US20140130373A1 - Article Of Footwear Incorporating A Knitted Component - Google Patents

Abstract

An article of footwear has an upper and a sole structure secured to the upper. The upper includes a knitted component and, in some configurations, a skin layer secured to the knitted component. The knitted component may have a plurality of protruding areas that extend outward and away from a void within the upper for receiving a foot of a wearer. The protruding areas may include one or both of (a) a first tubular structure and an inlaid strand extending through the first tubular structure and (b) a second tubular structure and yarn sections extending across the second tubular structure.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This non-provisional patent application is a continuation of and claims priority to U.S. Provisional Patent Application Ser. No. 61/727,010 (Attorney Docket No. 51-2906), which was filed in the U.S. Patent and Trademark Office on 15 Nov. 2012 and entitled Article Of Footwear Incorporating A Knitted Component, the disclosure of which is entirely 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 on the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. In some articles of athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. The outsole is secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material. The sole structure may also include a sockliner positioned within the void and proximal a lower surface of the foot to enhance footwear comfort.
• The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing system also permits the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter to limit movement of the heel.
• Various materials are conventionally utilized in manufacturing the upper. The upper of athletic footwear, for example, may be formed from multiple material elements. The materials may be selected based upon various properties, including stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, and moisture-wicking, for example. With regard to an exterior of the upper, the toe area and the heel area may be formed of leather, synthetic leather, or a rubber material to impart a relatively high degree of wear-resistance. Leather, synthetic leather, and rubber materials may not exhibit the desired degree of flexibility and air-permeability for various other areas of the exterior. Accordingly, the other areas of the exterior may be formed from a synthetic textile, for example. The exterior of the upper may be formed, therefore, from numerous material elements that each impart different properties to the upper. An intermediate or central layer of the upper may be formed from a lightweight polymer foam material that provides cushioning and enhances comfort. Similarly, an interior of the upper may be formed of a comfortable and moisture-wicking textile that removes perspiration from the area immediately surrounding the foot. The various material elements and other components may be joined with an adhesive or stitching. Accordingly, the conventional upper is formed from various material elements that each impart different properties to various areas of the footwear.
SUMMARY
• An article of footwear has an upper and a sole structure secured to the upper. In various configurations, the upper includes a knitted component having a plurality of protruding areas that extend outward and away from a void within the upper for receiving a foot of a wearer. The protruding areas include one or both of (a) a first tubular structure and an inlaid strand extending through the first tubular structure and (b) a second tubular structure and yarn sections extending across the second tubular structure. In addition, a skin layer may be secured to the knitted component.
• A method for manufacturing an upper for an article of footwear may include positioning a skin layer adjacent to a knitted component and in an overlapping configuration, the knitted component having regions with different thicknesses. The skin layer and the knitted component may be located between a first surface and a second surface of a press. The first surface includes a first material, and the second surface includes a second material, the first material having greater compressibility than the second material. In addition, the skin layer and the knitted component may be compressed between the first surface and the second surface to join the skin layer to the knitted component.
• An article of footwear has an upper and a sole structure secured to the upper. In various configurations, the upper includes a foot region and an ankle region. The foot region covers at least a portion of a foot of a wearer and includes a foot part of a knitted component. The ankle region covers at least a portion of an ankle of the wearer and includes an ankle part of the knitted component. The foot part and the ankle part of the knitted component are formed from unitary knit construction. The foot region has a first degree of stretch and the ankle region has a second degree of stretch, with the first degree of stretch being less than the second degree of stretch.
• An article of footwear has an upper and a sole structure secured to the upper. In various configurations, the upper includes a knitted component extending through a throat area of the upper. The knitted component defines a channel in the throat area, with the channel including two overlapping knit layers formed of unitary knit construction. The upper also includes a plurality of lace-receiving elements located on opposite sides of the throat area, two of the lace-receiving elements are located adjacent to opposite ends of the channel. A lace extends through the channel and engages the lace-receiving elements.
• The advantages and features of novelty characterizing aspects of the invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying figures that describe and illustrate various configurations and concepts related to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
• The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
• FIG. 1 is a lateral side elevational view of a first configuration of an article of footwear.
• FIG. 2 is a medial side elevational view of the first configuration of the article of footwear.
• FIG. 3 is a top plan view of the first configuration of the article of footwear.
• FIGS. 4A-4C are cross-sectional views of the first configuration of the article of footwear, as respectively defined bysection lines4A-4C inFIG. 3.
• FIG. 5 is a top plan view of a knitted component and a skin layer from an upper of the first configuration of the article of footwear.
• FIG. 6 is an exploded top plan view of the knitted component and the skin layer.
• FIGS. 7A-7C are cross-sectional views of the knitted component and the skin layer, as respectively defined bysection lines7A-7C inFIG. 5.
• FIGS. 8A and 8B are perspective views of an exemplary portion of the knitted component and the skin layer.
• FIGS. 9A-9C are top plan views depicting further configurations of the knitted component.
• FIGS. 10A-10D are perspective views of a process for utilizing a press to bond the knitted component and the skin layer.
• FIGS. 11A-11D are cross-sectional views of the process for utilizing the press, as respectively defined bysection lines11A-11D inFIGS. 10A-10D.
• FIG. 12 is a lateral side elevational view of a second configuration of the article of footwear.
• FIG. 13 is a medial side elevational view of the second configuration of the article of footwear.
• FIG. 14 is a top plan view of the second configuration of the article of footwear.
• FIG. 15 is a cross-sectional view of the second configuration of the article of footwear, as defined bysection line15 inFIG. 14.
• FIG. 16 is a top plan view of a third configuration of the article of footwear.
• FIG. 17 is a cross-sectional view of the third configuration of the article of footwear, as defined bysection line17 inFIG. 16.
• FIG. 18 is a top plan view of a tongue from the third configuration of the article of footwear.
• FIG. 19 is a cross-sectional view of the tongue, as defined bysection line19 inFIG. 18.
• FIGS. 20 and 21 are top plan views of further configurations of the knitted component and a lace.
• FIG. 22 is a cross-sectional view, as defined bysection line22 inFIG. 21.
• FIG. 23 is a bottom plan view of a configuration of the knitted component that includes an interior layer.
• FIG. 24 is a cross-sectional view of the article of footwear corresponding withFIG. 4A and depicting the interior layer.
• FIGS. 25A and 25B are top plan views corresponding withFIG. 5 and depicting further configurations for the skin layer from an upper of the first configuration of the article of footwear.
DETAILED DESCRIPTION
• The following discussion and accompanying figures disclose an article of footwear having an upper that includes a knitted component and a skin layer. The article of footwear is disclosed as having a general configuration suitable for walking or running. Concepts associated with the footwear, including the upper, may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, soccer shoes, sprinting shoes, tennis shoes, and hiking boots, for example. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. The concepts disclosed herein apply, therefore, to a wide variety of footwear types.
• General Footwear Structure
• An article offootwear100 is depicted inFIGS. 1-4C as including asole structure110 and an upper120. Whereassole structure110 is located under and supports a foot of a wearer, upper120 provides a comfortable and secure covering for the foot. As such, the foot may be located within a void in upper120 to effectively secure the foot withinfootwear100 or otherwise unite the foot andfootwear100. Moreover,sole structure110 is secured to a lower area of upper120 and extends between the foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence the motions of the foot, for example.
• For reference purposes,footwear100 may be divided into three general regions: aforefoot region101, amidfoot region102, and aheel region103.Forefoot region101 generally encompasses portions offootwear100 corresponding with forward portions of the foot, including the toes and joints connecting the metatarsals with the phalanges.Midfoot region102 generally encompasses portions offootwear100 corresponding with middle portions of the foot, including an arch area.Heel region103 generally encompasses portions offootwear100 corresponding with rear portions of the foot, including the heel and calcaneus bone.Footwear100 also includes alateral side104 and amedial side105, which extend through each of regions101-103 and correspond with opposite sides offootwear100. More particularly,lateral side104 corresponds with an outside area of the foot (i.e. the surface that faces away from the other foot), andmedial side105 corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Regions101-103 and sides104-105 are not intended to demarcate precise areas offootwear100. Rather, regions101-103 and sides104-105 are intended to represent general areas offootwear100 to aid in the following discussion. In addition tofootwear100, regions101-103 and sides104-105 may also be applied tosole structure110, upper120, and individual elements thereof.
• The primary elements ofsole structure110 are amidsole111, anoutsole112, and asockliner113.Midsole111 is secured to a lower surface of upper120 and may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further configurations,midsole111 may incorporate plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motions of the foot, or midsole21 may be primarily formed from a fluid-filled chamber.Outsole112 is secured to a lower surface ofmidsole111 and may be formed from a wear-resistant rubber material that is textured to impart traction.Sockliner113 is located within the void in upper120 and is positioned to extend under a lower surface of the foot to enhance the comfort offootwear100. Although this configuration forsole structure110 provides an example of a sole structure that may be used in connection with upper120, a variety of other conventional or nonconventional configurations forsole structure110 may also be utilized. Accordingly, the features ofsole structure110 or any sole structure utilized with upper120 may vary considerably.
• Upper120 includes anexterior surface121 and an oppositeinterior surface122. Whereasexterior surface121 faces outward and away fromfootwear100,interior surface122 faces inward and defines a majority or a relatively large portion of the void withinfootwear100 for receiving the foot. The void is shaped to accommodate the foot. When the foot is located within the void, therefore, upper120 extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Moreover,interior surface121 may lay against the foot or a sock covering the foot.Upper120 also includes acollar123 that is primarily located inheel region103 and forms an opening that provides the foot with access to the void. More particularly, the foot may be inserted into upper120 through the opening formed bycollar123, and the foot may be withdrawn from upper120 through the opening formed bycollar123.
• Athroat area124 of upper120 is located forward ofcollar123 and primarily inmidfoot region102. Although the extent ofthroat area124 may vary,throat area124 corresponds with an instep region or upper surface of the foot and includes alace125, a plurality of lace-receivingelements126, and atongue127.Lace125 engages the various lace-receivingelements126 and follows a zigzagging path between lace-receivingelements126. Moreover,lace125 repeatedly-passes acrossthroat area124 and between opposite sides ofthroat area124. When usingfootwear100,lace125 permits the wearer to modify dimensions of upper120 to accommodate the proportions of the foot. More particularly,lace125 may be manipulated in a conventional manner to permit the wearer to (a) tighten upper120 around the foot and (b) loosen upper120 to facilitate insertion and withdrawal of the foot from the void in upper120 (i.e., through the opening formed by collar123). Although lace-receivingelements126 are depicted as apertures in upper120, and withlace125 passing through the apertures, lace-receivingelements126 may be loops, eyelets, hooks, or D-rings.
• A majority of upper120 is formed from aknitted component130 and askin layer140, which are depicted separate from a remainder offootwear100 inFIGS. 5 and 6.Knitted component130 may, for example, be manufactured through a flat knitting process and extends through each of regions101-103, along bothlateral side104 andmedial side105, overforefoot region101, and aroundheel region103. Although portions ofknitted component130 formexterior surface121, knittedcomponent130 forms a majority or a relatively large portion ofinterior surface122, thereby defining a portion of the void within upper120. In some configurations, knittedcomponent130 may also extend under the foot. For purposes of example in various figures, however, astrobel sock128 is secured toknitted component130 and forms a majority of the portion of upper120 that extends under the foot. In this configuration,sockliner113 extends overstrobel sock128 and forms a surface upon which the foot rests. In addition, aseam129 extends vertically throughheel region103, as depicted inFIGS. 3 and 4C, to join edges ofknitted component130.
• Skin layer140 lays adjacent toknitted component130 and is secured to an exterior ofknitted component130, thereby forming a majority or a relatively large portion ofexterior surface121. Various materials may be utilized to formskin layer140, including a polymer sheet, elements of leather or synthetic leather, a woven or non-woven textile, or a metal foil. As withknitted component130,skin layer140 extends through each of regions101-103, along bothlateral side104 andmedial side105, overforefoot region101, and aroundheel region103.Skin layer140 is depicted as being absent from portions of throat area124 (e.g., tongue127) andinterior surface122. In further configurations offootwear100,skin layer140 may be absent from other areas of upper120 or may extend over portions ofthroat area124 and intointerior surface122.
• The combination ofknitted component130 andskin layer140 provides various advantages tofootwear100. As an example,knitted component130 andskin layer140 impart a relatively tight and glove-like fit to upper120 that secures the foot withinfootwear100 during walking, running, and other ambulatory activities. When formed as a soccer shoe, for example, the relatively tight and glove-like fit may provide the wearer with enhanced feel and control of a ball.Skin layer140 may also be utilized to reinforce areas of upper120. For example,skin layer140 may inhibit stretch inknitted component130 and may enhance the wear-resistance or abrasion-resistance of upper120.Skin layer140 may also impart water-resistance tofootwear100. Additionally, formingfootwear100 in this configuration may provide a relatively light weight or mass, support for the foot, uniform fit and conformance to a shape of the foot, and a relatively seamless interior with enhanced comfort for the wearer.
• The discussion above presents various features and elements of upper120. In further configurations offootwear100, however, upper120 may also include one or more of (a) a heel counter inheel region103 for enhancing stability, (b) a toe guard inforefoot region101 that is formed of a wear-resistant material, and (c) logos, trademarks, and placards with care instructions and material information. Accordingly, upper120 may incorporate a variety of other features and elements, in addition to the features and elements discussed herein and shown in the figures.
• Knitted Component Configuration
• Knitted component130 extends throughout upper120 and forms a majority ofinterior surface122, thereby defining a portion of the void within upper120. Although seams may be present inknitted component130, a majority ofknitted component130 has a substantially seamless configuration. Moreover, knittedcomponent130 may be formed of unitary knit construction. As utilized herein, a knitted component (e.g., knitted component130) is defined as being formed of “unitary knit construction” when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures ofknitted component130 without the need for significant additional manufacturing steps or processes. Although portions ofknitted component130 may be joined to each other (e.g., edges ofknitted component130 being joined together, as at seam129) following the knitting process, knittedcomponent130 remains formed of unitary knit construction because it is formed as a one-piece knit element. Moreover, knittedcomponent130 remains formed of unitary knit construction when other elements (e.g.,lace125,strobel sock127 logos, trademarks, placards) are added following the knitting process. Examples of various configurations of knitted components that may be utilized for knittedcomponent130 are disclosed in U.S. Pat. No. 6,931,762 to Dua; U.S. Pat. No. 7,347,011 to Dua, et al.; U.S. Patent Application Publication 2008/0110048 to Dua, et al.; U.S. Patent Application Publication 2010/0154256 to Dua; and U.S. Patent Application Publication 20120233882 to Huffa, et al., each of which are entirely incorporated herein by reference.
• The primary elements ofknitted component130 are aknit element131 and aninlaid strand132.Knit element131 is formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a variety of courses and wales. That is, knitelement131 has the structure of a knit textile.Inlaid strand132 extends through knitelement131 and passes between the various loops withinknit element131. Although inlaidstrand132 generally extends along courses withinknit element131, inlaidstrand132 may also extend along wales withinknit element131. Advantages of inlaidstrand132 include providing support, stability, and structure. For example, inlaidstrand132 assists with securing upper120 around the foot, limits deformation in areas of upper120 (e.g., imparts stretch-resistance), and operates in connection withlace125 to enhance the fit offootwear100. U.S. Patent Application Publication 20120233882 to Huffa, et al., which was referenced above and incorporated herein, provides discussion of the manner in which knittedcomponent130 may be formed, including the process of inlaying or otherwise locating inlaidstrand132 withinknit element131.
• Knit element131 may incorporate various types and combinations of stitches and yarns. With regard to stitches, the yarn formingknit element131 may have one type of stitch in one area ofknit element131 and another type of stitch in another area ofknit element131. Depending upon the types and combinations of stitches utilized, areas ofknit element131 may have a plain knit structure, a mesh knit structure, or a rib knit structure, for example. The different types of stitches may affect the physical properties ofknit element131, including aesthetics, stretch, thickness, air permeability, and abrasion-resistance ofknit element131. That is, the different types of stitches may impart different properties to different areas ofknitted component130. With regard to yarns,knit element131 may have one type of yarn in one area ofknit element131 and another type of yarn in another area ofknit element131. Depending upon various design criteria,knit element131 may incorporate yarns with different deniers, materials (e.g., cotton, elastane, polyester, rayon, wool, and nylon), and degrees of twist, for example. The different types of yarns may affect the physical properties ofknit element131, including aesthetics, stretch, thickness, air permeability, and abrasion-resistance ofknit element131. That is, the different types of yarns may impart different properties to different areas ofknitted component130. By combining various types and combinations of stitches and yarns, each area ofknit element131 may have specific properties that enhance the comfort, durability, and performance offootwear100. In some configurations, multiple yarns with different colors may be utilized to form knittedcomponent130. When yarns with different colors are twisted together and then knitted, knittedcomponent130 may have a heathered appearance with multiple colors randomly distributed throughout upper120.
• One or more of the yarns withinknit element131 may be partially formed from a thermoplastic polymer material, which softens or melts when heated and returns to a solid state when cooled. More particularly, the thermoplastic polymer material transitions from a solid state to a softened or liquid state when subjected to sufficient heat, and then the thermoplastic polymer material transitions from the softened or liquid state to the solid state when sufficiently cooled. As such, thermoplastic polymer materials are often used to join two objects or elements together. In this case, a yarn incorporating thermoplastic polymer material may be utilized to join (a) the yarn to other portions of the yarn, (b) the yarn to other yarns, (c) the yarn to inlaidstrand132, or (d)knitted component130 toskin layer140, for example.
• Inlaid strand132, as noted above, extends through knitelement131 and passes between the various loops withinknit element131. More particularly, inlaidstrand132 is located within the knit structure ofknit element131. Referring toFIGS. 7A and 7B, for example,knit element131 forms two separate and spaced textile layers, which effectively define a channel or tubular structure, and inlaidstrand132 is located between the spaced textile layers. In some configurations, however, knitelement131 may have the configuration of a single textile layer in the area of inlaidstrand132. In either configuration, inlaidstrand132 is located withinknit element131 and between opposite surfaces ofknit element131. Although inlaidstrand132 is primarily withinknit element131, portions of inlaidstrand132 may be visible or exposed on one or both surfaces ofknit element131.
• When knittedcomponent130 is incorporated intofootwear100, inlaidstrand132 extends in a generally vertical direction and fromthroat area124 to an area wheresole structure110 is secured to upper120. More particularly, inlaid strand repeatedly passes throughknit element131 fromthroat area124 to an area adjacent tosole structure110. Inthroat area124, inlaid strand may also extend around lace-receivingelements126, there by forming loops through which lace125 passes. In comparison withknit element131, inlaidstrand132 may exhibit greater stretch-resistance. That is, inlaidstrand132 may stretch less thanknit element131. Given that numerous sections of inlaidstrand132 extend towardsole structure110 fromthroat area124, inlaidstrand132 imparts stretch-resistance to this area of upper120. Moreover, placing tension uponlace125 may impart tension to inlaidstrand132, thereby inducing the portion of upper120 betweenthroat area124 andsole structure110 to lay against the foot. As such, inlaidstrand132 operates in connection withlace122 to assist with securing upper120 around the foot and enhance the fit offootwear100.
• The configuration of inlaidstrand132 may vary significantly. In addition to yarn, inlaidstrand132 may have the configurations of a filament (e.g., a monofilament), thread, rope, webbing, cable, or chain, for example. In comparison with the yarns formingknit element131, the thickness of inlaidstrand132 may be greater. In some configurations, inlaidstrand132 may have a significantly greater thickness than the yarns ofknit element131. Moreover, the materials forming inlaidstrand132 may include any of the materials for the yarn withinknit element131, such as cotton, elastane, polyester, rayon, wool, and nylon, but may also include metals and 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. As another example, a braided polyester thread may also be utilized as inlaidstrand132.
• The combination ofknitted component130 andskin layer140 provide various advantages tofootwear100. In some configurations, however,skin layer140 may be absent fromfootwear100. That is, knittedcomponent130 may be utilized individually to form portions of upper120, andknitted component130 may form a majority of relatively large portion of each ofsurfaces121 and122. Moreover, the presence of protrudingareas133 whenskin layer140 is absent may impart additional thickness or loft to upper120, while also varying the stretch properties of upper120. Although discussed in combination withskin layer140, therefore,knitted component130 may be utilized individually.
• Skin Layer Configuration
• Skin layer140 lays adjacent toknitted component130 and is secured toknitted component130 to form a portion ofexterior surface121. As noted above,skin layer140 may be formed from a polymer sheet, elements of leather or synthetic leather, a woven or non-woven textile, or a metal foil. When formed as a polymer sheet or polymer layer,skin layer140 may initially be a polymer film, polymer mesh, polymer powder, or polymer resin, for example. With any of these structures, a variety of polymer materials may be utilized forskin layer140, including polyurethane, polyester, polyester polyurethane, polyether polyurethane, and nylon. An example of a non-woven textile with thermoplastic polymer filaments that may be bonded toknitted component130 is disclosed in U.S. Patent Application Publication 2010/0199406 to Dua, et al., which is incorporated herein by reference. Moreover, additional considerations relating toskin layer140 may be found in U.S. Patent Application Publication 2012/0246973 to Dua, which is incorporated herein by reference.
• Althoughskin layer140 may be formed from a thermoset polymer material, many configurations ofskin layer140 are formed from thermoplastic polymer materials (e.g., thermoplastic polyurethane). In general, a thermoplastic polymer material softens or melts when heated and returns to a solid state when cooled. More particularly, the thermoplastic polymer material transitions from a solid state to a softened or liquid stare when subjected to sufficient heat, and then the thermoplastic polymer material transitions from the softened or liquid state to the solid state when sufficiently cooled. As such, the thermoplastic polymer material may be melted, molded, cooled, re-melted, re-molded, and cooled again through multiple cycles. Thermoplastic polymer materials may also be welded or thermal bonded to textile elements, such asknitted component130.
• In many configurations offootwear100, a single element ofskin layer140 is secured throughout knittedcomponent130 and covers substantially all ofknitted component130. In further configurations, however, different elements ofskin layer140 may be formed from different materials and positioned in separate areas ofknitted component130. That is, a portion ofskin layer140 formed from one material may be bonded to one area ofknitted component130, and another portion ofskin layer140 formed from another material may be bonded to a different area ofknitted component130. By varying the materials formingskin layer140, different properties may be applied to different areas of upper120. In other configurations,skin layer140 may only cover specific areas ofknitted component130, thereby leaving other areas ofknitted component130 exposed.Skin layer140 may, therefore, be absent from some areas ofknitted component130.
• Skin layer140 is discussed above as being positioned on an exterior ofknitted component130. In some configurations, however,skin layer140 may be bonded with an opposite surface ofknitted component130, thereby forming a portion ofinterior surface122. In other configurations, twoskin layers140 may be bonded to opposite surfaces ofknitted component130, orskin layer140 may impregnate or otherwise extend into knittedcomponent130.
• Protruding Areas
• Knitted component130 includes a plurality of protrudingareas133 that extend outward and away from the void within upper120.Protruding areas133 form bulges, protrusions, bumps, or other outwardly-extending portions inknitted component130. As with inlaidstrand132, many of protrudingareas133 extend in a generally vertical direction and fromthroat area124 to the area wheresole structure110 is secured to upper120. Some of protrudingareas133 correspond with and incorporate inlaidstrand132. In addition, some of protrudingareas133 extend in a generally horizontal direction and between two other protrudingareas133. That is, the horizontal protrudingareas133 extend between and effectively join with two of the vertical protrudingareas133. In addition to providing a unique aesthetic tofootwear100, protrudingareas133 may enhance the strength of upper120 or impart a variety of different properties to upper120.
• Skin layer140 extends overprotruding areas133 and may be secured to protrudingareas133, as well as other areas ofknitted component130. As such,skin layer140 forms corresponding bulges, protrusions, bumps, or other outwardly-extending portions at the locations of protrudingareas133 and onexterior surface121, as depicted inFIGS. 7A and 7C, for example. An advantage of this configuration is that the friction properties offootwear100 may be controlled through the specific pattern that protrudingareas133 form in upper120. As an example, the combination of protrudingareas133 andskin layer140 may provide enhanced control of a ball during the sport of soccer. That is, a soccer player may obtain enhanced control of a soccer ball through the raised or outwardly-extending portions of upper120 that are formed by protrudingareas133.
• Protruding areas133 may be formed to have various configurations. That is, multiple knit structures and knitting techniques may be utilized to form protrudingareas133. As examples, each ofFIGS. 8A and 8B depict an exemplary portion of upper120 with two different configurations for protrudingareas133. More particularly, a first of protrudingareas133 includes a firsttubular structure134 and a portion of inlaidstrand132, and a second of protrudingareas133 includes a secondtubular structure135 and a plurality ofyarn sections136. Each of these configurations will be discussed in more detail below.
• Firsttubular structure134 is an area ofknit element131 with two separate and spaced textile layers137. Whereas edge areas of firsttubular structure134 are joined and formed of unitary knit construction, a central area is unjoined and forms a channel in which inlaidstrand132 is located. Although firsttubular structure134 alone is sufficient to form one of protrudingareas133, the presence of inlaidstrand131 provides additional thickness.Inlaid strand132 extends longitudinally and through firsttubular structure134, thereby extending along a length of firsttubular structure134.
• Secondtubular structure135 is an area ofknit element131 with two separate and spacedtextile layers138, thereby having a configuration that is similar to firsttubular structure134. Whereas edge areas of secondtubular structure135 are joined and formed of unitary knit construction, a central area is unjoined and forms a channel in which the plurality ofyarn sections136 are located. Although secondtubular structure135 alone is sufficient to form one of protrudingareas133, the presence ofyarn sections136 provides additional thickness.
• Yarn sections136 extend laterally and across secondtubular structure135, thereby extending across a width of secondtubular structure135 rather than along a longitudinal length of secondtubular structure135. Although the manner in whichyarn sections136 are secured may vary,yarn sections136 are depicted as crossing each other inFIGS. 7A,7C,8A, and8B and may form tuck stitches on opposite sides of secondtubular structure135. That is, tuck stitches may joinyarn sections136 with opposite sides of secondtubular structure135. As depicted in a broken-away area ofFIG. 8B, one of protruding areas133 (i.e., a horizontal protruding area133) includesadditional yarn sections136 and extends between and effectively joinstubular structures134 and135, thereby extending from firsttubular structure134 to secondtubular structure135. Althoughyarn sections136 may cross each other in extending across the width of secondtubular structure135,yarn sections136 may have various other configurations. As examples,yarn sections136 may lay in a plane and not cross each other, oryarn sections136 may extend longitudinally and along a length of secondtubular structure135.
• As discussed above, protrudingareas133 form bulges, protrusions, bumps, or other outwardly-extending portions inknitted component130. As such, protrudingareas133 are portions ofknitted component130 that have greater thickness than other areas ofknitted component130. In this configuration, a majority or a relatively large portion ofknitted component130 has a first thickness and the various protrudingareas133 have a second thickness, with the first thickness being less than the second thickness. Depending upon the knit structures and knitting techniques that are utilized to form knittedcomponent130, as well as the yarns utilized inknitted component130, the difference between the first thickness and the second thickness may range from one to ten millimeters or more. In many configurations, the first thickness is less than four millimeters, and the second thickness is at least two millimeters greater than the first thickness.
• The specific pattern that protrudingareas133 form in upper120 may vary significantly. Referring toFIGS. 1 and 2, for example, protrudingareas133 extend though a majority oflateral side104 andmedial side105, but are absent from a forward portion offorefoot region101 and a rear portion ofheel region103. The locations and configurations of protrudingareas133 may, however vary significantly. As an example,FIG. 9A depicts a configuration wherein the spacing between various protrudingareas133 varies throughout knittedcomponent130. Moreover, protrudingareas133 that extend between and connect other protrudingareas133 are present in some areas, but absent in other areas. Although protrudingareas133 are present in an area ofknitted component130 that corresponds withforefoot region101, protrudingareas133 are absent in areas corresponding withheel region103. In this configuration,knit element131 extends across a region corresponding withthroat area124, thereby replacingtongue127.FIG. 9B depicts another configuration wherein protrudingareas133 are present throughoutknitted component130. Another configuration is depicted inFIG. 9C, wherein protrudingareas133 are located to correspond with inlaidstrand132, but are absent in other areas. In addition, in each of the configurations depicted inFIGS. 9A-9C, portions of inlaidstrand132 are exposed to form loops that receivelace125. Accordingly, various aspects regarding knittedcomponent130 and protrudingareas133 may vary considerably.
• Bonding Process
• A variety of processes may be utilized to join knittedcomponent130 andskin layer140. In some configurations,skin layer140 may be formed from a thermoplastic polymer material, which may be welded or thermal bonded toknitted component130. As discussed above, a thermoplastic polymer material melts when heated and returns to a solid state when cooled sufficiently. Based upon this property of thermoplastic polymer materials, thermal bonding processes may be utilized to form a thermal bond that joins portions ofskin layer140 to knittedcomponent130. As utilized herein, the term “thermal bonding” or variants thereof is defined as a securing technique between two elements that involves a softening or melting of a thermoplastic polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled. Similarly, the term “thermal bond” or variants thereof is defined as the bond, link, or structure that joins two elements through a process that involves a softening or melting of a thermoplastic polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled. As examples, thermal bonding may involve (a) the melting or softening ofskin layer140 such that the thermoplastic polymer material intermingles with materials ofknitted component130 and are secured together when cooled and (b) the melting or softening ofskin layer140 such that the thermoplastic polymer material extends into or infiltrates the structure of knitted component130 (e.g., extends around or bonds with filaments or fibers in knitted component130) to secure the elements together when cooled. Additionally, thermal bonding does not generally involve the use of stitching or adhesives, but involves directly bonding elements to each other with heat. In some situations, however, stitching or adhesives may be utilized to supplement the thermal bond or the joining of elements through thermal bonding.
• The bonding process utilizes apress150, which includes afirst press portion151 and asecond press portion152, as depicted inFIGS. 10A and 11A. Each ofpress portions151 and152 have facing surfaces that compressknitted component130 andskin layer140 together. The surfaces ofpress portions151 and152 are substantially planar and include materials with different compressibilities. More particularly,first press portion151 includes afirst material153 andsecond press portion152 includes asecond material154. In comparison,first material153 has greater compressibility thansecond material154. As examples of suitable materials, (a)first material153 may be silicone andsecond material154 may be steel, (b) both ofmaterials153 and154 may be silicone, withfirst material153 having greater thickness thansecond material154, or (c) both ofmaterials153 and154 may be silicone, withfirst material153 having lesser density or hardness thansecond material154. A variety of other materials may also be utilized, including various polymers and foams, such as ethylvinylacetate, and rubber. An advantage to silicone, however, relates to compression set. More particularly, silicone may go through numerous compression operations without forming indentations or other surface irregularities.
• A process for bonding or otherwise joiningknitted component130 andskin layer140 will now be discussed. In order to illustrate details associated with the bonding process, the exemplary portions ofknitted component130 andskin layer140 that are depicted inFIGS. 8A and 8B are utilized inFIGS. 10A-10D and11A-11D. One skilled in this art will recognize, however, that the concepts discussed herein and depicted in the figures may be applied to the entirety ofknitted component130 andskin layer140. Referring again toFIGS. 10A and 11A,skin layer140 is positioned adjacent toknitted component130 and in an overlapping configuration. Whereasskin layer140 is positioned adjacent tofirst press portion151, knittedcomponent130 is positioned adjacent tosecond press portion152. More particularly,skin layer140 is positioned to contact first material153 (i.e., the more compressible material), andknitted component130 is positioned to contact second material154 (i.e., the less compressible material). In order to properly position knittedcomponent130 andskin layer140, one or both of (a) a jig that holds the components relative to each other and (b) a shuttle frame or other device that moves the components may be utilized. Additionally, a jig or other device may assist with ensuring thatknitted component130 retains a proper shape and remains in a generally planar configuration during the bonding process.
• Press150 is utilized to compress knittedcomponent130 andskin layer140 together. In order to join knittedcomponent130 andskin layer140, however, one or both ofknitted component130 andskin layer140 are heated to a temperature that facilitates bonding. Various radiant heaters or other devices may be utilized to heat knittedcomponent130 andskin layer140 prior to placement betweenpress portions151 and152. In some manufacturing processes, however,press150 may be heated such that contact betweenpress150 and knittedcomponent130 andskin layer140 raises the temperature of the components to a level that facilitates bonding. Accordingly, the point at which one or both ofknitted component130 andskin layer140 are heated during this process may vary.
• Once knittedcomponent130 andskin layer140 are positioned,press portions151 and152 translate toward each other and begin to dose upon the components such that (a) the surface offirst press portion151 havingfirst material153 begins to contactskin layer140 and (b) the surface ofsecond press portion152 havingsecond material154 begins to contactknitted component130, as depicted inFIGS. 10B and 11B.Press portions151 and152 then translate further toward each other to fully compress the components, as depicted inFIGS. 10C and 11C. At this stage,skin layer140 is effectively bonded or otherwise joined toknitted component130. More particularly, the compressive force ofpress150, coupled with the elevated temperature of the compressed components, forms a thermal bond that joins knittedcomponent130 andskin layer140.
• As noted above,first material153 compresses more easily thansecond material154. Referring toFIGS. 10C and 11C, areas ofskin layer140 that are adjacent to protrudingareas133 press intofirst material153, whereassecond material154 remains more planar, but compresses to a lesser degree. Due to the different compressibilities betweenmaterials153 and154,first material153 compresses at the locations of protrudingareas133. Moreover, (a) portions ofskin layer140 that are incontact protruding areas133 ofknitted component130 protrude into the surface formed byfirst material153 to a first depth and (b) portions ofskin layer140 that are in contact with other regions of knitted component130 (i.e., regions with lesser thickness) protrude into the surface formed byfirst material153 to a second depth, the first depth being greater than the second depth. When bonding is complete,press150 is opened and the bonded components are removed and permitted to cool, as depicted in FIGS.10D and11D. As a final step in the process, the combination ofknit component130 andskin layer140 may be incorporated into upper120 offootwear100.
• The relative hardnesses, densities, and thicknesses betweenmaterials153 and154 may vary considerably to provide different compressibilities between the surfaces ofpress150. By varying the hardnesses, densities, and thicknesses, the compressibilities of the surfaces may be tailored to specific pressing operations or configurations. While hardness, density, and thickness may each be considered, some configurations ofpress150 may havematerials153 and154 with only different hardnesses, only different densities, or only different thicknesses. Additionally, some configurations ofpress150 may havematerials153 and154 with (a) the same hardnesses and densities, but different thicknesses, (b) the same hardnesses and thicknesses, but different densities, or (c) the same densities and thicknesses, but different hardnesses. Accordingly, the various properties ofmaterials153 and154 may be modified in various ways to achieve different relative compressibilities between the surfaces ofpress150.
• Each ofmaterials153 and154 are depicted as having a substantially planar surface. Depending upon the configuration ofknitted component130 and the various protrudingareas133, however, the surfaces ofmaterials153 and154 may also be contoured. For example,first material153 may include various depressions or indentations that correspond with the positions of protrudingareas133, thereby enhancing the degree to whichskin layer140 wraps around protrudingareas133.
• Press150 provides one example of a device that may be utilized to bond knittedcomponent130 andskin layer140. As another example, one ofpress portions151 and152 may be replaced with a flexible membrane and a pump may be utilized to evacuate air from between the membrane andsecond press portion152. As the air is evacuated, the membrane will press uponskin layer140 and induce bonding. As another example, a dual membrane system may be utilized to compress knittedcomponent130 andskin layer140 together.
• An advantage of selectingmaterials153 and154 to have different compressibilities relates to the three-dimensional aspect of upper120 that protrudingareas133 provide. More particularly, the different compressibilities ensures that protrudingareas133 continue to form bulges, protrusions, bumps, or other outwardly-extending portions when knittedcomponent130 andskin layer140 are compressed and bonded. In the absence of compressible materials, the degree to which upper120 includes outwardly-extending portions at protrudingareas133 may be lessened.
• Ankle Cuff Configuration
• Another configuration offootwear100 is depicted inFIGS. 12-15 as including anankle cuff160 for covering at least a portion of an ankle of the wearer. In addition to covering the foot, therefore, upper120 extends upward and covers a portion of the ankle. For reference purposes, upper120 may be divided into two general regions: afoot region106 and anankle region107, as shown inFIGS. 12,13, and15.Foot region106 extends through each of regions101-103 and generally encompasses portions of upper120 corresponding with the foot. In many configurations offootwear100,foot region106 corresponds with portions of upper120 that are intended to be below the lateral malleolus and the medial malleolus (i.e., the bony prominences on each side of the ankle) of the wearer.Ankle region107 is primarily located inheel region103 and generally encompasses portions of upper120 corresponding with the ankle. In many configurations offootwear100,ankle region107 corresponds with portions of upper120 that are intended to cover and extend above the lateral malleolus and the medial malleolus.
• Ankle cuff160 is located inankle region107 and forms an ankle part ofknitted component130. A remainder ofknitted component130, which is located infoot region106, forms a foot part ofknitted component130. Whereas the foot part ofknitted component130 covers the foot of the wearer, the ankle part ofknitted component130, which includesankle cuff160, covers the ankle of the wearer whenfootwear100 is worn. Moreover,ankle cuff160 and the ankle part ofknitted component130 may be formed of unitary knit construction with the foot part ofknitted component130.
• Althoughseam129 may be present inankle cuff160, the ankle part ofknitted component130 has a continuous structure for extending entirely around the ankle of the wearer. Referring to the top plan view ofFIG. 14,ankle cuff160 forms a circular, oval, or otherwise continuous androunded opening161 that provides access to the void within upper120. Opening161 may have relatively large dimensions that allow the foot to pass through and into the void. In many configurations offootwear100, however, opening161 stretches to accommodate the foot. Moreover,ankle cuff160 may have dimensions that are less than an average ankle, and ankle cuff may remain somewhat stretched and lay firmly against the ankle once the foot is located within the void. Accordingly,ankle cuff160 and other portions ofknitted component130 inankle region107 may be formed to have stretch properties.
• Whereasankle region107 has stretch properties, foot region108 of upper120 may stretch to a lesser degree to provide support for the foot and limit movement of the foot relative tosole structure120. That is,foot region106 may have a first degree of stretch andankle region107 may have a second degree of stretch, with the first degree of stretch being less than the second degree of stretch. In some configurations, portions ofknitted component130 in both ofregion106 and107 may have similar stretch properties, and the presence of inlaidstrand132 andskin layer140 infoot region106 may limit stretch infoot region106. In other configurations, the ankle part ofknitted component130 may be formed from yarns or knit structures that impart stretch, whereas the foot part ofknitted component130 may be formed from yarns or knit structures that impart less stretch.
• In order to enhance the stretch properties ofankle cuff160,skin layer140 may be absent fromankle region107. That is,skin layer140 may be absent from the ankle part ofknitted component130. In this configuration, the ankle part ofknitted component130, includingankle cuff160, forms a portion ofexterior surface121 andinterior surface122 inankle region107. As such,skin layer140 and the portions knittedcomponent130 that formankle cuff160 form a majority ofexterior surface121, andknitted component130 alone may form a relatively large portion ofinterior surface122.
• In the area ofankle cuff160,skin layer140 forms aconcave edge141 that extends downward on each ofsides104 and105. More particularly,skin layer140 may be absent from areas ofknitted component130 that cover the lateral malleolus and the medial malleolus. An advantage of this configuration is thatankle cuff160 may stretch over the lateral malleolus and the medial malleolus, thereby enhancing the comfort offootwear100. In other configurations,skin layer140 may extend upward to cover the lateral malleolus and the medial malleolus, or edge141 may be relatively straight or convex in the area ofankle cuff160.
• Based upon the above discussion,ankle cuff160 may exhibit greater stretch than other portions of upper120. In addition to allowing the foot to enterfootwear100, this structure provides support for the foot and limits movement of the foot relative tosole structure120. In addition,ankle cuff160 may remain in a stretched state and lay against the ankle whenfootwear100 is worn, which imparts two advantages: First,ankle cuff160 prevents or limits dirt, dust, and other debris from enteringfootwear100. Second, the wearer may sense the presence ofankle cuff160 around the ankle, which enhances the wearer's proprioceptive awareness of the foot.
• Lace Channel Configuration
• A further configuration offootwear100 is depicted inFIGS. 16 and 17 as includingvarious lace channels170 intongue127. Lace125 passes throughlace channels170, thereby locating portions oflace125 withintongue127. Referring toFIGS. 18 and 19, which depicttongue127 separate from a remainder offootwear100, each oflace channels170 are oriented diagonally with respect to a longitudinal axis offootwear100. The locations oflace channels170 generally correspond with the locations of lace-receivingelements126 and follow the natural path oflace125 as it passes between lace-receivingelements126. That is, the positions and orientations oflace channels170 are selected such that two of lace-receivingelements126 are located adjacent to opposite ends of eachlace channel170. In effect, therefore,lace channels170 are located along a line that extends between two lace-receivingelements126. Moreover,lace125 extends through thevarious lace channels170 and engages lace-receivingelements126 that are located on opposite sides oflace channels170. As such,lace125 follows a zigzagging path between lace-receivingelements126.
• Lace channels170 have a structure that is similar totubular structures134 and135. As such,lace channels170 include two separate and spacedtextile layers171 that overlap each other. Whereas edge areas oflace channels170 are joined and formed of unitary knit construction, a central area is enjoined and forms a tubular structure in which lace125 is located. That is,lace125 extends longitudinally and through eachlace channel170, thereby extending along a length of eachlace channel170.
• Although various methods may be utilized to formtongue127, a knitting process (e.g., flat knitting process) may be utilized. In configurations where a similar knitting process is utilized fortongue127 and knittedcomponent130, each oftongue127 and knittedcomponent130 may have similar properties, materials, and aesthetics. Additionally, an advantage of the knitting process is thatlace channels170 may be formed of unitary knit construction with a remainder oftongue127, which provides efficient manufacture and imparts a smooth and seamless configuration totongue127.
• A configuration ofknitted component130 in combination withlace125 is depicted inFIG. 20. As with the configurations inFIGS. 9A-9C,knit element131 extends across a region corresponding withthroat area124, thereby replacingtongue127. Moreover,knit element131 forms thevarious lace channels170. As with thevarious lace channels170 intongue127,lace channels170 in this configuration are two separate and spaced textile layers that overlap each other, are formed of unitary knit construction, and receivelace125.
• Lace125 is depicted as extending throughlace channels170 inFIG. 20. In place of apertures that form lace-receivingelements126, inlaidstrand132 is exposed and forms loops for receivinglace125. That is, the loops formed by inlaidstrand132 are lace-receivingelements126, which are located on opposite sides ofthroat area124.Lace125 extends through (a) the loops formed by inlaidstrand132 and (b) thevarious lace channels170. As withtongue127, each oflace channels170 are oriented diagonally with respect to a longitudinal axis and follow the natural path oflace125. That is, the positions and orientations oflace channels170 are selected such that two loops are located adjacent to opposite ends of eachlace channel170. As such,lace125 follows a zigzagging path between the loops formed by inlaidstrand132.
• Lace channels170 may have various lengths. InFIG. 16, ends oflace channels170 are positioned adjacent to an edge ofknitted component130 inthroat area124. Althoughknitted component130 overlaps portions oftongue127, ends oflace channels170 are exposed and receivelace125. InFIG. 20, ends oflace channels170 are positioned adjacent to the loops that form lace-receivingelements126. In either configuration, one or more oflace channels170 may have a length greater than three centimeters. In other configurations, however,lace channels170 may range from one to more than ten centimeters.
• A further configuration ofknitted component130 is depicted inFIGS. 21 and 22 as definingvarious apertures172 between loops formed by inlaidstrand132 and in the region corresponding withthroat area124.Apertures172 form openings that extend throughknit element131. In this configuration,lace125 extends through thevarious apertures172, and portions oflace125 are located adjacent to an opposite side ofknit element131. More particularly,lace125 passes through the loops formed by inlaidstrand132 and entersapertures172, thereby positioning portions oflace125 that are between the loops adjacent to the opposite side ofknit element131. The locations ofapertures172 generally correspond with the locations of the loops formed by inlaidstrand132 and follow the natural path oflace125. That is,apertures172 are located along a line that extends between two of the loops formed by inlaidstrand132.
• Further Configurations
• Various configurations offootwear100, upper120, knittedcomponent130, andskin layer140 are discussed above. There configurations, however, are intended to provide examples of structures and other features that may be incorporated intofootwear100. Although many variations uponfootwear100, upper120, knittedcomponent130, andskin layer140 are possible, some additional configurations are discussed below.
• In many configurations offootwear100, knittedcomponent130 forms a majority ofinterior surface122. Referring toFIGS. 23 and 24, aninterior layer180 is depicted as being secured toknitted component130 and forming a portion ofinterior surface122.Interior layer180 may inhibit stretch in upper120 and may enhance the wear-resistance or abrasion-resistance of upper120.Interior layer180 may also impart water-resistance tofootwear100. Additionally, formingfootwear100 to includeinterior layer180 may provide uniform fit and conformance to the foot, a relatively seamless interior with enhanced comfort for the wearer, a relatively light weight, and support for the foot. Althoughinterior layer180 may be utilized in configurations that also includeskin layer140,interior layer180 may be utilized in the absence ofskin layer140 or as a replacement forskin layer180.
• Interior layer180 may extend over substantially all ofknitted component130 or may be absent in specific areas ofknitted component130. In areas corresponding withforefoot region101 for example,interior layer180 defines a plurality ofapertures181 that may enhance the stretch, flex, and breathability properties of upper120. By varying the size, position, and number ofapertures181, the properties of upper120 may also be varied. In areas adjacent to inlaidstrand132,interior layer180 is formed to define larger apertures and has an articulated structure, which may promote flex in areas corresponding withmidfoot region102, while also providing stability and stretch-resistance. This portion ofinterior layer180 may also experience tension and resist stretching whenlace125 is tightened. As such, the combination ofinterior layer180 and inlaidstrand132 may impart greater resistance to stretch in upper120. In areas corresponding withheel region103,interior layer180 is located to provide additional stretch-resistance and durability tocollar123. It should also be noted thatinterior layer180 extends to edges ofknitted component130 that are joined withstrobel sock128, which effectively ties or joinsinterior layer180 tosole structure110.
• Various materials may be utilized forinterior layer180. As an example,interior layer180 may be a polymer layer with many of the properties ofskin layer140.Interior layer180 may also be a textile, such as a microfiber textile, that is adhered or bonded toknitted component130. In some configurations,interior layer180 may have a layered configuration that includes a thermoplastic polymer material for thermal bonding withknitted component130.
• Althoughskin layer140 may cover substantially all ofknitted component130,skin layer140 may be absent from some areas ofknitted component130. With reference to examples discussed above,skin layer140 may be absent fromthroat area124 orankle region107. As another example,FIG. 25A depictsskin layer140 as being present in areas corresponding withmidfoot region103 and areas that include inlaidstrand132, but absent in areas corresponding withforefoot region101 andheel region103. Moreover,skin layer140 covers some of protrudingareas133, but leaves other protrudingareas133 exposed. Accordingly,skin layer140 may only cover specific areas ofknitted component130, thereby leaving other areas ofknitted component130 exposed.
• A single element ofskin layer140 is secured toknitted component130 in many configurations discussed above. Referring toFIG. 25B, aparting line142 extends longitudinally through an area corresponding withforefoot region101, thereby separating different sections ofskin layer140. In this configuration, each section ofskin layer140 may have different properties. More particularly, the material formingskin layer140, the thickness of the material, or other properties may vary between the sections ofskin layer140, thereby imparting different properties to different areas of upper120. In further configurations, partingline142 may be located in other areas, or the sections ofskin layer140 may be spaced from each other to expose a portion ofknitted component130.
• The invention is disclosed above and in the accompanying figures with reference to a variety of configurations. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the configurations described above without departing from the scope of the present invention, as defined by the appended claims.

Claims (28)

What is claimed is:

1. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising a knitted component having a plurality of protruding areas that extend outward and away from a void within the upper for receiving a foot of a wearer, the protruding areas extending from a throat area of the upper to an area where the sole structure is secured to the upper, and the protruding areas including (a) a first tubular structure and an inlaid strand extending through the first tubular structure and (b) a second tubular structure and yarn sections extending across the second tubular structure.

2. The article of footwear recited inclaim 1, wherein the yarn sections extending across the second tubular structure form tuck stitches.

3. The article of footwear recited inclaim 1, wherein the yarn sections extending across the second tubular structure cross each other.

4. The article of footwear recited inclaim 1, wherein the protruding areas include a third tubular structure that extends from the first tubular structure to the second tubular structure.

5. The article of footwear recited inclaim 4, wherein additional yarn sections extend across the third tubular structure.

6. The article of footwear recited inclaim 1, wherein a majority of the knitted component has a first thickness and the protruding areas have a second thickness, the first thickness being less than four millimeters, and the second thickness being at least two millimeters greater than the first thickness.

7. The article of footwear recited inclaim 1, wherein a skin layer is secured to the knitted component and extends over the protruding areas, the skin layer forming a portion of an exterior surface of the upper.

8. The article of footwear recited inclaim 7, wherein the skin layer is absent from an ankle part of the knitted component.

9. The article of footwear recited inclaim 1, wherein the knitted component includes (a) a foot part for covering at least a portion of the foot of the wearer and including the protruding areas and (b) an ankle part for covering at least a portion of an ankle of the wearer, the foot part and the ankle part being formed of unitary knit construction, and the foot part having less stretch than the ankle part.

10. The article of footwear recited inclaim 9, wherein the ankle part has a continuous structure for extending entirely around the ankle of the wearer.

11. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a knitted component having a plurality of protruding areas that extend outward and away from a void within the upper for receiving a foot of a wearer, the protruding areas including (a) a first tubular structure and an inlaid strand extending through the first tubular structure and (b) a second tubular structure and yarn sections extending across the second tubular structure; and

a skin layer secured to the knitted component and forming a portion of an exterior surface of the upper, the skin layer extending over the protruding areas.

12. The article of footwear recited inclaim 11, wherein the first tubular structure and the second tubular structure extend from a throat area of the upper to an area where the sole structure is secured to the upper.

13. The article of footwear recited inclaim 11, wherein the yarn sections extending across the second tubular structure form tuck stitches.

14. The article of footwear recited inclaim 11, wherein the yarn sections extending across the second tubular structure cross each other.

15. The article of footwear recited inclaim 11, wherein the protruding areas include a third tubular structure that extends from the first tubular structure to the second tubular structure.

16. The article of footwear recited inclaim 15, wherein additional yarn sections extend across the third tubular structure.

17. The article of footwear recited inclaim 11, wherein a majority of the knitted component has a first thickness and the protruding areas have a second thickness, the first thickness being less than four millimeters, and the second thickness being at least two millimeters greater than the first thickness.

18. The article of footwear recited inclaim 11, wherein the skin layer is secured to the protruding areas.

19. The article of footwear recited inclaim 18, wherein the skin layer is absent from an ankle part of the knitted component.

20. The article of footwear recited inclaim 11, wherein the knitted component includes (a) a foot part for covering at least a portion of the foot of the wearer and including the protruding areas and (b) an ankle part for covering at least a portion of an ankle of the wearer, the foot part and the ankle part being formed of unitary knit construction, and the foot part having less stretch than the ankle part.

21. The article of footwear recited inclaim 11, further including an interior layer secured to the knitted component and forming a portion of an interior surface of the upper.

22. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising a knitted component having a plurality of protruding areas that extend outward and away from a void within the upper for receiving a foot of a wearer, the protruding areas including a tubular structure and yarn sections extending across the tubular structure.

23. The article of footwear recited inclaim 22, wherein the yarn sections extending across the tubular structure form tuck stitches.

24. The article of footwear recited inclaim 22, wherein the yarn sections extending across the tubular structure cross each other.

25. The article of footwear recited inclaim 22, wherein a majority of the knitted component has a first thickness and the protruding areas have a second thickness, the first thickness being less than four millimeters, and the second thickness being at least two millimeters greater than the first thickness.

26. The article of footwear recited inclaim 22, wherein a skin layer is secured to the knitted component and extends over the protruding areas.

27. The article of footwear recited inclaim 22, wherein an inlaid strand extends through another tubular structure of the knitted component.

28. The article of footwear recited inclaim 27, wherein the inlaid strand extends from a throat area of the upper to an area where the sole structure is secured to the upper.

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