and second knit structures 140 and 150 of the knitted component 130. The inlaid strands 160 may generally extend through or along a course without being interlooped with another yarn or strand, such as the first yarn or the second yarn. The inlaid strands 160 may further provide containment by increasing tensile strength and providing structure to the upper 110. The inlaid strands 160 may include a least a partial loop around a part of one or more eyelets 129, which may provide strength and tear resistance to the eyelets 129. The inlaid strands 160 may be extend through the throat area 126 to provide additional strength for the fasteners or laces 128

The various rows of inlaid strands 160 shown in FIG. 1B are referred to herein as a plurality of inlaid strands. It should be understood that the plurality of inlaid strands may be sections of a continuous strand. In some aspects, the knitted component 130 may include an inlaid strand 160 formed form a continuous strand in a continuous serpentine pattern. For example, the inlaid strand 160 may be inlayed across one course of the knitted component 130, the inlaid strand 160 may exit the knit structures of the knitted component 130 or run along a course of the knitted component 130 and re-enter the knitted component 130 to extend through another course in the opposite direction.

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

As illustrated in FIG. 1B, the inlaid strands 160 are depicted as extending across the upper 110 such that they extend from the throat area 126 to the biteline 115. Some inlaid strands 160 may extend from the heel region 118 to the forefoot region 114. Some inlaid strands, such as the inlaid strands 160 in the forefoot region 114, extend from the biteline 115 on a medial side, over the top of the upper 110, to the biteline 115 on a lateral side. In other aspects, the inlaid strands 160 may be oriented to extend in a different direction, such as a heel-toe direction. While inlaid strands 160 illustrated in the upper 110 extend generally parallel to one another, other examples include inlaid strands 160 within the same upper 110 extending in different directions. The inlaid strands 160 may also be used to introduce additional physical attributes or characteristics to the upper 110, such as elasticity or wear resistance. The inlaid strands 160 may also be used to form a visual pattern on the upper 110 for decorative or trademark purposes.

FIG. 2A depicts the knitted component 130 in the shape of the upper 110 of FIGS. 1A-1B before being secured to the sole structure 112. In example aspects, the knitted component 130 may have a generally U-shaped configuration that is outlined by an outer perimeter edge 210, a pair of heel edges 212, and an inner edge 214. The outer perimeter edge 210 encompasses the forefoot region 114 opposite the heel edges 212. In some aspects, the knitted component 130 (specifically, the first knit structure 140 and the second knit structure 150) are knit as larger textile pieces from which a U-shaped portion is cut for formation of the upper 110. In some aspects, the knitted component 130 is formed into the U-shaped configuration of the upper 110 during a knitting process without further processing to form the desired configuration. Further, in some examples, the knitted component 130 is knit at least partially to shape with some, but not all of the edges in the U-shaped configuration shown in FIG. 2A being formed after knitting. For example, the heel edges 212 and at least part of the outer perimeter edge 210 may be defined during knitting of the knitted component 130, while some portions of the outer perimeter edge 210 and the inner edge 214 may be cut after knitting and, in cases, after additional post-knitting processes, such as steaming.

The U-shaped configuration is just one example shape of the upper 110 and other shapes are contemplated herein. Additionally, the knitted component 130 configured to form the upper 110 is just one example of how the knitted component 130 may be configured, other configurations of the knitted component 130 are contemplated herein, where the knitted component 130 comprises a portion of the upper 110. For example, the knitted component 130 may be configured to comprise a portion of the upper 110 and a portion of an underfoot portion. In another example, the knitted component 130 may be integrated with other components to form the upper 110. Further, the knitted component 130 may contain a third knit structure adjacent to and integrally knit with the first and second knit structures, where the third knit structure has a different knit construction (e.g., may be double knit construction or may be single knit construction but with different knit stitch patterns). The third knit structure may be formed from the first yarn 302, the second yarn 305, a new yarn or a combination of any of these yarns.

When incorporated into the article of footwear 100, the outer perimeter edge 210 may be positioned against the upper surface of the sole structure 112 and may be joined to a strobel in example aspects. In other aspects, the upper 110 may include an underfoot portion also formed from the knitted component 130. In this example, the article of footwear 100 may not include a strobel. In example aspects, the pair of heel edges 212 are joined to each other and extend generally vertically in the heel region 118 of the article of footwear 100. The inner edge 214 forms the ankle collar 124 and extends forward to define the throat area 126. Eyelets 129 may also be formed proximate to the inner edge 214.

The knit stitch pattern of the knitted component 130 is illustrated in FIG. 2A, where the wale-wise direction 218 is defined by the lengthwise direction of a column of loops and the course-wise direction 220 is defined by the lengthwise direction of a course of the knitted component 130. In this example, the wale-wise direction 218 extends from the heel edge 212 to the outer perimeter edge 210 in the forefoot region 114 (i.e., the wale-wise direction 218 extends in a heel-to-forefoot direction), and the course-wise direction 220 extends either between the outer perimeter edge 210 to the inner edge 214 or to between opposite sides of the outer perimeter edge 210 (I.e., the course-wise direction 220 extends in a medial-lateral direction). The orientation of the knit stitch pattern of the knitted component 130 as described is just one example of the orientations of the wale-wise and course-wise directions relative to the knitted component 130, which are discussed further herein. However, other orientations of the are contemplated, including wherein the wale-wise direction is a medial-to-lateral direction and the course-wise direction is a heel-to-forefoot direction or where the course-wise direction is radially extending from the outer perimeter edge 210 to a common portion, such as the throat area 126 and/or ankle collar 124 defined by the inner edge 214.

Turning to FIG. 2B, which depicts the knitted component 130 from FIG. 2A with the addition of the inlaid strands 160 as described earlier in FIG. 1B. For example, the inlaid strands 160 may extend generally in the course-wise direction. In some aspects, a portion of the inlaid strands 160 may extend partially in a course-wise direction but also extend partially in another direction, such as a wale-wise or diagonal direction. The inlaid strands 160 may extend from the outer perimeter edge 210 to the closest inner edge 214. The inlaid strands 160 may extend from the outer perimeter edge 210 to the closest throat area 126 and may further form a portion of an eyelet 129. The inlaid strands 160 may extend from the outer perimeter edge 210 on one side of the forefoot region 114 to the outer perimeter edge 210 on the opposing side of the forefoot region 114. The inlaid strands 160 may extend generally in the heel-to-forefoot direction, being in laid in a plurality of courses and or wales. At least a portion of the inlaid strands 160 may cross one or more wales while extending in the wale-wise direction across the knitted component 130. Further, the inlaid strands 160 may extend in a skew direction or change direction within the knitted component 130.

FIG. 3 depicts a close-up view of a portion of the knitted component 130 having the first knit structure 140 and the second knit structure 150. One or more yarns, such as the first yarn 302, form the first knit structure 140. In this example, only one first yarn 302 (e.g., one end of the first yarn 302) forms the first knit structure 140, but it is contemplated that a plurality of yarns having the same or different types may form the first knit structure 140. One or more yarns, such as the second yarn 304, form the second knit structure 150. In this example, only one second yarn 304 (e.g., one end of the second yarn 304) forms the second knit structure 150, but it is contemplated that a plurality of yarns having the same or different types may form the second knit structure 150.

In certain aspects, the knitted component 130 may be formed by knitting the first knit structure 140 and the second knit structure 150 in an interconnected manner on a single needle bed. The first yarn 302 of the first knit structure 140 may form a first knit stitch pattern by forming knit loops (e.g., knit loop 332) in a first wale 308, forming a float (e.g., float 334) across a second wale 309, and then forming knit loops in a third wale 310. The first yarn 302 may continue the first knit stitch pattern by floating across a fourth wale 311, forming a knit loop at a fifth wale 312, and so on. It is contemplated that the first yarn 302 of the first knit structure 140 may form a different knit stitch pattern other than the first knit stitch pattern shown. For example, the first yarn 302 may form knit loops at two or more wales in each course, followed by a float at two wales. As such, the first yarn 302 may form knit loops in a first set of wales and float across a second set of wales, where wales within the sets may be interspersed throughout the knitted component 130.

Further, the second yarn 304 of the second knit structure 150 may form a second knit stitch pattern that is different than the first knit stitch pattern of the first yarn 302. While the first yarn 302 may alternate between a knit loop stitch and a float stitch to create the first knit stitch pattern shown in FIG. 3, the second yarn 304 may follow a sequence of a knit loop stitch, a float stitch, a tuck stitch, and another float stitch to create the second knit stitch pattern in FIG. 3. As previously described, when a loop of a yarn (e.g., the second yarn 304) is held on a needle of the knitting machine, instead of being knocked off in a subsequent pass of the carrier, the loop of yarn, when it is eventually knocked off, will form a held loop spanning at least two courses. With each subsequent pass of the carrier over that needle, the yarn (e.g., the second yarn 304) may form a loop that is tucked in with the held loop until the held loop and tucked loops are released from the needle. The tuck stitch results in the second yarn 304 extending between different courses as the yarn moves to different wales. It is contemplated that the first yarn 302 may change knit stitch patterns after a plurality of courses, therefore not filling an entire wale with knit loops or floats.

For example, the second yarn 304 may float (e.g., float 336) across the first wale 308 and form a first knit loop 320 at the second wale 309 at a first course 314, and then the second yarn 304 may float across the third wale 310 before forming a first tuck loop 321 at a second course 315 in the fourth wale 311. The first tuck loop 321 of the second yarn 304 may have been released at the same time as a first held loop 329 of the second yarn 304 and, therefore tucks into the first held loop 329 of the second yarn 304. The second yarn 304 may then continue the second knit stitch pattern between the first course 314 and the second course 315, forming a second knit loop 322 on the first course 314 at a sixth wale 313, after floating across the fourth wale 311.

Further, subsequent passes of the carrier knitting the second yarn 304 may switch between the knit loop stitch and the tuck stitch at the same needle position, resulting in a wale that alternates between a knit loop and a held loop/tuck loop combination. Looking to FIG. 3, for example, the second yarn 304 may float across the first wale 308 before forming a second held loop 324 on the second wale 309 at a second course 315. The second held loop 324 may extend from the second course 315 to a third course 316 of the second wale 309 where it is interlooped with a third knit loop 325 formed from the second yarn 304 at a fourth course 317. The second yarn 304 may float across the third wale 310 and form a second tuck loop 326 alongside the first tuck loop 321 at the second course 315 on the fourth wale 311. The second tuck loop 326 may be formed by tucking into the first held loop 329 of the second yarn 304. The second yarn 304 may float across the fifth wale 312 and form a third held loop 327 in the third course 316 at the sixth wale 313. The third held loop 327 may be interlooped with a fourth knit loop 328 formed from the second yarn 304 at a fourth course 317. The second yarn 304 may then continue this pattern between the second course 315 and the third course 316.

At least a portion of the floats in the second knit structure 150 may traverse at least two courses. It is contemplated that the second knit structure 150 may form a different knit stitch pattern other than the second knit stitch pattern. For example, for the second yarn 304 may have the held loops extending over additional courses, a different the ratio of held loops versus knit loops, or a different length of floats (which creates a different spacing between the held loops and knit loops).

In some aspects, the knit stitch patterns of the first knit structure 140 and the second knit structure 150 may provide certain desired properties of the knitted component 130. For example, the floats stitches in the first and second knit structures 140 and 150 as well as the tuck stitches in the second knit structure 150 may reduce stretch in at least the course-wise direction and increase strength of the knitted component 130. Thus, each of the first knit structure 140 and the second knit structure 150 may provide a reduced amount of stretch in a course-wise direction. Further, alternating the needles on which the first and second yarns 302 and 304 knit allow each wale within a course to include a float-either from the first yarn 302 or the second yarn 304, such that the combination of the first knit structure 140 and the second knit structure 150 may further reduce stretch compared to the two structures 140 and 150 individually.

Further, alternating float stitches with another type of stitch on each of the first and second knit structures 140 and 150 enables both structures to be knit on a single needle bed to create a single knit construction, which may reduce weight and increase breathability of the knitted component 130.

While the first and second knit structures 140 and 150 may be knit on separate needles and not interlooped together in at least a portion of the knitted component 130 (such as the portion showed in FIG. 3), the first and second knit structure 140 and 150 may nevertheless be interconnected so that they are not separable. For example, the first yarn 302 and the second yarn 304 may alternate, in different wales, which yarn is positioned in front of the other, which may effectively interweave the first and second knit structures 140 and 150 together. The example of FIG. 3 shows the floats 334 of the first yarn 302 positioned behind the loops (e.g., knit loop, tuck loop, held loop) of the second yarn 304, while the floats (e.g., float 336) of the second yarn 304 are positioned behind the knit loop 332 of the first yarn 302.

Further, the orientation of the knitted component 130 with relation to the article of footwear 100 may also enhance or modify certain physical attributes to the article of footwear 100. As previously described, each of the first knit structure 150 and the second knit structure 150 have floats, which reduces stretch in the course-wise direction. The second knit structure 150 also has knit loops, held loops, and tuck loops in a set of wales, which also reduces stretch in the course-wise direction. In various aspects, the knitted component 130 may be oriented such that the course-wise direction extends in a medial-to-lateral direction as shown in FIGS. 2A and 2B. In this way, the reduced stretch in the course-wise direction due to the disclosed first knit structure 140 and second knit structure 150 may provide increased containment around a wearer's foot and increase stretch to the upper 110.

In another example, the knitted component 130 may have a second orientation, which is perpendicular to the first orientation shown in FIGS. 2A and 2B. In such an orientation, the disclosed knit structures 140 and 150 may provide reduced stretch in the longitudinal direction (e.g., heel-to-forefoot direction) to provide a particular fit that may be useful during running or striding motions. Further, it has also been contemplated that it may be advantageous in other examples for the knitted component 130 to have a third orientation, where the course-wise direction radiates from the outer perimeter to the throat area and/or ankle collar.

The first and second knit stitch patterns described for the first and second knit structures 140 and 150 may be present in some areas of the knitted component 130 but may not be presented throughout. For example, some areas of the knitted component 130 may have a double knit structure, where the first yarn 302 and the second yarn 304 are knit on separate needle beds or at least where one of the yarns is knit on two needle beds within the same course. For example, as previously described, the inlaid strands 160 shown in FIG. 2B may be inlaid in a portion of the knitted component 130 where there are two overlapping and separable layers forming a tunnel (e.g., such as the first yarn 302 forms a first layer and the second yarn 304 forms a second layer). Further, the first yarn 302 or the second yarn 304 may follow a different knit stitch pattern near the outer perimeter edge 210, which may provide more knit material per area to allow for easier attachment to the sole structure 112, and/or at the throat area 126 to provide more material for reinforcement around the eyelets 129.

In some aspects, the first yarn 302 and the second yarn 304 may be formed from different materials with different mechanical or physical properties. Particularly, the first yarn 302 and the second yarn 304 may have different tenacities. As the knit stitch patterns for the first knit structure 140 and the second knit structure 150 may result in structures with different strengths (e.g., a higher strength generally found where there is less stretch), the different tenacities of the first and second yarns 302 and 304 may be selected to either enhance the differences in the structure or balance them. For example, the first yarn 302 may have a lower tenacity than the second yarn 304. The second yarn 304 may have a tenacity greater than 5 g/denier, where the first yarn 302 may have a tenacity less than 5 g/denier. These constructions may enhance the differences in the strengths of the first knit structure 140 and the second knit structure 150. However, in other examples, the first yarn 302 may have a higher tenacity (such as a tenacity greater than 5 g/denier) than the second yarn 304, which may allow for more elongation in either the course-wise direction or the wale-wise direction in the second knit structure 150 and the knitted component 130 overall. One or both of the first yarn 302 and the second yarn 304 may be formed of an ultra-high molecular weight polyethylene (UHMWPE) yarn, yielding the benefits of higher tenacity with lower weight. In other aspects described herein, a UHMWPE yarn can also be used.

In some aspects, the first yarn 302 and the second yarn 304 may be formed from polymeric compositions to provide levels of abrasion resistance, traction (which may also be referred to as grip), or both, making these materials suitable for use in articles where abrasion resistance or traction are desirable, e.g., articles of apparel, footwear (e.g., soccer cleats), and sporting equipment. In many cases, the level of abrasion resistance, traction, or both provided by these polymeric compositions can be equivalent to or better than that of standard vulcanized rubber compositions used in the manufacturing of footwear, apparel, and sporting equipment. Unlike vulcanized rubber, due to the thermoplastic nature of these polymeric compositions and their properties in the solid and molten state, it is possible to readily form them into coated yarns that have suitable properties for use in industrial-scale knitting or weaving equipment. These properties result in yarns that can be readily incorporated into various articles, e.g., textiles used in conventional manufacturing processes such as knitting and weaving, as well as industrial-scale processes for making non-woven textiles. Also, unlike vulcanized rubber, these textiles and articles into which these textiles are incorporated can then, in turn, be thermoformed in a manner that reflows the polymeric composition of the coated yarns and creates an abrasion-resistant or higher-grip surface on the textile or article under conditions that help limit degradation to other components of the textile or article, such as, for example, other yarns, other textiles, foams, molded resin components, or the like.

In example aspects, one or both of the yarns 302 and/or 304 may have a first core yarn (also referred to herein as a “core”) and a first coating (also referred to herein as a “coating”). In one aspect, the first yarn 302 and/or the second yarn 304 may comprise one or more core yarns that may be at least partially coated with a coating, e.g., formed of a grip material.

In one instance, the coating of a core yarn can be a thermoplastic elastomer. In example aspects, the thermoplastic elastomer may comprise a thermoplastic polyurethane or a styrene ethylene/butylene styrene (SEBS). In addition, the core and the coating can be formed of different materials. For example, the core can be formed of a polymer and/or an elastomer that is different than a thermoplastic elastomer of the coating. The core and the coating can be formed to have different material properties, e.g., elasticity, melting temperature, and/or decomposition temperature, and/or other different properties. For example, the coating may have a first material composition (which may include a thermoplastic elastomer) having a lower melting temperature than the melting temperature of a second material composition forming the core. The second material forming the core may exclude the thermoplastic elastomer that is present in the coating.

The properties that a particular type of yarn will impart to an area of the knitted component 130 partially depend upon the materials that form the various filaments and fibers within the yarn 302 and 304. The yarns 302 and/or 304 may be made from synthetic materials, which include but are not limited to polyesters; polyamides, such as any of the various types of homopolymeric and co-polymeric nylon; aramides, and urethanes, such as thermoplastic polyurethane. Nylon is a durable and abrasion-resistant material with relatively high strength. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Chenille provides a soft hand, natural aesthetics, and higher durability. The yarns 302 or 304 may be made from a plurality of materials as well. For example, the yarns 302 and 304 may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. For example, one or both of the yarns 302 and 304 may be a Chenille yarn (e.g., two core yarns having short lengths of fiber forming a pile therebetween to form a single yarn) made from any of the materials listed above. In another example, one or both of the yarns 302 and 304 may be a yarn having at least one filament coated with thermoplastic polyurethane (“TPU”). Different degrees of twist and crimping, as well as different deniers, may also affect the properties of upper 110. The second yarn 304 may be formed at least in part of a high tenacity fiber, such as a nylon or polyester. The first yarn 302 may be a monofilament yarn. The second yarn 304 may by formed from a sheathed yarn with a greater stretch properties than a monofilament yarn.

In aspects herein, yarns used in a knitted component, e.g., like the first yarn 302 and the second yarn 304 described herein, can be different. For example, the first yarn and the second or additional yarns can differ through being formed from different materials, e.g., thermoforming materials or non-thermoforming materials, can differ through having different material properties, e.g., diameters, densities, deniers, tenacities, elasticities, tensile strengths, melting or decomposition temperatures, static/dynamic coefficients of friction, and/or other material properties, and/or can differ through having different constructions, e.g., a core/sheath construction or a singular or unified construction without a distinct core and sheath. Desired advantages, such as lightweight, durability, soft hand, grip/traction, may be achieved by alternating a yarn yielding the desired property with another yarn that yields a different desired property or maintains integrity of the article of footwear. For instance, the yarns can be alternated where one yarn provides high tenacity where another yarn provides a soft hand and the properties of both are preserved by interconnecting (not interlooping) the yarns in a way that the stronger, higher tenacity yarn is not weakened by the lower tenacity/weaker yarn.

Continuing on, the inlaid strands 160 may be formed from a material with a higher tensile strength, greater stretch resistance, and/or diameter than the first yarn 302 and the second yarn 304. The inlaid strands may be multi-filament yarn, a monofilament yarn, thread, rope, webbing, cable, or chain, for example. Materials forming the inlaid strands 160 may include any of the materials for disclosed for the yarns 302 and 304, such as cotton, elastane, polyester, rayon, wool, and nylon. As noted above, the inlaid strands may exhibit greater stretch-resistance than the knitted components that form the upper 110. As such, suitable materials for the inlaid strands 160 may include a variety of engineering filaments that are utilized for high tensile strength applications, including glass, aramids (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene, and liquid crystal polymer. It is contemplated that this knit structure of the knitted component 130 disclosed herein may also be used a component in other items such as apparel, accessories, and anywhere else knitted textiles are currently used.

FIGS. 4A and 4B illustrate a schematic depictions of the technical face 400 (or the face side) and the technical back 450 (or the back side), respectively, with portions of the opposite face being shown as dashed outlines. It should be understood that FIGS. 4A and 4B represent schematic representations that have been simplified for clarity.

During a manufacturing process for the article of footwear 100, the knitted component 130 may be bent, folded, or otherwise formed into a shape capable of receiving a user's foot in order to form the upper 110. The footwear 100 may then have an upper 110 with an inner-facing surface and an outer-facing surface. As a result, either the technical face 400 or the technical back 450 may form at least a portion of the outer-facing surface of the upper 110 and the opposite may form at least a portion of the inner-facing surface of the upper 110.

As can be seen in FIG. 4A, the first knit structure 140 and the second knit structure 150 may not be interconnected along the technical face 400. The technical face 400 may be formed of a first set of 410 wales of knit loops (e.g., 412) of the first yarn 302 (representing part of the first knit structure and a second set of wales 420 of knit loops, tuck loops, and held loops (e.g., 422) of the second yarn 304 (representing part of the second knit structure 150). Along the technical face 400, the first set of wales 410 and the second set of wales 420 are primarily visible and in front of the floats (shown as dashed lines in FIG. 4A) of both knit structures 140 and 150.

The technical back 450, as illustrated in FIG. 4B, may be formed by a set of floats 460 of the first yarn 302 (representing part of the first knit structure 140) and a set of floats 470 of the second yarn 304 (representing part of the second knit structure 150). The floats 460 of the first yarn 302 may extend in a different direction than floats 470 of the second yarn 304. For example, floats 460 of the first yarn 302 may extend horizontally, or in a course-wise direction, whereas floats 470 of the second yarn 304 may extend in a direction that is neither course-wise nor wale-wise (i.e., diagonally).

Further, the floats 470 of the second yarn 304 may extend in different directions. For example, some floats 470, such as float 470A, may extend in a first diagonal direction, and other floats 470, such as 470C, may extend in a second diagonal direction that is different than the first diagonal direction. In some aspects, the first and second diagonal directions may be between approximately 90 degrees and approximately 30 degrees relative to each other. Additionally, some floats 470 of the second yarn 304 may extend across at different angles, as seen with floats 470A and 470B, which may be the result of the floats 470A and 470B traversing a different quantity of courses before forming a tuck loop.

FIG. 4B also depicts that groups of floats 470 within the second knit structure 150 may generally form a pattern. For example, a group of floats 471 forms a pattern with a repeating diamond shape as the second yarn 304 cross one or more courses to become a tuck loop in a subsequent wale. In other examples, the second knit structure 150 may use a different knit stitch pattern and therefore form a different pattern of floats on the technical back 450. In aspects, at least a portion of the floats 470 may be skew from the course-wise direction, due to the nature of forming tuck loops after floating the yarn 304.

The interconnection between the first knit structure 140 and the second knit structure 150 may be visible on the technical back 450, as the floats 460 of the first yarn 302 crosses in front of the floats 470 of the second yarn 304. The floats 460 and floats 470 may be intertwined such that the first knit structure 140 and the second knit structure 150 form the knitted component 130.

FIG. 5 illustrates a close-up view of a knitting machine 500 in the process of manufacturing a portion of a knitted component 130 in accordance with aspects described herein. The knitting machine 500 may include a first yarn feeder 502 and a second yarn feeder 504 in communication with one or more carriages 510 (depicted as a single carriage in FIG. 5). The first yarn feeder 502 feeds at least the first yarn 302 and the second yarn feeder 504 feeds at least the second yarn 304. The carriage 510 (or carriages) is moveable along a first needle bed 506, such that the first yarn feeder 502 and the second yarn feeder 504 may be selectively engaged along the first needle bed 506. The first needle bed 506 may be a single needle bed containing a plurality of needles, at least containing these consecutive needles; a first needle 512, a second needle 514, a third needle 516, and a fourth needle 518. Although only one needle bed is shown, the knitting machine 500 may have another needle bed that is not being knit on at least during formation of the structures shown in FIG. 5.

As FIG. 5 depicts the knitting machine 500 in the process of forming the knitting component, the knitted component 130 is shown as partially formed and having some completed courses (i.e., those that are not secured on a needle) and a working course 520 (i.e., the course currently being formed by loops secured on a needle). Along the working course 520, the second needle 514 and the fourth needle 518 hold loops 522 and 526 of the second yarn 304, respectively, while the first yarn 302 floats over the second needle 514 and the fourth needle 518 without forming loops. Similarly, the first needle 512 and the third needle 516 hold loops 524 and 528 of the first yarn 302, while the second yarn 304 floats over the first needle 512 and the third needle 516 without forming loops. In this way, the first and second yarn feeders 502 and 504 feed the first and second yarns 302 and 304, respectively, on different sets of needles within a single needle bed, while those sets of needles are interspersed with each other (e.g., alternating). In this example, the sets of needles used to knit the first and second yarns 302 and 304 are interspersed in a 1×1 pattern. Additionally, some of the needles hold multiple loops. For example, in FIG. 5, the fourth needle 518 currently holds loop 526 of the second yarn 304, which was previously formed on the fourth needle 518 in an earlier course and held, instead of being released, as the working course 520 is worked. During working course 520, the second yarn feeder 504 formed a tuck loop 530 with the held loop 526.

The knitting machine 500 may float the yarns 302 and 304 along the same side of the needles 512-518, where the loops are formed on the needles 512-518, which results in the first yarn 302 and the second yarn 304 alternating moving from being on the same plane as the needles to just in front of the needles while the knitted component 130 is being formed. In this way, the first yarn 302 and the second yarn 304 may be interwoven, even though not interlooped, to interconnect the first knit structure 140 and the second knit structure 150.

The yarn feeders 502 and 504 may traverse the first needle bed 506 concurrently forming the working course 520. In other aspects, yarn feeders 502 and 504 may traverse the working course 520 in a sequential manner. In some aspects, a third yarn feeder (not shown) may inlay inlaid strands 160 during the knitting process.

Only a portion of the needles of the knitting machine 500 are illustrated in FIG. 5, and it should be understood that other needles on the first needle bed 506 depicted may be used to knit the first knit structure 140 and the second knit structure 150 in a similar manner as needles 512-516. Additionally, in aspects, the knitting machine 500 may knit with needles 512, 514, 516, and 518 in a different manner than described above to form different parts of the knitted component 130. As described, the knitting machine 500 may form a knitted element that includes the knitted component 130 as disclosed herein and, in some aspects, may include other portions of the upper 110 and/or other textile portions to be removed in subsequent processing.

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 invention.

The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting.

Clause 1: A knitted component comprising: a first knit structure comprising a first yarn forming knit loops on a first set of wales and floating across a second set of wales; a second knit structure comprising a second yarn floating across the first set of wales and forming knit loops, tuck loops, and held loops on the second set of wales; wherein the first yarn and second yard have different tenacities; and wherein the first knit structure and the second knit structure are interconnected in at least a portion of the knitted component where the first yarn alternatively passes in front of and behind the second yarn, the first yarn and the second yarn are not interlooped together in at least the first and second sets of wales within the portion.

Clause 2: The knitted component of claim 1, wherein the second set of wales includes a first subset of wales and a second subset of wales, wherein along a first set of courses of the second knit structure, the second yarn forms knit loops on the first subset of wales and forms tuck loops and held loops on the second subset of wales, wherein the second set of wales comprises the third set of wales and the fourth set of wales.

Clause 3: The knitted component of claim 2, wherein along a second set of courses of the second knit structure, the second yarn forms tuck loops and held loops on the first subset of wales and knit loops on the second subset of wales.

Clause 4: The knitted component of claim 1, wherein the second yarn has a greater tenacity than the first yarn.

Clause 5: The knitted component of claim 1, wherein the second yarn has a tenacity greater than 5 g/denier.

Clause 6: The knitted component of claim 1, wherein the first yarn has a tenacity less than 5 g/denier.

Clause 7: The knitted component of claim 1, wherein the first yarn is a monofilament yarn and the second yarn is a multi-filament yarn.

Clause 8: The knitted component of claim 1, wherein at least over the first and second sets of wales in the portion, the knitted component is a single knit jersey structure.

Clause 9: The knitted component of claim 1, wherein the knitted component includes a tensile strand inlaid within a third knit structure.

Clause 10: The knitted component of claim 9, wherein the third knit structure is a double knit structure where the tensile strand is inlaid.

Clause 11: The knitted component of claim 10, wherein the third knit structure includes a yarn comprising elastane forming at least part of the double knit structure.

Clause 12: An article of footwear comprising an upper with the knitted component of claim 1.

Clause 13: A knitted component, comprising: a first yarn knitted into knit loops and floats extending in a first direction; a second yarn knitted into knit loops and floats extending in a second direction that is different that the first direction; the first yarn and the second yarn are knit along a plurality of courses comprising a plurality of adjacent wales, wherein each wale within the plurality of adjacent wales comprises at least one float that is formed by one of the first yarn or the second yarn; wherein at least a portion of the floats of the second yarn traverse at least two courses; and wherein the first yarn and second yard have different tenacities.

Clause 14: The knitted component of claim 13, wherein a first set of floats of the second yarn each extend between two adjacent courses and a second set of floats of the second yarn each extend between two courses that are separated by a third course.

Clause 15: The knitted component of claim 14, wherein the second yarn has a greater tenacity of the first yarn.

Clause 16: The knitted component of claim 13, wherein the first direction of the floats of the first yarn is a course-wise direction, and the second direction of the floats of the second yarn is in a direction other than the course-wise direction or a wale-wise direction.

Clause 17: The knitted component of claim 13, wherein the knitted component has a first side and a second side, the floats of the first yarn and the floats of the second yarn each positioned on the first side.

Clause 18: An article of footwear comprising an upper with the knitted component of claim 13.

Clause 19: A method for manufacturing a knitted component, the method comprising: knitting, on a single needle bed of a knitting machine, a plurality of courses each having a first yarn and a second yarn having a different tenacity than the first yarn, knitting the plurality of courses comprises: knitting the first yarn to form knit loops over a first set of needles and floating the first yarn over a second set of needles that are interspersed with the first set of needles along the single needle bed, knitting the second yarn to form knit loops on the second set of needles and floating over the first set of needles, wherein some of the knit loops of the second yarn that are knit on the second set of needles are released from the respective needle and some of the knit loops of the second yarn are held on the respective needle to be released in a subsequent course.

Claim 20: The method of claim 19, wherein the first set of needles comprise every other needle on the single needle bed.

Clause 21: The knitted component of claim 19, wherein the second yarn has a greater tenacity than the first yarn.

Clause 22: The knitted component of claim 19 wherein the first yarn follows a knit loop-float stitch pattern with each pass of a feeder of the first yarn, and the second yarn follows a tuck stitch-float pattern with each pass of a feeder of the second yarn.

Clause 23: The knitted component of claim 1, wherein the first yarn is a monofilament yarn and the second yarn is an elasticated yarn.

Clause 24: The knitted component of claim 1, wherein the first yarn is an ultra-high molecular weight polyethylene yarn and the second yarn is a thermoplastic yarn.

Clause 25: The knitted component of claim 1, wherein the first yarn is a monofilament yarn and the second yarn is a chenille yarn.

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.

INTERLACED KNITTED UPPER AND METHODS OF MANUFACTURE

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

Provisional Applications (1)