Patent Description:
The upper of the article of footwear generally extends over the instep and toe areas of the foot, along the media! and lateral sides of the foot, and around the heel area of the foot and in some instances under the foot. Access to the void in the interior of the upper is generally provided by an ankle opening in and/or adjacent to a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the void within the upper. 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 other structures such as, for example, a heel counter to provide support and limit movement of the heel.

<CIT> discloses an upper for an article of footwear. The upper may include a knitted component having a first yarn and a second yarn, where the first yarn comprises a core with a sheath, the sheath being formed of a thermoplastic material having a melting temperature. The second yarn may be substantially free of the thermoplastic material. The knitted component may further comprise a first layer having a first surface and a second layer having a second surface, where the first layer and the second layer are secured via a knit structure of the knitted component.

<CIT> discloses a knitted component formed of unitary knit construction and includes multiple tubular rib structures and multiple webbed areas. An article of footwear may include an upper incorporating a knitted component. The upper may comprise areas with tubular rib structures arranged in different orientations over the forefoot region, the midfoot region, the vamp region, and the heel region. Some regions of the upper may have a greater number of tubular rib structures than other regions, and some tubular rib structures can include tensile elements.

<CIT> discloses an upper that includes a knitted component and a sole structure secured to the upper. The knitted component may define a tube formed of unitary knit construction, and a strand may extend through a length of the tube. The knitted component may have a pair of at least partially coextensive knitted layers formed of unitary knit construction, and a plurality of floating yarns may extend between the knitted layers. In some configurations, the knit type or yarn type may vary in different regions of the knitted component to impart different properties. Additionally, the knitted component may incorporate a thermoplastic yarn that is fused in different regions of the knitted component to impart different properties. A flat knitting process or a variety of other knitting processes may be utilized to form the knitted component.

<CIT> discloses an upper for an article of footwear that includes a textile having fusible filaments or fibers.

<CIT> discloses a knitted component comprising a first surface and a second surface. The first surface faces opposite the second surface. A pod may have the first surface and the second surface, and an edge region may have the first surface and the second surface, where the edge region at least partially demarcates the pod. A first yarn may substantially form the first surface of the pod, where the first yarn is a fusible yarn. A second yarn may substantially form the second surface of the pod, and the second yarn may substantially form the first surface of the edge region.

The objective technical problem to be solved may be considered to consist in overcoming or at least reducing the disadvantages according to the prior art. The problem is solved by the subject matter of the independent claims.

A knitted component is provided according to the subject matter of claim <NUM>.

A method is provided according to the subject matter of claim <NUM>.

<FIG> is an illustration showing an article of footwear <NUM>, and <FIG> is a top view of the article of footwear <NUM> according to background art useful for understanding the invention. Referring to <FIG>, the article of footwear <NUM> may include an upper <NUM>, where the upper <NUM> is substantially formed as a textile component. The textile component may be any suitable type of textile, and in some embodiments it may be formed as a knitted component. As shown, the upper <NUM> may be secured to a sole structure <NUM>. The upper <NUM> may include a lateral side <NUM> and a medial side <NUM>. The area where the sole structure <NUM> joins the upper <NUM> may be referred to as a biteline <NUM>. The upper <NUM> may be joined to the sole structure <NUM> in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, etc. The upper <NUM> may extend partially or completely around a foot of a wearer and/or may be integral with the sole structure <NUM>, and a sockliner may or may not be used. In some configurations, the sole structure <NUM> may include a midsole (not shown) and an outsole. The upper <NUM> may extend under the foot of a wearer and form an underfoot portion, which may be in place of the sole structure <NUM>, if desired.

The upper <NUM> may additionally include a throat area <NUM> extending from and an ankle opening <NUM> leading to the void <NUM>, and a collar <NUM> may at least partially surround an ankle opening <NUM>. The void <NUM> of the article of footwear <NUM> may be configured (e.g., sized and shaped) to receive and accommodate a foot of a person. The throat area <NUM> may be generally disposed in a midfoot area <NUM> of the upper <NUM>. The midfoot area <NUM> of the upper <NUM> may be located between a heel area <NUM> and a toe area <NUM>. In some configurations, an optional tongue (such as the tongue <NUM> shown in <FIG>) may be disposed at least partially in the throat area <NUM>, but no tongue is depicted in <FIG> according to background art useful for understanding the invention. If a tongue is included, the tongue may be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included, the lateral and medial sides of the throat area <NUM> may be joined together.

As depicted in <FIG> according to background art useful for understanding the invention, an outer surface <NUM> of the upper <NUM> be subdivided into two or more generally defined areas referred to as pods <NUM>. The pods <NUM> may be at least partially demarcated by edge regions <NUM> of the upper <NUM>. The edge regions <NUM> may substantially or completely surround at least some of the pods <NUM>. Within a given pod <NUM>, the outer surface <NUM> may be formed primarily of a fused area of material that is heat-processed during the manufacturing of the article of footwear <NUM>. Herein a "fused area" is an area where distinct portion(s) of material forming the upper (e.g., distinct individual strands or yarns formed of thermoplastic polymer material) are partially or substantially melted and then cooled such that the material is bonded together. A fused area is not required to be formed by any specific process. More specific constructions of the pods <NUM> and the surrounding edge regions <NUM> are described in further detail below.

At least a portion of the upper <NUM> may be formed by a knitted component <NUM> (and at least a portion of the knitted component may be referred to as a "knit element"). <FIG> according to background art useful for understanding the invention shows the knitted component <NUM> as it may appear after knitting (e.g., on a flat knitting machine) but before being lasted or otherwise manipulated into a wearable shape in the depicted article of footwear <NUM> of <FIG> according to background art useful for understanding the invention. While the upper <NUM> is described herein as being formed primarily of the knitted component <NUM>, it alternatively or additionally could include a textile component formed by a process other than knitting (e.g., weaving) and may also include other materials including but not limited to leather, plastics, rubbers, and any other materials suitable for incorporation into the upper of an article of footwear.

Forming the upper <NUM> with the knitted component <NUM> may provide the upper <NUM> with advantageous characteristics including, but not limited to, a particular degree of elasticity (for example, as expressed in terms of Young's modulus), breathability, bendability, strength, moisture absorption, weight, abrasion resistance, and/or a combination thereof. These characteristics may be accomplished by selecting a particular single layer or multi-layer knit structure (e.g., a ribbed knit structure, a single jersey knit structure, or a double jersey knit structure), by varying the size and tension of the knit structure, by using one or more yarns formed of a particular material (e.g., a polyester material, a relatively inelastic material, or a relatively elastic material such as spandex), by selecting yarns of a particular size (e.g., denier), and/or a combination thereof.

The knitted component <NUM> 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 of the knitted component <NUM> may be varied at different locations such that the knitted component <NUM> has two or more portions with different properties (e.g., a portion forming the throat area <NUM> of the upper <NUM> may be relatively elastic while another portion may be relatively inelastic). The knitted component <NUM> may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). For example, the knitted component <NUM> may include yarns formed of one or more thermoplastic polymer materials (including material composites) that transition from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to the solid state when cooled. The thermoplastic polymer material(s) may provide the ability to heat and then cool a portion of the knitted component <NUM> to thereby form an area of bonded or continuous material (herein referred to as a "fused area") that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example. Non-limiting examples of thermoplastic polymer materials are polyurethanes, polyamides, polyolefins, and/or nylons.

As shown in <FIG> according to background art useful for understanding the invention, the knitted component <NUM> may substantially form the pods <NUM> and the surrounding edge regions <NUM>. When thermoplastic polymer material is included and configured to be fused during a heat-processing step, the thermoplastic polymer material may be exposed on the outer surface <NUM> of the knitted component <NUM> only at the pods <NUM>, and other materials may be used to form the outer surface <NUM> at the edge regions <NUM>. Thus, once heat is applied to the outer surface <NUM> during a heat-processing step (e.g., steaming or otherwise applying heat after knitting), the result of this process may be the formation of a "shell" on the outer surface <NUM> of the pods <NUM>. The shell may enhance the stiffness, strength, rigidity, durability, and other characteristics of the article of footwear <NUM>. The enhanced characteristics may provide additional support and structure and may bolster or replace other structural elements (such as a heel counter, brio cables, etc.). Certain methods of heat-processing an outer surface of a knitted component are described in detail in <CIT>.

In some situations, the heat-processing of the outer surface <NUM> of the pods <NUM> may cause the melted thermoplastic polymer material to flow over the edge regions <NUM> such that the edge regions <NUM> are at least partially covered by fused material once it has cooled. Alternatively, the fused material may be isolated on the outer surface <NUM> only adjacent to the pods <NUM> and may terminate adjacent to the edge regions <NUM> leaving at least a portion of the outer surface <NUM> free of the fused material at the edge regions <NUM>. Thus, at least after heat-processing, the edge regions <NUM> may have a first degree of flexibility, the pods <NUM> may have a second degree of flexibility, and the first degree of flexibility may be substantially greater than the second degree of flexibility (which may be at least partially attributed to the lack of fused material on the edge regions <NUM>). Similarly, the edge regions <NUM> may have a first degree of stiffness, the pods <NUM> may have a second degree of stiffness, and the first degree of stiffness may be substantially less than the second degree of stiffness. The relative degrees of flexibility and stiffness may be compared by applying a force to the respective components and then measuring the amount of displacement through those same components.

Different pods <NUM> may have identical dimensions, but at least some of the pods <NUM> may have dimensions that are substantially different. Similarly, the edge regions <NUM> may be about the same size throughout the knitted component <NUM>, but alternatively the edge regions <NUM> may vary in size. The sizes and locations of the pods <NUM> and/or the edge regions <NUM> may thus be selected to provide the upper <NUM> with strength, rigidity, protection, and other characteristics where desired, while also providing suitable flexibility, stretchability, and other characteristics at other zones or locations. To illustrate, the pods <NUM> in a first zone <NUM> may be larger, on average, than the pods <NUM> located in a second zone <NUM>, where the first zone <NUM> is located closer to the heel area <NUM> and the second zone <NUM> is located closer to the toe area <NUM>. Thus, the edge regions <NUM> may be more prevalent in the second zone <NUM> than the first zone <NUM> per unit area. As a result, the first zone <NUM> may have a higher degree of strength, rigidity, durability, and stiffness (along with other characteristics associated with the pods <NUM>) while the second zone <NUM> may have a higher degree of flexibility, stretchability, and other characteristics associated with the edge regions <NUM>. It is also contemplated that different pods <NUM> may have different material compositions such that, even correcting for size, the pods <NUM> provide differing degrees of the associated characteristics. To illustrate, a first pod may have a greater density of a thermoplastic polymer material on the outer surface <NUM> than a different second pod, and as a result, the first pod may have a greater degree of stiffness than the second pod.

While not required in all versions, it is contemplated that the substantial entirety of the heel area <NUM> may be constructed in a manner similar to the construction of the pods <NUM> (e.g., such that one large pod <NUM> forms the majority of the heel area <NUM>). Similarly, substantially the entirety of the toe area <NUM> may be formed by a large pod <NUM>. Advantageously, the heel area <NUM> and/or the toe area <NUM> may bolster or replace heel counter and/or toecap elements to thus offer a degree of desirable rigidity, strength, and structural support to a wearer etc. that is desirable in certain applications in contrast, other portions such as the collar <NUM> may be formed with an elastic knit structure, and/or may not be heat-processed, such that the collar <NUM> is configured to stretch when receiving a foot.

Whether formed of the knitted component <NUM> or not, the upper <NUM> may have a single layer or multiple layers. For example, as shown in <FIG> according to background art useful for understanding the invention (showing a side cutout view of one of the pods <NUM>), at least one pod <NUM> of the upper <NUM> may include a first layer <NUM> and a second layer <NUM>, where the first layer <NUM> is an outer layer and the second layer <NUM> is an inner layer nearer the void when incorporated into the article of footwear <NUM>. The knitted component may also have the first surface <NUM> formed by the first layer <NUM> (which may include the outer surface <NUM> of <FIG>) and the second surface <NUM> formed by the second layer <NUM>. The second surface <NUM> and the first surface <NUM> may face in opposite directions. For example, the first surface <NUM> may face outward (e.g., such that it is exposed for viewing when the article of footwear <NUM> is in use), and the second surface <NUM> may face the void, or interior of the article of footwear <NUM>.

The first layer <NUM> may include the above-described fused area, such that it can be considered to have formed a "shell" for providing protection and other desirable properties for the outer surface <NUM>, and the second layer <NUM> may be formed of a material (e.g., elastane, cotton, or polyester) having desirable comfort-related characteristics for contacting a foot or sock of a wearer, such as a desirable elasticity, absorption and/or anti-abrasiveness. A third layer <NUM> may be located in a pocket <NUM> that is formed between the first layer <NUM> and the second layer <NUM>. As described in more detail below, if the upper <NUM> is formed of a knitted component <NUM>, the third layer <NUM> may include an inlaid material located at least partially between the first layer <NUM> and the second layer <NUM>, where the first layer <NUM> and the second layer <NUM> are both knitted layers. The third layer <NUM> may be substantially bonded to the first layer <NUM> due to heat processing of the material of the first layer <NUM>, but this is not required. More or fewer than three layers are also contemplated. For example, as shown in <FIG> according to background art useful for understanding the invention, a fourth layer <NUM> may be located between the second layer <NUM> and the third layer <NUM>, but the fourth layer <NUM> may alternatively be located in any other location.

The fused material forming the first layer <NUM> may be transparent (at least after heat-processing) such that when a viewer looks at the first surface <NUM>, he or she can detect the visual characteristics of the underlying third layer <NUM>. The third layer <NUM> can be formed/manipulated during the manufacturing process to provide desirable visual effects without limitation, as the third layer <NUM> may not have the necessity of providing structural characteristics (which may instead be substantially provided by the first layer <NUM>). However, it is also contemplated that the third layer <NUM> may provide certain structural or other functional characteristics, if desired, such as cushioning. Similarly, the fourth layer <NUM> may provide cushioning and/or other characteristics, such as additional stiffness, or alternatively, such as a water resistant layer, for example, that may be desired in the upper <NUM>. In some embodiments, the thermoplastic polymer material of the first layer <NUM> may not be transparent prior to the heat-processing step, and instead may have a color or may be opaque (e.g., white) and may hide or otherwise obscure the third layer <NUM> from view. This may be advantageous where it is beneficial to easily view the position of the material forming the first layer <NUM> during manufacturing to ensure quality standards are met.

<FIG> according to background art useful for understanding the invention is an illustration showing a detailed side-cutout view of a multi-layer knitted component <NUM> forming the upper <NUM>. The depicted knitted component <NUM> has a first pod <NUM>, a second pod <NUM>, and a third pod <NUM>. The first pod <NUM> and the second pod <NUM> may be separated by a first edge region <NUM>, and the second pod <NUM> and the third pod <NUM> may be separated by a second edge region <NUM>. For illustration purposes, in <FIG>, four yarns (e.g., yarn types having one or more strands) are included: a first yarn <NUM>, a second yarn <NUM>, a third yarn <NUM>, and a fourth yarn <NUM>.

While the yarns <NUM>, <NUM>, <NUM>, <NUM> can be made of any suitable material, the first yarn <NUM> may be at least partially formed with a thermoplastic polymer material having a suitable melting point that is substantially lower than the melting point and decomposition point of the second yarn <NUM> (for example, <NUM> lower or more) and also substantially lower than the melting point and decomposition point of the third yarn <NUM> and fourth yarn <NUM>. Illustrative, non-limiting examples of suitable thermoplastic polymer materials include polyurethanes, polyamides, polyolefins, and nylons. Substantially the entirety of the first yarn <NUM> may be formed of the thermoplastic polymer material, but alternatively the first yarn <NUM> may be a yarn with a thermoplastic polymer sheath with a relatively low melting point surrounded by a core that remains stable at higher temperatures. The melting temperature of the thermoplastic polymer material may be, for example, between about <NUM> and about <NUM>, such as from about <NUM> to about <NUM> based on atmospheric pressure at sea level. In another configuration, the thermoplastic polymer may be a nylon co-polymer with a melting point of between about <NUM> and about <NUM>, such as about <NUM>. Additionally or alternatively, the first yarn <NUM> may include a thermoplastic polyurethane. Additionally or alternatively, the thermoplastic polymer material may be formed of a material that becomes translucent or transparent when raised above its melting point and then cooled.

The second yarn <NUM> may be made from a yarn substantially formed of polyester or a polyester in combination with elastane. Such a yarn may provide elasticity and anti-abrasion that is well suited for forming the inner surface of an upper. The melting point or decomposition point of the material(s) forming the second yarn <NUM> may be relatively high (e.g., above <NUM> or higher, such as <NUM> or higher for certain polyesters) such that the material remains stable during heat processing of the knitted component <NUM>.

Like the second yarn <NUM>, the depicted third yarn <NUM> may be formed of a material that remains stable during heat processing. The third yarn <NUM> may comprise a plurality of polyester yarns having different colors. Advantageously, the third yarn <NUM> may provide a desirable visual effect when the first yarn <NUM> forms a transparent shell on the first surface <NUM> (as described in more detail below). Optionally, the third yarn <NUM> may additionally or alternatively be formed of a material that provides loft within the pockets <NUM> to provide the knitted component <NUM> with a visually-appealing texture where the pods <NUM> extend outward with respect to the edge regions <NUM>. The third yarn <NUM> may include a bulking material that expands in size after the knitting process (e.g., in response to a stimulus, such as heat), thus enhancing the optional loft provided within the pod <NUM>. Such yarns are described in detail in <CIT> and <CIT>.

The fourth yarn <NUM> may be a monofilament yarn, which may be advantageous for providing a durable and inelastic tie (as described in more detail below). Monofilament yarns are formed of a single elongated, continuous filament of a synthetic polymer material. Some monofilament yarns, such as those made of a single filament of an inelastic synthetic polymer material may have substantially no elasticity, or very little, elasticity. For example, a monofilament yarn made of an inelastic synthetic polymer material may have maximum elongation of less than <NUM>% (e.g., the maximum length of the yarn when subjected to a tensile force approaching its breaking force is less than <NUM>% of its length when not subjected to a tensile force), and it is contemplated that a such a yarn could have a maximum elongation of <NUM>%, <NUM>%, or even less.

Referring to the knit construction illustrated in <FIG> according to background art useful for understanding the invention, the knitted component <NUM>, including each of the depicted pods and edge regions, may include the first surface <NUM> (e.g., an outward-facing surface) and the second surface <NUM>. Referring to the second pod <NUM>, the first surface <NUM> may be formed substantially by the first yarn <NUM> such that, when heat-processed, the fusible material of the first yarn <NUM> fuses to form a rigid first surface <NUM>. in contrast, the first surface <NUM> of the first edge region <NUM> may be substantially formed by the second yarn <NUM>. If the second yarn <NUM> is substantially free of fusible material, and/or the material of the second yarn <NUM> has a melting point that is higher than a melting point of the first yarn <NUM>, the edge regions <NUM>, <NUM> may remain relatively flexible with respect to the first pod <NUM> after heat processing (at least on the first surface <NUM>). Similarly, the first surface <NUM> of the second edge region <NUM> may be substantially formed of the second yarn <NUM> and also remain relatively flexible with respect to the second pod <NUM> and third pod <NUM> after heat processing (at least on the first surface <NUM>).

The second surface <NUM> of the knitted component may be substantially formed of the second yarn <NUM> throughout the depicted pods and edge regions. Advantageously, when the second yarn <NUM> is a polyester yarn, for example, the second layer <NUM> may have characteristics that are desirable for facing a void. For example, the second surface <NUM> may have relative softness and/or other comfort-related characteristics that are suitable and desirable for contacting the foot or sock of a wearer. As described in more detail below, this construction may be achieved by utilizing a knitting process that forms a multi-layer structure. For example, within the first, second, and/or third pods <NUM>, <NUM>, <NUM>, the first layer <NUM> having the first surface <NUM> may be substantially formed on a first needle bed of a flat knitting machine, and the second layer <NUM> having the second surface <NUM> may be substantially formed on a second bed of the flat knitting machine such that the pocket <NUM> is formed between the first layer <NUM> and the second layer <NUM>. At least a portion of the second yarn <NUM> may be knit with the first needle bed at the edge regions <NUM>, <NUM>. Other suitable knitting processes are also contemplated (e.g., a technique utilizing transfers between both needle beds). A specific knitting process is described in more detail below with reference to <FIG> according to background art useful for understanding the invention.

The third yarn <NUM> may be a yarn that is inlaid between the first layer <NUM> and the second layer <NUM>. While only one third yarn <NUM> is depicted in <FIG> according to background art useful for understanding the invention, a plurality of yarns may be inlaid between the first layer <NUM> and the second layer <NUM>, and thus the depicted third yarn <NUM> may represent a plurality of yarns in reality (e.g., a plurality of yarn types, and/or a plurality of individual yarns of the same type). The third yarn <NUM> may have one or more visual characteristics to provide the knitted component <NUM> with desirable visual properties. For example, when the knitted component <NUM> is viewed from a perspective looking towards the first surface <NUM>, the third yarn <NUM> may be visible within at least one of the pods <NUM>, <NUM>, <NUM> due to the transparency of the material of the heat-treated first yarn <NUM>. Thus, it is contemplated that the third yarn <NUM> may include a variety of colors, visual textures, patters, or other visual properties that may be deemed visually appealing. Optionally, a material (e.g., a material other than a yarn) may be included within the pocket <NUM> as an alternative to, or in addition to, the third yarn <NUM>. Such a material may enhance the padding or cushioning-related characteristics of the pod. Alternatively, such material may enhance the rigidity or stiffening characteristics of the pod to provide greater structure to the particular region. Once the first yarn <NUM> is heat-processed, the thermoplastic polymer material of the first yarn <NUM> may be at least partially bonded to the third yarn <NUM>.

Optionally, the fourth yarn <NUM> may be included to provide a tie (e.g., a structural connection) between the first layer <NUM> and the second layer <NUM> within the pods <NUM>, <NUM>, <NUM>. The fourth yarn <NUM> may thus be advantageous for providing the pods <NUM>, <NUM>, <NUM> with structural integrity and/or for reducing movement of the third yarn <NUM> within the pod. As described above, the fourth yarn <NUM> may be a monofilament yarn or strand. Advantageously, since monofilament strands are often relatively small in diameter and formed of a transparent material while still having relatively high tenacity and strength, the fourth yarn <NUM> may provide an adequate tie between the layers <NUM>, <NUM> without interrupting the visual characteristics provided by the inlaid third yarn <NUM>. The resulting knit structure of the knitted component <NUM> may have suitable strength, durability, rigidity, and other desirable structural characteristics. In other versions, the fourth yarn <NUM> may be excluded such that the first layer <NUM> and the second layer <NUM> are separable at the pods <NUM>, <NUM>, <NUM>.

<FIG> according to background art useful for understanding the invention illustrates exemplary knit diagrams for the pod and edge regions, respectively, and one skilled in the art would know how to accomplish it based on the diagrams alone. In one example, the sequence identified as "A" on the left side of <FIG> illustrates one knitting sequence that may be used for the pods <NUM>, <NUM>, <NUM> of the knitted component <NUM> as shown in <FIG> according to background art useful for understanding the invention. Similarly, the sequence identified as "B" on the right side of <FIG> illustrates a knitting sequence that may be used to form the edge regions <NUM>, <NUM> of the knitted component <NUM>. As is apparent to a person of ordinary skill in the art, the types of yarns and manner of knitting each yarn may differ between different areas of the knitted component <NUM>, and the sequences depicted and described herein can be slightly or substantially altered to form similar structures.

Referring to sequence "A" of <FIG> according to background art useful for understanding the invention, step <NUM> represents one or more knitting passes of knitting the first yarn <NUM> on every other needle of a first needle bed (e.g., a front bed). In step <NUM>, the third yarn <NUM> may be inlaid between the first needle bed and a second needle bed of the knitting machine. As described in more detail above, the third yarn <NUM> may represent a plurality of strands or yarns which may be inlaid with one pass or multiple passes. For example, the third yarn <NUM> may include eight (<NUM>) inlaid polyester yarns having selected colors or other visual characteristics. In step <NUM>, the fourth yarn <NUM> may be knit to anchor or secure (e.g., "tie") the first layer <NUM> to the second layer <NUM> using tuck stitching. In step <NUM>, the second yarn <NUM> may be knitted on every other needle of the back bed, as shown, with the second yarn <NUM> again being knitted in step <NUM> on the alternate needles of the back bed. In step <NUM>, the third yarn <NUM> may again be inlaid. In step <NUM>, the fourth yarn <NUM> may again be knit to tie the first layer <NUM> to the second layer <NUM>, using tuck stitches. Finally, in step <NUM>, the first yarn <NUM> is knit on every other needle of the front bed that was not used in step <NUM>. The resulting structure may be similar to at least one of the pods <NUM>, <NUM>, <NUM> depicted in <FIG>.

Referring sequence "B" of <FIG> according to background art useful for understanding the invention, which may represent the formation of one of the edge regions <NUM>, <NUM> (shown in <FIG>), step <NUM> may include inlaying the first yarn <NUM>. In step <NUM>, the third yarn <NUM> may be inlaid. In step <NUM>, the fourth yarn <NUM> may be knit to anchor the adjacent yarns using tuck stitching. In step <NUM>, the second yarn <NUM> may be knitted on the back bed, as shown, with the elastic yarn again knitted in step <NUM> on the front bed. In step <NUM>, the third yarn <NUM> may again be inlaid. In step <NUM>, the fourth yarn <NUM> may again be knit to tie yarns using tuck stitches. Finally, in step <NUM> the first yarn <NUM> may be inlaid as shown.

<FIG> according to background art useful for understanding the invention is an illustration showing a top perspective view of another version of an article of footwear <NUM>. As shown, the article of footwear <NUM> may include an upper <NUM> that is formed of a knitted component <NUM>. The upper <NUM> may include a tongue <NUM> extending through a throat area <NUM> of the upper <NUM>. The tongue <NUM> may be formed as a portion of the knitted component <NUM> on a knitting machine, or it may be separately formed and then later attached to the knitted component <NUM> after the knitting process (e.g., via sewing). The article of footwear <NUM> may also include a fastening element. Any suitable type of fastening element may be used, such as the depicted lace <NUM>, a cable-tensioning system, and/or any other suitable device. The upper <NUM> may be configured to secure to and communicate with the fastening element such that the fastening element may adjust and/or tighten the upper <NUM> around a foot of a wearer. For example, the upper <NUM> may include a set of apertures for receiving the fastening element, but other suitable element(s) may alternatively be used.

Like certain configurations described above, the knitted component <NUM> may include one or more pods <NUM>. The pods <NUM> may incorporate any of the characteristics, constructions, or other features described with respect to the versions above. As shown, the pods <NUM> may be located on the knitted component <NUM> on an outer surface <NUM> of the upper <NUM> in a location other than in the throat area <NUM>. Additionally or alternatively, the pods <NUM> may be located on the tongue <NUM>. Advantageously, the pods <NUM> on the tongue <NUM> may provide protection, rigidity, cushioning, durability, and/or other related characteristics in the throat area <NUM> without sacrificing the ability of the upper <NUM> to be tightened around the foot.

<FIG> according to background art useful for understanding the invention is an illustration showing a top view of an embodiment of an article <NUM>. The article <NUM> may be a swatch for an article of apparel. Non-limiting examples of articles of apparel include shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats, and the like. Like the examples above, the article <NUM> may include a plurality of pods <NUM> surrounded by edge regions <NUM>. The article <NUM> may be substantially formed by a knitted component <NUM>. The knitted component <NUM> may include a construction similar to the construction described with respect to the examples above, though other constructions are also contemplated. As shown, the pods <NUM> may include a variety of shapes and sizes. Certain pods <NUM> may be substantially formed as triangles, rectangles, pentagons, hexagons, etc. Optionally, at least some of the pods <NUM> may be demarcated by edge regions <NUM> that are curved, as shown (see, e.g., pod <NUM>).

In some configurations, dimensions of the edge regions <NUM> may vary. For example, a first edge region <NUM> may have a first thickness, a second edge region <NUM> may have a second thickness, and the first thickness may be greater than the second thickness. Advantageously, thicker edge regions may be placed in locations where more flexibility, stretchability, and/or other characteristics are desired. Similarly, larger pods <NUM> may be placed in locations where stiffness, rigidity and/or structure and other related characteristics are desired.

Referring to <FIG>, in some background art useful for understanding the invention, the pods <NUM> of the article <NUM> may have an irregular shape (and in some versions, only one irregular pod may be included). For example, the edge regions <NUM> may extend in an irregular path (e.g., a curved, swerved, jagged, or otherwise non-linear path) through the knitted component <NUM> of the article <NUM>.

<FIG> shows an embodiment according to the present invention of a knitted component <NUM> having an irregular pod with a fused front surface (similar to the above-described pods). Hereafter, the fused front surface (similar to the above-described pods) will be referred to as a "fused surface area <NUM>" for ease of illustration. However, the fused surface area <NUM> may incorporate any of the compatible features from the above-described pods without the tubular knit structures <NUM>, <NUM>, and in some embodiments, certain pods may be included without tubular knit structures in addition to one or more fused surface areas <NUM>. Like the configurations described above, one or more knitted webbed regions <NUM> are located on the first side <NUM> (or front) of the knitted component <NUM> to provide advantageous functional characteristics (e.g., flexibility, stretchability, and/or other functional characteristics) along with unique and desirable visual effects. The webbed regions <NUM> are similar, equivalent, and/or identical to the "edge regions" described above.

<FIG> is an illustration of tubular knit structures <NUM>, <NUM> that are similar or identical to the tubular knit structures <NUM>, <NUM> of the knitted component <NUM> shown in <FIG>. Referring to <FIG>, a first side <NUM> of the tubular knit structures <NUM>, <NUM> is on the first side <NUM>, and thus the front surface <NUM>, of the knitted component, and a second side <NUM> of the tubular knit structures <NUM>, <NUM> is on a second side <NUM>, and back surface, of the knitted component <NUM>. The tubular knit structures <NUM>, <NUM> is formed using a tubular knitting process, as described in more detail below (e.g., with reference to <FIG>). The tubular knit structures <NUM>, <NUM> may generally extend longitudinally in a course-wise direction (e.g., in a direction corresponding to the lengthwise dimension of a plurality of courses forming the knitted component <NUM>). Passages or pockets <NUM> are formed within the tubular knit structures <NUM>, <NUM> between the front surface <NUM> and back surface <NUM>, and (as described in more detail below), the passages receive a floating or inlaid strand <NUM>, which is inlaid in a manner similar to the third yarn <NUM> depicted in <FIG>.

The first side <NUM> of the tubular knit structures <NUM>, <NUM> is formed primarily (or entirely) with a first yarn <NUM>, and the second side <NUM> is formed primarily with a second yarn. The first yarn <NUM> is a yarn including a thermoplastic polymer material configured to be heat-processed. For example, the first yarn <NUM> may include, and may be substantially formed of, a thermoplastic polymer material (such as a polyurethanes, polyamides, polyolefins, nylons, and/or another suitable thermoplastic polymer material). Thus, the melting temperature of the thermoplastic polymer material of the first yarn is between about <NUM> and <NUM>, such as from about <NUM> to about <NUM> based on atmospheric pressure at sea level in another embodiment, the thermoplastic polymer may be a nylon co-polymer with a melting point of between about <NUM> and about <NUM>, such as about <NUM>. Additionally or alternatively, the first yam <NUM> may include a thermoplastic polyurethane. Additionally or alternatively, the thermoplastic polymer material may be formed of a material that becomes translucent or transparent when raised above its melting point and then cooled. As a result, heat-processing the first side <NUM> of the knitted component <NUM> forms a fused area on the front surface, thus enhancing the rigidity, water-resistance, and other characteristics of the front surface.

Further, after heat processing, the front surface of the tubular knit structures <NUM>, <NUM> may be transparent, thus providing a viewer that is looking at the front surface of the first side <NUM> with a unique and desirable visual effect. For example, referring to the tubular knit structure <NUM>, one viewing the front surface <NUM> may see through the transparent first side <NUM> of the tubular knit structure <NUM> and therefore see the interior surface of the second side <NUM> of the tubular knit structure <NUM>. Advantageously, the first yarn <NUM> may be utilized to provide desirable functional characteristics on the front surface <NUM> (regardless of its visual characteristics prior to fusing), and the front side of the fabric can be provided with unique and pleasing aesthetics through colors, textures, patterns, etc. that are imparted by the second yarn <NUM> on the second side of the tubular knit structure <NUM>.

As mentioned in the paragraph above, the second side <NUM> of the tubular knit structure <NUM> is formed with a second yarn <NUM> that is distinct from the first yarn <NUM>. The second yarn <NUM> is a yarn having a relatively high melting point (relative to the first yarn <NUM>), with specific characteristics desirable for the back surface <NUM> of the second side <NUM>. In some embodiments, the second yarn <NUM> may be a multi-filament polyester yarn (e.g., a yarn formed primarily or entirely of a polyester material), which may have a variety of colors for providing unique visual effects (e.g., to the front and/or back surfaces of the knitted component), and which may have characteristics such as softness and anti-abrasiveness that are desirable on a surface that may contact a user (such as an inner surface of an upper for an article of footwear or a skin-contacting surface of an article of apparel).

According to the claimed invention, some (or all) of the tubular knit structures receive an inlaid strand, such as the first tubular knit structure <NUM> that receives the inlaid strand <NUM> in its passage <NUM>. In some embodiments, the inlaid strand <NUM> may be referred to as a "cushioning yarn. " A cushioning yarn, as described herein, may have a full diameter (e.g., when not restricted or compressed) of about <NUM>/<NUM>" or larger, for example, though other cushioning yarns may have other diameters (e.g., <NUM>/<NUM>", <NUM>/<NUM>", or even larger). Two non-limiting exemplary examples of cushioning yarns are a <NUM> denier version and a <NUM> denier version of multifilament polyester yarn that has been texturized to loft. Particular examples are marketed as "LILY" yarns and are sold by Sawada Hong Kong Co. , though other yarns from other manufacturers may also be cushioning yarns. In this application, one or more cushioning yarns are inlaid such that it extends through the passage <NUM> in the first tubular knit structure <NUM>. When the passage <NUM> of a first tubular knit structure <NUM> is intersected by the non-tubular webbed region <NUM>, the inlaid strand may be inlaid through the webbed region <NUM>, or may be incorporated into the knit structure of the webbed region <NUM>. In examples where the inlaid strand <NUM> is a cushioning yarn, the yarn will expand to a natural equilibrium diameter, but will reduce in diameter if pressure is applied to the strand. For instance, if the inlaid strand <NUM> has a natural equilibrium diameter that is less than the diameter of the passage <NUM>, the inlaid strand <NUM> will have a diameter at about the natural equilibrium diameter of the inlaid strand <NUM>. However, if the diameter of the passage <NUM> is less than the natural equilibrium diameter of the inlaid strand <NUM>, the inlaid strand will exert a force from within the passage <NUM> on the second tubular knit structure <NUM>, imparting an amount of loft to the first tubular knit structure <NUM>, adding thickness to the knitted component <NUM>. This thickness in turn may provide for a buffer between the back surface <NUM> and any direct heat source applied to the front surface <NUM> during processing, which may be advantageous for preventing scorching of materials located in yarns forming the back surface <NUM> (if applicable).

The webbed region <NUM> shown in <FIG> utilizes the structures of the above-described webbed regions. The webbed region <NUM> is a location where the tubular knit structures <NUM>, <NUM>, and/or the fused surface region <NUM>, terminate. Further, the webbed region <NUM> extend through multipole courses (e.g., in the wale-wise direction) and has an irregular pattern in one non-limiting embodiment, the webbed region <NUM> is a double jersey knit structure (and/or any structure incorporating two needle beds), where the first yarn <NUM> (i.e., the fusible yarn) is located on the back surface of the second side <NUM> of the knitted component <NUM>. Advantageously, this orientation protects the first yam <NUM> from heat in the webbed region <NUM> (thus substantially preventing it from fusing during heat-processing) such that stretchability and other desirable characteristics of the webbed region <NUM> are not compromised. In this embodiment, the second yarn <NUM> substantially forms the front surface <NUM> in the webbed region <NUM>.

<FIG> is a photograph showing a magnified view of an area of the knitted component <NUM> of <FIG>, which includes tubular knit structures may be constructed in accordance with <FIG>. The knitted component <NUM> includes the second tubular knit structure <NUM>, where the front surface <NUM> is transparent. This transparency is formed due fusing thermoplastic polymer material that was initially incorporated into the first side <NUM> of the first tubular knit structure <NUM> via first yarn (e.g., the first yarn <NUM> of <FIG>). In the photograph, the red color of the second tubular knit structure <NUM> is a characteristic imparted by a second yarn located on the second side (e.g., back side) of the knitted component <NUM> (such as the second yarn <NUM> of <FIG>). In other words, from the perspective of <FIG>, the viewer is looking at the interior surface of the second side <NUM> (<FIG>) of the second tubular knit structure <NUM> since the first side <NUM> (<FIG>) of the second tubular knit structure <NUM> is transparent.

<FIG> also depicts a first tubular knit structure <NUM>, which appears white in the photograph. The white color is a characteristic provided by an inlaid cushioning yarn, such as a "LILY" yarn referenced above. More specifically, the inlaid strand <NUM> of the first tubular knit structure <NUM> is visible since the first side <NUM> (<FIG>) of the first tubular knit structure <NUM> is fused to form a transparent front surface. The second side <NUM> (<FIG>) of the first tubular knit structure <NUM> is not visible since it is blocked by the inlaid strand <NUM> from the perspective of <FIG>.

The knitted component <NUM> of <FIG> also includes a webbed region <NUM> that extends through the knitted component <NUM> in an irregular pattern. The webbed region <NUM> may be selectively placed to impart desirable characteristics (e.g., stretchability) to certain areas of the knitted component <NUM>. The first yarn (e.g., the fusible yarn) may be covered by a third yarn on the first side <NUM> of the knitted component <NUM> in the webbed region, thus protecting the first yarn from fusing during heat processing. In the depicted embodiment, the webbed region is grey, meaning the so-called "third yarn" has a grey color. The "second yarn," or red yarn, may be located behind the grey yarn (e.g., due to a plating technique known in the art where certain yarns on visible on certain sides of the fabric, selectively). Notably, the third yarn may be a yarn that is similar or identical to the second yarn, but having a different color. In other embodiments, the second yarn (e.g., the red yarn in <FIG>) may be on the front surface in the webbed region <NUM>, and it is contemplated that only one colored yarn (e.g., grey or red) may be included in the tubular knit structures <NUM>, <NUM> (e.g., in addition to the fusible yarn). More than two colored yarns may alternatively be included in some embodiments. Further, not all tubular knit structures necessarily include the same colors of yarns, nor the same types of yarns. Furthermore, it is contemplated that some of the tubular knit structures may not have fusible yarns on either surface, and/or some tubular knit structures may have fusible yarns on the back surface (or even both surfaces).

<FIG> is a knit diagram showing a knitting method for forming the second tubular knit structure <NUM> (e.g., as shown in <FIG>). As shown, the first yarn <NUM> is knitted on a first needle bed of the knitting machine, which may be a front needle bed. As described above, the first yarn <NUM> is a fusible first yarn <NUM>. On the second or back needle bed, two polyester yarns are knitted (e.g., the second yarn <NUM> and the third yarn <NUM>). The second yarn <NUM> and the third yarn <NUM> are plated in such a manner that the second yarn <NUM> appears on an interior surface of the second side <NUM> of the second tubular knit structure <NUM>, and thus the third yarn <NUM> will appear on a back surface of the knitted component <NUM>. If the first yarn <NUM> is transparent (or becomes transparent after fusing), the second yarn <NUM> will be visible from a front perspective (as described above). The plating process may be achieved by selecting which feeder (i.e., the feeder of the second yarn <NUM> or the feeder of the third yarn <NUM>) leads the other during knitting. If this sequence is repeated over a number of courses (e.g., two or more courses) prior to locking the front layer from the front needle bed and the back layer from the back needle bed together, the resulting structure is the second tubular knit structure <NUM>.

<FIG> is a knit diagram showing a knitting method for forming a webbed region <NUM>. The webbed region <NUM> is located in the same course as the above-described first tubular knit structure <NUM>, and selectively locating the webbed region <NUM> will selectively form the location and orientation of the webbed region <NUM> on the knitted component <NUM> (e.g., as shown in <FIG>). Referring to <FIG>, the first yarn <NUM> and the second yam <NUM> are knitted on the back needle bed, and the third yarn <NUM> is knitted on the front needle bed. Thus, the third yarn <NUM> will be substantially the only yarn visible from a front viewing perspective in the webbed region <NUM>. Notably, the first yarn <NUM> could float (e.g., be located between the needle beds and not looped, similar to an inlaid strand) rather than knit on the back needle bed, which would locate it between both surfaces (e.g., inside the fabric), which may be advantageous when it is desirable to protect it from heat during heat-processing.

<FIG> are similar to <FIG>, but <FIG> additionally include an inlaid strand <NUM> (e.g., as shown in the first tubular knit structure <NUM> of <FIG>). In <FIG>, the inlaid strand <NUM> is free between the front and back needle beds during knitting (and thus it ends up between two separable layers of the tubular knit structure), and thus expands into its default state with a cushioning diameter (as described above) in contrast, the inlaid strand is compacted when located between the surfaces of the tightly-bound webbed region <NUM>, and it is contemplated that the inlaid strand <NUM> is be visually apparent in this region (as is shown in <FIG>).

Advantageously, by including tubular knit structures and/or cushioning yarns that provide enhanced loft of the tubular knit structures, the knitted component may be heat-processed with a contact-based heat plate (e.g., rather than a steam gun), and such loft of the tubular knit structures will cause the tubular knit structures to contact the heat plate prior to the heat plate making contact with the webbed regions. In effect, the heat plate can avoid scorching or otherwise damaging the yarns on the surface in the webbed region while still providing heat to melt fusible yarn(s) on the front surface of the knitted component. This may also provide the ability for the heat plate to mold texture-proving characteristics in the front surface of the knitted component at select areas.

All of the structures and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While this disclosure may be embodied in many different forms, there are described in detail herein specific aspects of the disclosure. The present disclosure is an exemplification of the principles of the disclosure and is not intended to limit the disclosure to the particular aspects illustrated. In addition, unless expressly stated to the contrary, use of the term "a" is intended to include "at least one" or "one or more. " For example, "a yarn" is intended to include "at least one yarn" or "one or more yarns.

Claim 1:
A knitted component (<NUM>), comprising:
a first side (<NUM>) and an opposite second side (<NUM>);
a first tubular knit structure (<NUM>) having a first portion on the first side (<NUM>) and a second portion on the second side (<NUM>), wherein the first portion is at least partially formed with a first yarn (<NUM>) and wherein the second portion is at least partially formed with a different second yarn (<NUM>), and wherein the first yarn (<NUM>) includes a thermoplastic polymer material with a melting point of <NUM> or less;
wherein the first yarn (<NUM>) is located on the second side (<NUM>) of the knitted component (<NUM>) in a webbed region (<NUM>);
a fused surface region (<NUM>) on the first side (<NUM>) of the knitted component (<NUM>) formed with the thermoplastic polymer material of the first yarn (<NUM>);
the knitted component (<NUM>) being characterised by an inlaid strand (<NUM>) extending through a passage (<NUM>) formed by the first tubular knit structure (<NUM>) between the first portion and the second portion,
wherein the knitted component (<NUM>) includes the webbed region (<NUM>) on the first side (<NUM>) formed of the second yarn (<NUM>), and wherein the first tubular knit structure (<NUM>) and the fused surface region (<NUM>) terminate at the webbed region (<NUM>).