KNITTED COMPONENT, UPPER, AND ARTICLE OF FOOTWEAR WITH VARYING THERMOPLASTIC POLYMER CONCENTRATIONS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of provisional U.S. Application No. 63/711,421, entitled “Knitted Component, Upper, and Article of Footwear with Varying Thermoplastic Polymer Concentrations”, and filed Oct. 24, 2024.

BACKGROUND

In the footwear industry, the aesthetic appeal and functional quality of an article often hinge on the precision of its design and construction. Knitting technology, employed extensively for creating footwear uppers, offers significant advantages in terms of flexibility, breathability, and the potential for seamless design; however, it is sometimes difficult to maintain clearly demarcated boundaries between different visual areas within the knitted upper, particularly in regions with complex contours such as the transition from the toe box to the tongue. Variations in knit structure and composition (e.g., concentration of thermoplastic polymer material) between two adjacent areas can cause the fabric to stretch unevenly, especially in areas where the upper shifts from a flatter surface to a more contoured one, leading to distortions at the boundary line. This difficulty not only affects the visual sharpness and aesthetic appeal of the footwear but can also impact consumer perception of quality and brand reputation.

BRIEF DESCRIPTION OF THE DRAWINGS

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

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

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

FIG. 2A illustrates a top view of an example upper of the article of footwear of FIG. 1A in accordance with aspects herein;

FIG. 2B illustrates a top view of another example upper of the article of footwear of FIG. 1A in accordance with aspects herein;

FIG. 3 illustrates a knit diagram of an example knit structure for an upper in accordance with aspects herein;

FIG. 4 illustrates a knit diagram of another example knit structure for an upper in accordance with aspects herein;

FIG. 5 illustrates a knit diagram of another example knit structure for an upper in accordance with aspects herein;

FIG. 6 illustrates a knit diagram of another example knit structure for an upper in accordance with aspects herein;

FIG. 7 illustrates a knit diagram of another example knit structure for an upper in accordance with aspects herein; and

FIG. 8 illustrates a flow diagram of an example method of manufacturing an upper in accordance with aspects herein.

DETAILED DESCRIPTION

In brief, and at a high level, aspects herein are directed to knitted components, uppers, and articles of footwear that incorporate an upper, as well as methods of manufacturing a knitted component, an upper, and an article of footwear.

In aspects, an upper is provided that integrates a knitted component having a differential in the amount of thermoplastic polymer material that is incorporated throughout the knitted component in order to help address the functional challenges inherent in production of knit footwear and uppers. In aspects, an upper, and its various aspects discussed herein, can be formed in such a fashion that its construction helps in maintaining sharper, clearer, and more consistent boundaries between different areas (e.g., those that are intended to include different visual properties). This can be beneficial for aesthetic appeal, manufacturing consistency and sustainability (e.g., due to fewer rejected or discarded articles), and overall precision in repeated production of footwear, among other benefits. In accordance with aspects described herein, by differentiating the concentration of a thermoplastic polymer material in a knitted component incorporated into an upper of an article of footwear, each area of the upper can more precisely and consistently achieve desired performance aspects such as enhanced durability in higher-wear areas (e.g., a toe end) and increased flexibility in areas that experience greater wearer interaction (e.g., a forward end of a throat area that is stretched for insertion of a wearer's foot). In addition, aspects herein can allow for a knitted component, upper, and article of footwear with these characteristics to be at least partially produced during formation of the knitted component during a knitting operation. This integral formation can allow for such structures to be produced with reduced or limited need for the introduction of additional components (e.g., adhesives or embellishments). This helps with streamlining the manufacturing process, reducing unnecessary costs and manufacturing steps, and increasing the precision and sustainability of footwear manufacturing, among other benefits.

In example aspects, an upper may comprise a knit textile formed of a unitary knit construction, such that the knit textile extends at least partially through a forefoot region, a midfoot region, a lateral side, and/or a medial side of the upper or some combination of the same. In other aspects, a composite construction of multiple knit textiles each formed with a unitary knit construction and attached together can be used to form an upper. The knit textile of the upper can include at least a first area and a second area having different visual properties. The first area may extend continuously from a toe end of the forefoot region through the forefoot region and to a forward end of a throat area, and the second area may extend adjacent (e.g., substantially directly adjacent) to the first area from the toe end of the forefoot region to the forward end of the throat area. In some aspects, a third area also having a different visual property than the first area may extend adjacent (e.g., substantially directly adjacent) to the first area. In some aspects, the first area may be positioned between the second and third areas.

Aspects herein contemplate that the first area and/or the second area (and, in some aspects, a third area) may be integrally knitted with each other during a single knitting process. When the upper is knit as a unitary knit textile, which seamlessly extends through various areas of the shoe, it helps with minimizing potential irritations caused by seams and increasing comfort, particularly in areas subject to high movement or flexion.

In aspects, a knit textile can be produced using one of multiple processes. For example, a flat knitting process can be used to produce a knit textile as described herein. In addition to flat knitting, other knitting processes can be used to form knit textiles as described herein, e.g., wide-tube circular knitting, narrow-tube circular knit jacquard, single-knit circular knit jacquard, double-knit circular knit jacquard, warp knit tricot, warp knit raschel, double-needle bar raschel, or another knitting process. In aspects, a knit textile can be modified further through post-processing, e.g., to remove a portion of the knit textile (subtractive post-processing), to add components to the knit textile (additive post-processing), to create a fleece texture, to form apertures, to add embellishments, or the like. In aspects, the first and/or second areas described herein can include a jacquard pattern. In aspects, the knit textile can be a jacquard textile.

Additionally, in aspects, the first area can include a thermoplastic polymer material. In aspects, the amount or concentration of the thermoplastic polymer material that is incorporated into different portions of the first area can differ. In other words, a concentration of thermoplastic polymer material by weight or by volume per unit of surface area in different portions, areas, zones, and/or sections of the first area can differ in the aspects described herein. For example, the first area may have a greater concentration of thermoplastic polymer material in the toe end of the forefoot region than in the forward end of the throat area, which may help achieve different functional characteristics. The higher concentration of thermoplastic polymer material in the toe end, for instance, may help resist deformation and abrasion in a high-contact area subjected to more wear and potential degradation. The use of a thermoplastic polymer material not only adds durability but can also enhance the structural integrity of a shoe. It can also help maintain the shape and form of toe and forefoot areas, which is helpful for supporting the foot during various activities. In addition, in the same aspect, a lower concentration of thermoplastic polymer material in the forward end of the throat area may help the first area maintain flexibility for bending and flexing motions of the forefoot during walking or running with minimal distortion of the boundary between the first area and the second area, which have different visual properties. In this way, a more precise boundary between visually distinct first and second areas may be maintained at least partly due to the variance in the concentrations of the thermoplastic polymer material in the first area. Additionally, the strategic placement and concentration of thermoplastic polymers in the first area can protect a wearer's foot from external impacts, thereby improving the experience of the wearer.

In some examples, the first area of the knit textile is a stripe having a different color than the adjoining area(s) (e.g., the second area and, in some aspects, the third area). The stripe may be separated from the adjoining area(s) along a straight boundary, and the placement and concentrations of thermoplastic polymers may help maintain the precision and integrity of this boundary. For example, by integrating thermoplastic polymer material, the knit textile gains additional structural stability. This stability may be helpful where the shoe is subject to bending and stretching, as it helps maintain the form and alignment of the boundary line, helping to limit warping or distorting during wear.

Knitting a textile having distinct areas with different visual properties may benefit from precise joining techniques. For example, intarsia can be used to knit the first and second areas of the textile with different visual properties next to each other without carrying yarn across, which is useful for creating sharp, clean lines between different colors and/or texture zones. In some aspects, in order to increase the durability of the connection at the boundary and to maintain the alignment of the boundary, tuck stitches can be used to join the first area with the second area (e.g., to form a first side edge of the first area at the boundary between the first area and the second area). By tucking the second area's stitches behind those of the first area along the boundary line (e.g., with a two-needle overlap), a mechanical interlocking of yarns can be achieved that can help inhibit the boundary between the first area and the second area from shifting or stretching unevenly in response to applied forces. Similarly, tuck stiches can be used to join the first area and a third area (e.g., to form a second side edge of the first area at the boundary between the first area and the third area). In some aspects, the first side edge can be parallel or substantially parallel to the second side edge.

As used herein, an “article of footwear” generally includes a sole structure secured to an upper. A biteline of the upper represents where the upper meets the sole structure. The article of footwear described herein may comprise a soccer shoe, a running shoe, a baseball shoe, a basketball shoe, a skateboarding shoe, a cycling shoe, an American football shoe, a tennis shoe, a global football shoe, a training shoe, a walking shoe, a hiking shoe, and the like. The concepts described herein may also be applied to other footwear types that are considered non-athletic such as dress shoes, loafers, sandals, and work boots. As used herein, the article of footwear may be divided into different general regions. A forefoot region generally includes portions of the article of footwear that correspond to the toes and joints connecting the metatarsals with the phalanges; the forefoot region terminates in a toe end of the article of footwear. A midfoot region generally includes portions of the article of footwear corresponding with an arch area and an instep area of the foot. A heel region generally corresponds with rear portions of the foot including the calcaneus bone. The 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.

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

The “outward-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 outward-facing surface may mean the outermost-facing surface of the knitted upper or article of footwear.

The term “knit” or “knitted” 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, a missed stitch, a tuck stitch, a transfer stitch, a rib stitch, and the like, as these terms are known in the art of knitting. The term “course-wise direction” refers to a direction that is parallel to the knit courses of the textile piece. The term “wale,” as used herein, is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles. The term “wale-wise direction” refers to a direction that is parallel to the knit wales of the textile piece.

The term “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 example aspects, the two faces may be joined by yarns that interloop with yarns in both the first face and the second face of the double knit construction. Common double knit constructions include double jersey, rib, interlock, cardigan, other “double bed” knit structures initially formed on at least two needle beds, and other knit structures having two opposing faces of knit loops or tucks, including full-gauge and less-than-full-gauge variations of those structures. The term “single knit construction” as used herein refers to a knit construction generally formed on a single needle bed (i.e., a single-bed construction). Common single knit constructions include single jersey.

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 may have a seamless transition such that they seamlessly extend from one another in one or more example aspects.

The term “intarsia,” as used herein, may refer to a knitting technique that uses separate feeders to knit separate sections of wales across a same course, which may allow isolation of separate yarns to separate sections of wales in the same course.

The term “tuck stitch,” as used herein, refers to a knitting technique that involves retention of one or more stitches on a needle while new stitches are formed, and incorporating the retained one or more stitches into a subsequent row.

The yarns in accordance with aspects herein may include monofilament yarns and/or multifilament yarns formed from, for example, synthetic materials. Further, in example aspects, the yarns used in various areas, including yarns described above, may include material such as high-melting yarns and/or low-melting yarns. As used herein, the term “high-melting” generally means that the yarns melt at about 180 degrees Celsius or higher. These yarns may include high-melting thermoplastic yarns that include high-melting polyethylene terephthalate (PET) (commonly referred to as polyester) yarns, high-melting recycled PET yarns, cushioning yarns, core/sheath yarns in which the core comprises a high-melting material (e.g., a high-melting PET core), elastane yarns, and other high-melting synthetic, thermoplastic yarns.

Low-melting yarns generally comprise low-melting thermoplastic yarns. As used herein, the term “low-melting” generally means yarns that melt at about 175 degrees Celsius or less. The low-melting thermoplastic yarns comprise a synthetic polymeric material (e.g., a thermoplastic polymer material) formed from a polymer that melts at relatively lower temperatures compared to other materials in the yarns of the knit textile. In example aspects, the low-melting yarns may include yarns that are entirely formed from a low-melting thermoplastic material such as low-melting PET or low-melting polyamide (such as nylon). Low-melting yarns may also include low-melting thermoplastic polymer material covering yarns having a high-melting material formed from, for example, high-melting PET. For instance, an example yarn may include a high-melting nylon core surrounded by a low-melting thermoplastic polyurethane (TPU). Another example yarn includes a high-melting, high-tenacity PET surrounded by a thermoplastic elastomeric composition, such as TPU or styrene-ethylene-butylene-styrene (SEBS). In example aspects, the melting temperature of the thermoplastic polymer material may be sufficiently different from the melting temperature of the high-melting yarns that the thermoplastic material of the low-melting yarns may be essentially completely melted without melting or adversely affecting (e.g., burning, charring, or singeing) the characteristics of the high-melting yarns. Similarly, the melting temperature of the thermoplastic polymer material may be sufficiently different from the melting temperature of any high-melting material in the low-melting yarns (e.g., core) so that the thermoplastic polymer material may be essentially completely melted without melting or adversely affecting (e.g., burning, charring, or singeing) the characteristics of the high-melting material of the same yarn. For example, a first yarn having a thermoplastic polymer material may have a lower melting temperature than a second yarn, which may be a high-tenacity polyester yarn. In some examples, the first yarn may be a monofilament yarn comprising a thermoplastic polymer composition. In another example, the first yarn may have a core/sheath configuration where a sheath of thermoplastic polymer material surrounds a sheath of a different material having a higher melting temperature than the sheath.

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 the knitted upper may have different properties as described herein. Examples aspects herein may include varying visual properties in different areas of the knitted component. In example aspects, the yarns used in various areas include one or more visual properties configured to facilitate translucency or transparency of the area and may include, for example, transparency, color, haze, gloss, and/or reflectivity. The visual property may be afforded by the material that forms the yarn or may be imparted to the yarn by using an application technique compatible with both a respective visual property and the yarn. In one aspect, a visual property may be afforded by a material that interacts with light in a manner such that the yarn included in the material may be reflective, clear, glossy, metallic, exhibit shimmer, and the like. In another aspect, a visual component may be imparted by dyes, inks, pigments, finishes, and the like, such that the yarn may be a light color (e.g., white and light shades of grey, red, orange, yellow, green, and blue), reflective, glossy, metallic, and the like.

In some aspects, different areas of a knitted component can have distinct visual properties due to differences in the knit structures or yarns incorporated in those areas, even when yarns of a common color are used. These variations in knit structure can result in visual contrasts that do not rely on color differentials between the yarns themselves. For example, an area of an upper formed with a knitted component can include a denser, more tightly knit structure, which may create a more uniform appearance, while another area may have a looser, more open knit structure that can introduce a textured or more perforated look. Such visual distinctions may be achieved by altering a tension, stitch type, or knit pattern in the knitting process without necessarily changing the color of the yarns used in those areas. In some aspects, a differential in yarn color may also be incorporated. In some aspects, yarns with different surface textures can be incorporated to provide distinct surface appearances.

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

FIGS. 1A and 1B respectively schematically depict a medial view and a lateral view of an example article of footwear 100 having a knitted upper 110 and a sole structure 112 secured to the knitted upper 110. The article of footwear 100 is shown in the form of an athletic shoe, but other types of shoes (e.g., sandals, leisure shoes, and the like) are contemplated herein. The article of footwear 100 includes a forefoot region 114 having a toe end 115, midfoot region 116, a heel region 118, a medial side 120, and a lateral side 122. The article of footwear 100 includes a biteline 117, a collar 124, an ankle opening 125 for receiving a wearer's foot, and a throat area 126. Although not shown, aspects herein contemplate that the article of footwear 100 may include additional elements layered on top of the knitted upper 110 including, for example, leather materials, synthetic leather materials, knitted or woven textiles, polymer skins, and the like. The additional elements may be positioned at discrete locations of the knitted upper 110 including, for example, the toe end 115 (e.g., a toe cap), the heel region 118 (e.g., a heel counter), and the like.

In example aspects, the upper 110 may comprise a knit textile, e.g., formed of a unitary knit construction, and may be formed in a single knitting process, e.g., a knitting operation performed on an automated knitting machine. The knitted upper 110 includes a first area 131, a second area 132, and a third area 133. The first area 131 may have different visual properties than the second area 132 and the third area 133, as further described herein. The knitted upper 110 includes a boundary 135 between the first area 131 and the second area 132, and a boundary 136 between the first area 131 and the third area 133. In some aspects, the boundary 135 (e.g., a first boundary) can be parallel or substantially parallel with the boundary 136 (e.g., a second boundary). The knitted upper 110 includes a tongue component 140 that is further shown and described in at least FIGS. 2A and 2B. The throat area 126 may include a forward end 127 of the throat area 126 and a back end 128 of the throat area 126.

The first area 131 is located in the forefoot region 114 of the upper 110 and extends continuously from the toe end 115 of the upper 110 through the forefoot region 114 and to the forward end 127 of the throat area 126. For example, the first area 131 may extend from the biteline 117 at the toe end 115 in the forefoot region 114 where the upper 110 is secured to the sole structure 112 (e.g., a biteline area). In some aspects, the first area 131 may continuously extend from the forward end 127 of the throat area 126 through the throat area 126 area and to the back end 128 of the throat area 126. In some aspects, the first area 131 may form at least a portion of a tongue 140. For example, in some aspects, the first area 131 may form at least a central portion of the tongue 140. Additionally, the first area 131 may extend all or substantially all through the length of the tongue 140. In some aspects, the first area 131 may form a stripe extending from the toe end 115 of the forefoot region 114 and to the forward end 127 of the throat area 126. In some aspects, the stripe formed by the first area 131 further extends from the forward end 127 of the throat area 126 through the throat area 126 and to the back end 128 of the throat area 126.

In other aspects, the first area 131 (e.g., stripe) could be positioned in various alternative locations on the upper 110. For example, instead of extending from the biteline 117 near the toe end 115 as previously described, the first area 131 could extend from any location along the biteline 117 or an outer edge of the upper 110. In some aspects, the first area 131 could extend from the biteline 117 on the medial side 120 and/or on the lateral side 122 and extend diagonally or vertically toward the throat area 126 or the collar 124. In some aspects, the first area 131 may extend across the throat area 126 or the collar 124 to the other of the medial side 120 or the lateral side 122. Such an orientation may create a visually striking appearance while maintaining structural reinforcement in desired areas of the upper 110, e.g., that may experience increased flexion and wear during foot movement.

In other aspects, the first area 131 may in addition or in the alternative extend from the biteline 117 in the heel region 118 upward toward the collar 124 of the upper 110. Such an orientation may help enhance the structural integrity of a heel area or heel counter and/or help maintain the shoe's shape and help with providing a locked-in fit for the wearer. Additionally, by incorporating thermoplastic polymer material in the heel region 118, abrasion resistance and durability may be improved in this zone that experiences greater amounts of contact. The second area 132 is located at least partially in the forefoot region 114 of the upper 110. In some aspects, the second area 132 extends at least through at least part of the lateral side 122 of the upper 110. The second area 132 may be entirely contained on the lateral side 122. In some aspects, the second area 132 continuously extends from the toe end 115 in the forefoot region 114 and at least partially through the midfoot region 116 and/or the heel region 118 on the lateral side 122. In some aspects, the second area 132 may extend seamlessly from the first area 131 at the boundary 135 in the forefoot region 114. For example, the second area 132 may extend from the first area 131 at the boundary 135 in the forefoot region 114 to the biteline 117 of the upper 110. In some aspects, the second area 132 extends directly adjacent the first area 131 from the toe end 115 of the forefoot region 114 to the forward end 127 of the throat area 126. In aspects where the first area 131 continuously extends through the throat area 126, the second area 132 may extend directly adjacent the first area 131 through the throat area 126 along the boundary 135 (e.g., in the midfoot region 116). For example, the second area 132 may extend directly adjacent the first area 131 from the forward end 127 of the throat area 126 through the throat area 126 and to the back end 128 of the throat area 126. In some aspects, the second area 132 may extend seamlessly from the first area 131 at the boundary 135 in the forefoot region 114 and/or the midfoot region 116 to the biteline 117 of the upper 110.

In some aspects, the third area 133 may be included. In such aspects, the third area 133 is located at least partially in the forefoot region 114 of the upper 110. In such aspects, the third area 133 extends through at least part of the medial side 120 of the upper 110. The third area 133 may be entirely contained on the medial side 120. In some aspects, the third area 133 continuously extends from the toe end 115 in the forefoot region 114 and at least partially through the midfoot region 116 and/or the heel region 118 on the medial side 120. In some aspects, the third area 133 may extend seamlessly from the first area 131 at the boundary 136 in the forefoot region 114. For example, the third area 133 may extend from the first area 131 at the boundary 136 in the forefoot region 114 to the biteline 117 of the upper 110. In some aspects, the third area 133 extends directly adjacent the first area 131 from the toe end 115 of the forefoot region 114 to the forward end 127 of the throat area 126 in the forefoot region 114. In aspects where the first area 131 continuously extends through the throat area 126, the third area 133 may extend directly adjacent the first area 131 through the throat area 126 along the boundary 136. For example, the third area 133 may extend directly adjacent the first area 131 from the forward end 127 of the throat area 126 through the throat area 126 and to the back end 128 of the throat area 126. In such an example, the third area 133 may extend seamlessly from the first area 131 at the boundary 136 in the forefoot region 114 and/or the midfoot region 116 to the biteline 117 of the upper 110.

The first area 131 may have different visual properties than one or more adjacent areas of the upper 110. For example, in aspects, the first area 131 has a first visual property and the second area 132 has a second visual property that is different than the first visual property (e.g., in order to form a striped appearance). For example, in aspects, the first visual property may be a first color and the second visual property may be a second color that is different from the first color. In aspects where a third area 133 is included, the third area 133 may have a third visual property that is different than the first visual property. The third visual property may be the same as the second visual property so that the first area 131 may form a visually distinct separation between two areas (the second area 132 and the third area 133) that are otherwise similar. In other aspects, however, the third visual property is different from the second visual property. Including different visual properties between the different areas helps to further define the distinct boundaries between the areas.

In some aspects, the boundary 135 between the first area 131 and the second area 132 may generally be linear and, in some aspects, may be a straight boundary from the toe end 115 to at least the forward end 127 of the throat area 126. To enhance distinctions between two areas of different visual properties, the boundary 135 of the first area 131 and the second area 132 may be a visually distinct boundary. For example, the boundary 135 may provide a sharper, cleaner line that delineates between the different visual properties possessed by the first area 131 and the second area 132, which are beneficial for aesthetic appeal and brand identity, and has traditionally been challenging to accomplish consistently in the construction of knit uppers and footwear. Accordingly, it is helpful to select an appropriate method of joining the first area 131 and the second area 132 with precise joining techniques that will provide a straight and distinct boundary at the boundary 135. To accomplish this, in some aspects, the first area 131 is joined to the second area 132 through intarsia at least partially along the boundary 135 between the first area 131 and the second area 132. By selecting intarsia as the joining method, the first area 131 and the second area 132 may be joined together seamlessly without carrying yarns across from one area to the other that have different visual properties, thereby helping to maintain the alignment of the boundary 135. In some aspects, tuck stitches can be used at the boundary 135 to further increase the durability of the boundary 135, as well as to help maintain the alignment of the boundary 135. In such aspects, the stitches of a yarn knit in the second area 132 are tucked behind the stitches of a yarn knit in the first area 131 along the boundary 135. For example, the stitches of the yarn of the second area 132 may be tucked behind the stitches of the yarn of the first area 131 with a two-needle overlap to help ensure that the boundary 135 is limited from shifting or stretching unevenly, e.g., under tension or in response to other forces.

In order to enhance durability while having increased flexibility where desired to meet the functional challenges of maintaining a straight boundary between different areas in the upper 110, varying concentrations of thermoplastic polymer material may be incorporated within the same area (e.g., the first area 131). In some aspects, different concentrations of thermoplastic material may be incorporated between different areas (e.g., between the first area 131 and the second area 132). The varying concentrations of thermoplastic polymer materials may be provided by the use of different knit constructions such as shown in knit diagrams 300, 400, 500, 600, and 700, which will be discussed further below.

In some aspects, the first area 131 has a first concentration of a thermoplastic polymer material in the toe end 115 of the forefoot region 114 that is greater than a second concentration of the thermoplastic polymer material in the forward end 127 of the throat area 126. The relatively higher concentration of the thermoplastic polymer material in the toe end 115 may be helpful for maintaining a shape of a toe box when the upper 110 is incorporated into the article of footwear 100. The relatively lower concentration of the thermoplastic polymer material in the forward end 127 of the throat area 126 compared to the toe end 115 increases flexibility for bending and flexing motions of the forefoot in the first area 131, which may help reduce distortion of the upper 110 at such locations and help to maintain a precise boundary (e.g., boundary 135) between the first area 131 and the second area 132. Due to such a construction of the first area 131, the toe end 115 of the first area 131 may have a different degree of stiffness (e.g., as measured by Young's modulus and/or as determined using an ASTM D1388 testing method) than the forward end 127 of the throat area 126 in the first area 131. For example, in some aspects, the first area 131 has a first stiffness in the toe end 115 of the forefoot region 114 and a second stiffness in the forward end 127 of the throat area 126, where the first stiffness is greater than the second stiffness.

The concentration of the thermoplastic polymer material in the first area 131 may continue to change further back in the throat area 126. For example, in some aspects, the first area 131 has a third concentration of the thermoplastic polymer material in the back end 128 of the throat area 126 that is greater than the second concentration of the thermoplastic polymer material in the forward end 127 of the throat area 126. A greater concentration in the back end 128 of the throat area 126 than in the forward end 127 of the throat area 126 may provide greater stability and support for the ankle joint, which is desired, and/or may provide more structure to the tongue 140 to keep the tongue 140 in a desired position. In other aspects, the first area 131 has a third concentration of the thermoplastic polymer material in the back end 128 of the throat area 126 that is less than the second concentration of the thermoplastic polymer material in the forward end 127 of the throat area 126, which may provide increased flexibility for easier movement during activities like walking, which is desired, or may alleviate pressure points. In other aspects, the first area 131 has a third concentration of the thermoplastic polymer material in the back end 128 of the throat area 126 that is the same as the forward end 127 of the throat area 126.

The second area 132 may include a second thermoplastic polymer that could be the same, or different, than the first thermoplastic polymer. In some aspects, the second area 132 may have a consistent concentration of the second thermoplastic polymer material from the toe end 115 of the forefoot region 114 to the forward end 127 of the throat area 126. In some aspects where the second area 132 continuously extends through the midfoot region 116 adjacent to the first area 131 in the throat area 126, the second area 132 may have a consistent concentration of the second thermoplastic polymer material from the toe end 115 of the forefoot region 114 to the back end 128 of the throat area 126. The consistent concentration of thermoplastic materials helps provide a uniform level of support along a side of the upper 110, which may help ensure that the upper maintains its structural integrity and stability, even with the variation in concentrations in the first area 131. Therefore, in helping to maintain a more precise boundary (e.g., like boundary 135), the article of footwear 100 may benefit from the uniform level of support provided to the first area 131 by the second area 132 at least partially due to the first area 131 being more flexible in certain portions (e.g., the forward end 127 of the throat area 126 in the first area 131).

In some aspects, there is variation in the concentration of the second thermoplastic polymer throughout the second area 132. For example, the concentration of the second thermoplastic polymer may be generally consistent adjacent the boundary 135 from the toe end 115 to the forward end 127 of the throat area 126 while having variations in the concentration of the second thermoplastic polymer material elsewhere (e.g., adjacent the biteline 117 in the midfoot region 116 and/or in the heel region 118). In some aspects, there may be variation in the concentration of the second thermoplastic polymer material in the second area 132 adjacent the boundary 135. In some aspects, a transition between the first area 131 and the second area 132 may comprise a gradient of the first thermoplastic polymer material and/or the second thermoplastic polymer material. In other words, in various aspects herein, transitional areas of a knitted component can include a gradient of thermoplastic material, e.g., rather than an abrupt transition in the concentration of such materials.

Furthermore, the concentration of the second thermoplastic polymer material in the second area 132 may be greater than the concentration of the first thermoplastic polymer material in the forward end 127 of the throat area 126 in the first area 131 (referred to herein as the second concentration of the first thermoplastic polymer material in the first area 131). In some aspects, the concentration of the second thermoplastic polymer material in the second area 132 may also be greater than the concentration of the first thermoplastic polymer material in the toe end 115 in the first area 131 (referred to herein as the first concentration of the first thermoplastic polymer material in the first area 131). The greater concentration(s) of thermoplastic polymer material in the second area 132 may help with boundary reinforcement and with creating a distinct and stable edge that effectively delineates between the first area 131 and the second area 132.

It should be noted that, in aspects where the third area 133 is included, the third area 133 may have the same or similar features as the second area 132 of the upper 110, except for being located on an opposite side of the upper 110 from the second area 132 (e.g., the medial side 120) with the boundary 136 between the first area 131 and the third area 133 being a mirror image of the boundary 135. As such, further details of the third area 133 need not be repeated. However, it should be understood that other aspects of the upper 110 may include the third area 133 having different yarns and/or knit constructions than the second area 132. Therefore, references to the materials and/or construction of the third area 133 are made herein in conjunction with the second area 132 for ease, but it will be appreciated that in some aspects, such features are present in the second area 132 without necessarily being in the third area 133.

Looking now at FIGS. 2A and 2B, examples of a knit textile 200, e.g., formed of a unitary knit construction, with the knit textile 200 incorporated in the knitted upper 110 of FIGS. 1A and 1B before being secured to the sole structure 112 of the article of footwear 100 is shown, in accordance with aspects herein. In example aspects, the knit textile 200 may have a generally U-shaped configuration. The U-shaped configuration is just one example shape of the knitted upper 110 and other example shapes are contemplated herein.

For example, FIG. 2A depicts an example aspect of the knit textile 200 with a separate tongue component 240 that is joined at least to the first area 131 in the knit textile 200 in the throat area 126 to form the tongue (e.g., tongue 140). The example aspect of FIG. 2A is shown in an exploded view for illustrative purposes. In this example aspect, the boundary 135 between the first area 131 and the second area 132 in the throat area 126 may be cut, and the boundary 136 between the first area 131 and the third area 133 in the throat area 126 may be cut (e.g., as illustrated by the thicker lines at the boundaries 135 and 136 in the throat area 126). Cutting in such a way may result in separating the throat area 126 of the first area 131 from the remainder of the knit textile 200 so that it may be joined to the tongue component 240 to at least partially form the tongue 140. The portion of the boundaries 135 and 136 between the first area 131, the second area 132, and the third area 133 in the forefoot region 114 may remain joined as described above (e.g., integrally knitted and joined through intarsia). After cutting, the tongue component 240 may be secured to the knit textile 200 adjacent the forward end 127 of the throat area with the first area 131 overlaying a portion of an outward-facing surface 241 of the tongue component 240 such that the tongue 140 of the upper 110 comprises the tongue component 240 and the first area 131 of the knit textile 200. The first area 131 may be secured to the tongue component 240 via one or more of stitching, embroidery, bonding, adhesives, and the like. Forming the tongue 140 with the tongue component 240 and the first area 131 in this way may continue the visually distinct first area 131 through the tongue 140 while simplifying the processing of knitting across the throat area 126 from the medial side 120 and the lateral side 122 of the knit textile 200 and allowing the use of intarsia along the boundaries 135 and 136 in the forefoot region 114.

The example of FIG. 2B depicts an aspect of the knit textile 250 with an integrally knit tongue. That is, the tongue 140 may be formed of the first area 131 and additional portions of the knit textile 250 integrally knit with the first area 131. In this example, the boundaries 135 and 136 between the different areas may remain joined in the throat area 126. In some aspects with an integrally knit tongue, the boundaries 135 and 136 in the throat area 126, which join the first area 131 to the rest of the knit textile 250, may comprise a cross-tubular knit in order to provide the desired levels of adjustability and alignment of the tongue. For example, using a cross-tubular knit may help provide flexibility to the throat area 126 of the knit textile 200 so that the article of footwear 100 can accommodate variations in foot volume and instep height while still providing a durable connection to other areas of the knit textile 200 that helps ensure a straight alignment of the boundaries 135 and 136. Integrally forming the tongue from the tongue component 140 and the first area 131 in this way reduces the overall number of processing steps.

Looking now at FIGS. 3-7, a series of representations of differently configured knit structures that can be part of a knitted component incorporated into an upper of an article of footwear are shown, in accordance with aspects herein. FIGS. 3-7 depict example constructions that serve as non-limiting representative examples, demonstrating how distinct concentrations of thermoplastic polymer material can be incorporated in different areas of a knitted component to help provide unique functional characteristics in different areas, zones, or sections of the knit textile 200. For example, FIG. 3 depicts an example knit configuration of the second area 132 that can have a greater concentration (e.g., by weight, volume, or unit of surface area) of thermoplastic polymer material than some other areas (e.g., first area 131 and/or third area 133); FIG. 4 depicts an example knit configuration of the first area 131 in the forefoot region 114 that can have a lesser concentration of thermoplastic polymer material than the first area 131 but can have a greater concentration of thermoplastic polymer material (e.g., by weight, volume, or unit of surface area) than other parts of the first area 131 (e.g., the forward end 127 and the back end 128 of the throat area 126); FIG. 5 depicts an example knit configuration of the forward end 127 of the throat area 126 in the first area 131, and FIGS. 6-7 depict example knit configurations of the back end 128 of the throat area 126 of the first area 131. For example, FIG. 5 depicts an example knit configuration of the forward end 127 of the throat area 126 in the first area 131 that can have a lesser concentration of thermoplastic polymer material (e.g., by weight, volume, or unit of surface area) than the forefoot region 114 of the first area 131; FIG. 6 depicts an example knit configuration of the back end 128 of the throat area 126 in the first area 131 where the concentration of thermoplastic polymer material of the first area 131 increases (e.g., by weight, volume, or unit of surface area) from the forward end 127 of the throat area 126 to the back end 128 of the throat area 126; and FIG. 7 depicts an example knit configuration (e.g., alternative to the knit configuration of FIG. 6) where the concentration of the thermoplastic polymer material decreases (e.g., by weight, volume, or unit of surface area) from the forward end 127 of the throat area 126 to the back end 128 of the throat area 126.

In aspects, yarns that include thermoplastic polymer material can be incorporated into the knit textile 200 with other yarns in order to provide a particular concentration (e.g., by weight, volume, or unit of surface area) of thermoplastic polymer material in a particular area of the knit textile 200. For example, yarns that include thermoplastic polymer material can be plaited with yarns without thermoplastic polymer material. Examples of such plating are illustrated in FIGS. 3-7. The plaited yarns without thermoplastic polymer material can be high-melt and/or high-tenacity yarns as described herein. The concentration, e.g., per unit of surface area, of thermoplastic polymer material within an area (e.g., the first area 131) can be determined relative to the other yarns in the example knit constructions that are incorporated in a specified area. While the knit diagrams may be addressed to specific areas in the figures (e.g., as shown in FIG. 1A), these example knit constructions can be applied to other areas as well. Moreover, alternate knit constructions not depicted herein may be incorporated to achieve the desired objective of varying concentrations of thermoplastic polymer material. For example, for ease of representation to show relative concentrations, the knit constructions of FIGS. 3-7 are shown as having a single-bed construction, e.g., being a single-layer knit structure; however, it should be noted that configurations incorporating multiple needle beds, e.g., a double knit construction, are also contemplated as described below. The knit diagrams provided are not exhaustive, and other suitable knit constructions may be used to obtain differing concentrations of thermoplastic polymer material.

FIG. 3 depicts part of the knit textile 200 formed using plaited yarns to achieve a desired concentration of thermoplastic polymer material in the second area 132 of the knit textile 200, e.g., by weight, volume, or unit of surface area. The example knit construction 300 shown in FIG. 3 can at least partially form an outward-facing surface of a knit textile, e.g., the knit textile 200 shown in FIG. 2A or 2B. In particular, the configuration shown in FIG. 3 could be one that is incorporated as the second area 132 shown in FIGS. 2A and 2B. The knit construction 300 could also be present in the third area 133 shown in FIGS. 2A and 2B. In order to illustrate the example, the knit construction 300 is depicted with six courses 301-306.

As depicted in FIG. 3, each of the courses 301-306 may be knit with a high-melting yarn 310 and a low-melting yarn 312 having a thermoplastic polymer material. That is, the high-melting yarn 310 may have a higher melting temperature than the thermoplastic polymer material of the low-melting yarn 312. In this example, the high-melting yarn 310 is plaited with the low-melting yarn 312, although other methods for knitting the high-melting yarn 310 and the low-melting yarn 312 in the same course may be utilized. In this representative example, each of the courses 301-306 has one end of the high-melting yarn 310 and one end of the low-melting yarn 312. In some aspects, the knit construction 300 may have two ends of the high-melting yarn 310, which may be a high-tenacity polyester yarn, plaited with one end of the low-melting yarn 312 such that the end of the high-melting yarn 310 shown in FIG. 3 may be understood to represent two ends of the same high-melting yarn 310.

Additionally, because the low-melting yarn 312 is plaited with the end of the high-melting yarn 310, the low-melting yarn 312 may maintain a consistent quantity and density of stitches relative to the high-melting yarn 310. This pattern shown in courses 301-306 may be repeated throughout the second area 132 or at least through the second area 132 adjacent the boundary 135. In other words, the second area 132 may have the same number of ends of the low-melting yarn 312 in the toe end 115 of the forefoot region 114 as the forward end 127 of the throat area 126. In some aspects, the second area 132 may have a consistent concentration of the second thermoplastic polymer material from the toe end 115 of the forefoot region 114 to the forward end 127 of the throat area 126.

In some aspects, there may be a change in the concentration of the amount of thermoplastic polymer material, e.g., per unit of surface area, e.g., based on a number of loops of plaited thermoplastic polymer material that are present in a course or per set of courses. In other words, the concentration of thermoplastic polymer material (relative to the low-melting yarn 312) can change from the forward end 127 of the throat area 126 to the back end 128 of the throat area 126. For example, in some aspects, the second area 132 may have a change in the concentration of thermoplastic polymer material (which is referred to herein as the second thermoplastic polymer material) in a lateral direction across the upper 110 (which may correspond to a course-wise direction) such that the second area 132 may have a different concentration of thermoplastic polymer material adjacent the first area 131 (and boundary 135) versus adjacent the biteline 117. For example, a portion of the second area 132 adjacent the first area 131 may have a greater concentration of thermoplastic polymer material than a portion of the second area 132 adjacent the biteline 117 in order to help maintain a straight boundary (e.g., boundary 135) while providing additional comfort and flex to the side of a wearer's foot. It can be appreciated that, in aspects including the third area 133, the third area 133 may have the same or similar features on the medial side 120.

In some aspects, the second area 132 (and the third area 133 where the third area 133 is present) may have a double knit construction. In this case, the front bed and the back bed may be knit with the same number of ends of the high-melting yarn 310 and the low-melting yarn 312. Both sides of the double knit construction may have the same relative concentrations of the low-melting yarn 312 and the high-melting yarn 310. In some aspects, the front needle bed and the back needle bed may each have at least one end of low-melting yarn 312 plaited with one end of high-melting yarn 310 in every course in the same or similar construction as shown in FIG. 3, which may help provide improved durability and precision along the boundary line.

FIG. 4 depicts a part of the knit textile 200 formed using plaited yarns to achieve a desired concentration of thermoplastic polymer material of the first area 131 in the forefoot region 114 of the knit textile 200, in accordance with aspects herein. The example knit construction 400 shown in FIG. 4 can at least partially form an outward-facing surface of the knit textile 200 that may be present in the toe end 115 of the forefoot region 114 in the first area 131. As such, the example knit construction 400 may represent an example of what has been referred to herein as the first concentration of the first thermoplastic polymer material. In order to illustrate the example, the knit construction 400 is depicted with 14 courses 401-414.

As depicted in FIG. 4, each of the courses 401-414 may be a high-melting yarn 421 and, in at least some courses, a low-melting yarn 423 with a thermoplastic polymer material (the “first thermoplastic polymer material”) having a lower melting temperature than the high-melting yarn 421. The high-melting yarn 421 may be the same material (e.g., high-tenacity polyester) as the high-melting yarn 310 of FIG. 3 but, in some aspects, has different visual characteristics, such as a different color.

In the knit construction 400, the high-melting yarn 421 is plaited with the low-melting yarn 423 in every course except every twelfth course, in which the low-melting yarn 423 is omitted. As such, FIG. 3 shows courses 401, 403-412, and 414 with the low-melting yarn 423, and courses 402 and 413 with the low-melting yarn 423 are absent. This example concentration of the thermoplastic polymer material in the toe end 115 of the first area 131 is less than the example concentration of thermoplastic polymer in the second area 132 shown in FIG. 3. This pattern may be repeated in the first area 131 as the first area 131 extends through the forefoot region 114. In some examples, the pattern shown in FIG. 4 extends until the forward end 127 of the throat area 126.

In some aspects, the knit construction 400 may be knitted using two feeders to vary the ends of the high-melting yarn 421 and the low-melting yarn 423 independently of each other. For example, in one example, one feeder has two ends of the high-melting yarn 421 plaited with the low-melting yarn 423 and is used to knit courses 401, 403-412, and 414, and another feeder has two ends of the high-melting yarn 421 without the low-melting yarn 423 and is used to knit courses 402 and 413. In another example, one feeder may knit one or more ends of the high-melting yarn 421 and the other feeder may knit one or more ends of the low-melting yarn. This way, the first yarn may follow a different knit pattern and/or not be knit in all the same courses in order to provide a gradient of the first thermoplastic polymer material within the first area 131.

Additionally, the set of feeders used to knit the first area 131 may be different than the set of feeders used to knit the second area 132, and the third area 133 in some aspects. Using separate feeders may be useful to contain different sets of yarns in each area. The first area 131 may be joined to the second and third areas 132 and 133 through intarsia.

In some aspects, the first area 131 may have a double knit construction. In this case, the front bed and the back bed may be knit with the same number of ends of the high-melting yarn 421 and the low-melting yarn 423 in some but not all of the courses. For example, the back needle bed may be knit with the low-melting yarn 423 in every course (similar to the knit construction 300 in FIG. 3), while the front needle bed may omit the low-melting yarn 423 in every twelfth course, as shown in FIG. 4. Alternatively, both sides of the double knit construction may have the same relative concentrations of the low-melting yarn 423 and the high-melting yarn 421.

In some aspects, the amount of the thermoplastic polymer material may be varied in a manner other than changing the number of courses in which the low-melting yarn 423 is present. For example, the number of ends of the low-melting yarn 423 may vary with respect to other knit constructions. Additionally or alternatively, the type of knit stitches with the low-melting yarn 423 may vary. In some aspects in which the knit construction 400 is a double-bed knit construction, for example, the knit construction 400 may include the low-melting yarn 423 forming interlocking tuck stitches between the front and back knit layers to further increase the amount of the first thermoplastic polymer material in the toe end 115 of the forefoot region 114 in the first area 131. In addition to providing increased durability, interlocking the two needle beds together provides another option for increasing the concentration of thermoplastic polymers in an area of the textile.

FIG. 5 depicts part of the knit textile 200 formed using plaited yarns to achieve a desired concentration of thermoplastic polymer material of the first area 131 in the forward end 127 of the throat area 126 of the knit textile 200, in accordance with aspects herein. The example knit construction 500 shown in FIG. 5 can at least partially form an outward-facing surface of the knit textile 200 and may be present in the forward end 127 of the throat area 126 in the first area 131. As such, the example knit construction 500 may represent an example of what is referred to herein as the second concentration of the first thermoplastic polymer material.

FIG. 5 depicts a sample of courses 501-506, with the same feeder(s) as knit construction 400. As such, FIG. 5 depicts the high-melting yarn 421 and the low-melting yarn 423. As depicted in FIG. 5, every other course (e.g., course 501 and other odd courses) may be knit with the high-melting yarn 421 and may not include the low-melting yarn 423, while the remaining courses (e.g., course 502 and other even courses) may be knit with the high-melting yarn 421 plaited with the low-melting yarn 423. Accordingly, in such an example, the knit construction 500 may comprise the first thermoplastic polymer material in every other course.

This example concentration of thermoplastic polymer material of the first area 131 in the forward end 127 of the throat area is lower than the example concentration of thermoplastic polymer material of the first area 131 in the toe end 115 of the forefoot region 114 depicted in FIG. 4. Additionally, this example concentration of thermoplastic polymer material of the first area 131 in the forward end 127 of the throat area is lower than the example concentration of thermoplastic polymer material in the second area 132 (and in some aspects, the third area 133) depicted in FIG. 3.

In some aspects, the knit construction 500 may be utilized through the throat area 126 such that the back end 128 of the throat area 126 may have the same concentration of thermoplastic polymer as the forward end 127 of the throat area 126. In this way, the concentration of thermoplastic polymer material may be generally consistent throughout the throat area 126.

Alternatively, the concentration of thermoplastic polymer material may change in the first area 131 as the first area 131 extends further through the throat area 126. In this regard, FIGS. 6-7 depict contemplated variations of a part of the knit textile 200 formed using plaited yarns to achieve a desired concentration of thermoplastic polymer material in the back end 128 of the throat area 126 of the first area 131. The example knit constructions 600 and 700 can at least partially form an outward-facing surface of the knit textile 200 in the back end 128 of the throat area 126 in the first area 131 in aspects in which the concentration differs from the forward end 127. As such, these example knit constructions 600 and 700 may represent what has been referred to herein as the third concentration of the first thermoplastic polymer material.

FIGS. 6 and 7 depict a sample of courses (courses 601-606 in FIG. 6 and courses 701-706 in FIG. 7) knit with the same feeder(s) as knit constructions 400 and 500. As such, FIGS. 6 and 7 depict the high-melting yarn 421 and the low-melting yarn 423.

The knit construction 600 of FIG. 6 illustrates an example aspect where the concentration of thermoplastic polymer material increases from the forward end 127 of the throat area 126 to the back end 128 of the throat area 126. In such aspects, the concentration of thermoplastic polymer material in the back end 128 of the throat area 126 may be greater than the concentration of thermoplastic polymer material in the forward end 127 of the throat area 126. As depicted in FIG. 6, one out of every three courses (e.g., courses 603 and 606) includes the high-melting yarn 421 knit without the low-melting yarn 423, while two out of every three courses (e.g., courses 601, 602, 604, and 605) may include the high-melting yarn 421 plaited with the low-melting yarn 423.

The knit construction 700 of FIG. 7 illustrates an example aspect where the concentration of thermoplastic polymer material decreases from the forward end 127 of the throat area 126 to the back end 128 of the throat area 126. In such aspects, the concentration of thermoplastic polymer material in the back end 128 of the throat area 126 may be less than the concentration of thermoplastic polymer material in the forward end 127 of the throat area 126. As depicted in FIG. 7, two out of every three courses (e.g., courses 701, 702, 704, and 705) may be knit with the high-melting yarn 421 and without including the low-melting yarn 423, while one out of every three courses (e.g., courses 703 and 706) may have the high-melting yarn 421 plaited with the low-melting yarn 423.

FIG. 8 depicts a flow diagram of an example method 800 of manufacturing an upper for an article of footwear such as the upper 110. In example aspects, the method 800 includes knitting on a knitting machine, which may be a weft knitting machine, such as a flat knitting machine or a circular weft knitting machine.

At a step 810, a knit textile of unitary construction is formed on the knitting machine. The knit textile, which may be knit textile 200 or 250, may be intended for incorporation into an upper (e.g., upper 110) so that the knit textile may extend through a forefoot region (e.g., forefoot region 114), a midfoot region (midfoot region 116), a heel region (e.g., heel region 118), a medial side (e.g., medial side 120), and a lateral side (e.g., lateral side 122). Step 810 includes knitting a first area (e.g., first area 131) at step 812 and knitting a second area (e.g., second area 132) at step 814.

At step 812, the first area of the upper is knit and may extend continuously from a toe end (e.g., toe end 115) of the forefoot region through the forefoot region and to a forward end (e.g., forward end 127) of a throat area (e.g., throat area 126). The first area may extend at least partially in the medial side and the lateral side. In some aspects, the first area is formed to extend at least partially through the medial side and the lateral side of the knit textile. In some aspects, the first area may be knit to continuously extend from the forward end of the throat area through the throat area and to a back end (e.g., back end 128) of the throat area to form at least a portion of a tongue.

In some aspects, an additional step is included that comprises securing a separately formed tongue component (e.g., tongue component 240) to the knit textile adjacent the forward end of the throat area. In this example, at least part of the first area of the knit textile overlays a portion of an outward-facing surface of the tongue component (e.g., outward-facing surface 241) such that the tongue (e.g., tongue 140) of the upper comprises the tongue component and the first area of the knit textile.

The first area may have a first visual property (e.g., a color). Knitting the first area of the textile at step 812 may include knitting with a first yarn comprising a first thermoplastic polymer material such that the first area may have a first concentration of the first thermoplastic polymer material in the toe end of the forefoot region that is greater than a second concentration of the first thermoplastic polymer material in the forward end of the throat area. Step 812 may be knit in accordance with the knit diagrams in FIGS. 4 and 5 (and in some aspects, FIG. 6 or 7), but it should be understood that these example diagrams represent one example for the different portions of the first area that may be used. Unless otherwise indicated, the first area knit at step 812 may have the same configuration as first area 131, and all such features are not repeated here for brevity.

At step 814, the second area of the upper is knit and may extend directly adjacent the first area from the toe end of the forefoot region to the forward end of the throat area. The second area may have a second visual property (e.g., a color) that is different than the first visual property in the first area. Step 814 may be knit in accordance with the knit diagram in FIG. 3, but it should be understood that FIG. 3 represents one example that may be used for the second area. Unless otherwise indicated, the second area knit at step 814 may have the same configuration as second area 132, and all such features are not repeated here for brevity.

Due at least in part to different knit constructions and/or yarns knit at steps 812 and 814, the first area and the second area may be formed with different concentrations of thermoplastic polymer materials. Particularly, the second area may have a concentration of thermoplastic polymer material that is greater than a concentration of thermoplastic polymer material in the first area (e.g., the toe end of the forefoot region).

Additional steps may include knitting the first area 131 and the second area 132 with separate knit feeders and joining the first area 131 with the second area 132 through intarsia. Intarsia uses separate feeders to knit separate sections of wales across the same course, which allows isolation of separate yarns to separate sections of wales in the same course. For example, one yarn carrier, which may include multiple feeders for separate yarns, generally only traverses across a set of needles intended to be used to form the first area, while a second yarn carrier, which may include one feeder for separate yarns, generally only traverses across a different set of needles intended to be used to form the second area. The two areas may be joined through a variety of ways. In some aspects, the first area in step 812 has overlap with the second area in step 814. For example, tuck stitches may be used such that the yarns of the second area are tucked behind the yarns of the first area for a two-needle overlap. In another example, there is a one-needle overlap.

Additional steps of the method 800 may also include knitting a third area (e.g., third area 133) of the knit textile that may extend on the medial side directly adjacent the first area from the toe end of the forefoot region to the forward end of the throat area. The third area may have a third visual property (e.g., a color) that is different than the first visual property. In some aspects, the third visual property is the same as the second visual property. Unless otherwise indicated, the third area that is knit in some aspects of method 800 may have the same configuration as the third area 133, and all such features of the respective areas are not repeated here for brevity.

Additional aspects of method 800 may include applying one or more additional components to the knit textile, such as a separate skin. Additionally, the knit textile may be formed into the shape of the upper. The method 800 may also include securing the upper to one or more sole structures.

In aspects, an upper can be a flat knitted upper that includes an inner perimeter edge, e.g., extending along a throat and/or a collar of the upper, and an outer perimeter edge, e.g., that extends adjacent to a biteline. In aspects, a knit textile forming at least part of the upper includes a thermoplastic polymer material (e.g., inlaid or formed as plaited yarns). In aspects, the knit textile includes a first area that extends from the biteline to a throat area of the upper, the first area including the thermoplastic polymer material that transitions from a lower concentration proximate to the biteline to a higher concentration proximate to the throat area. The first area can be adjacent to a second area that includes a substantially consistent concentration of the thermoplastic polymer material or a lower degree of transition than the first area.

In aspects, an upper can be a circular knitted upper or a flat knitted upper formed to have a sock-like construction with an underfoot portion. In aspects, a knit textile forming at least part of the upper includes a thermoplastic polymer material (e.g., inlaid or formed as plaited yarns). In aspects, the knit textile includes a first area that extends from the underfoot portion to a throat area of the upper, the first area comprising a thermoplastic polymer material that transitions from a lower concentration proximate to the underfoot portions to a higher concentration proximate to the throat area.

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

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

The following clauses describe various examples of methods for forming an upper for an article of footwear in accordance with aspects of the present disclosure. These clauses are provided to illustrate certain knit-formation processes and structural relationships between regions of the upper. Unless otherwise indicated, the features described in connection with any particular clause or example may be combined with the features of other clauses or examples as appropriate to achieve desired performance, appearance, or manufacturing characteristics.

Clause 1. A method of forming an upper for an article of footwear, the method comprising: forming a knit textile comprising at least part of a forefoot region, a midfoot region, a lateral side, and a medial side, wherein forming the knit textile comprises: knitting a first area of the knit textile, the first area extending from a toe end of the forefoot region, through the forefoot region, and to a forward end of a throat area, and where the first area is formed to comprise a first visual property and a first concentration of a thermoplastic polymer material in the toe end of the forefoot region that is greater than a second concentration of a thermoplastic polymer material in the forward end of the throat area; and knitting a second area of the knit textile, the second area extending adjacent to the first area from the toe end of the forefoot region to the forward end of the throat area, the second area formed to comprise a second visual property that is different than the first visual property.

Clause 2. The method of clause 1, wherein the first area of the knit textile is formed to extend at least partially through the medial side and the lateral side.

Clause 3. The method of clause 1, wherein the second area of the knit textile is formed to extend at least partially through the lateral side.

Clause 4. The method of clause 3, further comprising knitting a third area of the knit textile, the third area extending on the medial side adjacent to the first area from the toe end of the forefoot region to the forward end of the throat area, the third area knit to comprise a third visual property that is different than the first visual property.

Clause 5. The method of clause 4, wherein the first area, the second area, and the third area are knit with separate feeders and joined through intarsia.

Clause 6. The method of clause 4, wherein the third visual property is the same as the second visual property.

Clause 7. The method of clause 1, wherein the first visual property is a color and the second visual property is a color.

Clause 8. The method of clause 1, wherein the first area is knit to continuously extend from the forward end of the throat area through the throat area and to a back end of the throat area to form at least a portion of a tongue.

Clause 9. The method of clause 8, further comprising securing a tongue component to the knit textile adjacent the forward end of the throat area, the first area of the knit textile overlaying a portion of an outward-facing surface of the tongue component, the tongue of the upper comprising the tongue component and the first area of the knit textile.

Clause 10. The method of clause 8, wherein the first area is formed to have a third concentration of thermoplastic polymer material in the back end of the throat area that is greater than the second concentration of thermoplastic polymer material in the forward end of the throat area.

Clause 11. The method of clause 1, wherein the first area is at least partially formed with a first yarn comprising the thermoplastic polymer material, and wherein the first area has a greater quantity of ends of the first yarn in the toe end of the forefoot region than in the forward end of the throat area.

Clause 12. The method of clause 11, wherein the second area is at least partially formed with a second yarn comprising a thermoplastic polymer material, and wherein the second area has the same quantity of ends of the second yarn in the toe end of the forefoot region and the forward end of the throat area.