Patent Description:
The upper of the article of footwear generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot 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 a double-sided fabric stacked with a continuous cord material and forming a thickness in a stitched sack comprising an interlayer which is stitched from a face yarn by a flat knitting machine. The stitched sack comprising an interlayer includes therein at least one continuous cord material, which is pressed into the stitched sack comprising an interlayer by right-directed and left-directed stitching pressing pieces to become folded and stacked to form a thickness.

<CIT> discloses an article of footwear which has an upper that includes a knitted component and a sole structure secured to the upper. 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. The knit type or yarn type may vary in different regions of the knitted component to impart different properties.

The present disclosure can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the present disclosure. Moreover, in the figures, like-referenced numerals designate corresponding parts throughout the different views.

Certain aspects of the present disclosure relate to uppers configured for use in an article of footwear and/or other articles, such as articles of apparel. When referring to articles of footwear, the disclosure may describe basketball shoes, running shoes, biking shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennis shoes, and/or walking shoes, as well as footwear styles generally considered non-athletic, including but not limited to dress shoes, loafers, and sandals.

A knitted component for use in articles of footwear is provided according to the subject matter of claim <NUM>.

Background information useful for understanding the invention relates to a knitted component, including: a knit element having a cushioning area and a secured area, where the cushioning area and the secured area have a first surface and an opposite second surface, the first and second surfaces being separable in the cushioning area; and an inlaid yarn extending through the knit element and between the first surface and the second surface in the secured area and the cushioning area, where in the secured area, each of the first and second surfaces is formed by at least a first course and a second course, where in the secured area, the first course and the second course have at least one intermeshed loop, where in the secured area, a first segment of the inlaid yarn extends through the first course in the secured area, and a second segment of the inlaid yarn extends through the second course, where in the cushioning area, the first course is located on a first side of the inlaid yarn such that it forms the first surface, and where in the cushioning area, the second course is located on a second side of the inlaid yarn such that it forms the second surface.

Background information useful for understanding the invention relates to an upper for an article of footwear, the upper including: a knitted component having a knit element formed with a plurality of courses and having a first surface and an opposite second surface, the plurality of courses including a first course and a second course; the first course having a set of first loops and the second course having a set of second loops; an inlaid yarn, extending through at least one of the first course and the second course; and a cushioning area, where in the cushioning area, each of the first loops is located on a first side of the inlaid yarn and forms the first surface, and where in the cushioning area, each of the second loops is located on a second side of the inlaid yarn and forms the second surface.

Background information useful for understanding the invention relates to a knitted component, including: a first layer and a second layer, where the first layer and the second layer are secured via at least one common yarn extending at least partially through a boundary region, where the first layer includes a first cushion, where the second layer includes a second cushion, and where the second layer is inverted with respect to the first layer such that the first layer and the second layer overlap.

Background information useful for understanding the invention relates to an upper for an article of footwear, including: a knitted component having a first layer and a second layer, where the first layer and the second layer are secured via at least one common yarn, where the first layer includes a first cushion, where the second layer includes a second cushion, and where the second layer is inverted with respect to the first layer such that the first layer and the second layer overlap.

Background information useful for understanding the invention relates to an upper for an article of footwear, including: a first layer and a second layer, the first layer forming an exterior surface of the upper and the second layer forming an interior surface of the upper, the first layer and the second layer being at least partially coextensive, where the second layer is formed of a knitted component, the knitting component including a tubular knit structure with an inlaid cushioning yarn extending therethrough to form a first cushion, and where the cushion contacts the first layer.

Background information useful for understanding the invention relates to an article of footwear, including: a knitted component, the knitted component forming at least a portion of an upper and an underfoot area of the article of footwear, where the underfoot area includes at least one cushion, the at least one cushion including an inlaid cushioning yarn extending through a tubular knit construction of the knitted component.

Referring to <FIG>, a knitted component <NUM> suitable for a number of applications, e.g., footwear, apparel, and industrial textiles, is shown. Knitted component <NUM> may be formed as an integral one-piece element from a single knitting process, such as a weft knitting process (e.g., with a flat knitting machine with one, two, or more needle beds, or with a circular knitting machine), a warp knitting process, or any other suitable knitting process. The process that forms knitted component <NUM> may be a hybrid knitting process, in that one or more materials that form knitted component <NUM> are not knitted. For example, one or more materials (e.g., yarns or strands) of knitted component <NUM> may be inlaid. As used in this application, a yarn may include a strand, and is not intended to limit the present disclosure to multifilament materials. The process that forms knitted component <NUM> may substantially form the knit structure of knitted component <NUM> without the need for significant post-knitting processes or steps. Alternatively, two or more portions of knitted component <NUM> may be formed separately as distinct integral one-piece elements, and then the respective elements may be attached.

The primary elements of knitted component <NUM> are a knit element <NUM> and one or more inlaid yarns <NUM>, <NUM>, <NUM>. Knit element <NUM> may incorporate various types of yarn that impart different properties to separate areas of knit element <NUM>. That is, one area of knit element <NUM> may be formed from a first type of yarn that imparts a first set of properties, and another area of knit element <NUM> may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout knit element <NUM> by selecting specific yarns for different areas of knit element <NUM>. The properties that a particular type of yarn will impart to an area of knit element <NUM> partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength.

Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the yarns selected for knit element <NUM> may affect the properties of knit element <NUM>. For example, a yarn forming knit element <NUM> may be a monofilament yarn or a multifilament yarn. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of knit element <NUM>. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of knit element <NUM>.

Knit element <NUM> is formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a variety of courses and wales. That is, knit element <NUM> has the structure of a knit textile. Knit element <NUM> may include at least a first layer <NUM> and a second layer <NUM>. First layer <NUM> and second layer <NUM> may be formed on one or more needle beds of a knitting machine, e.g., a first needle bed and/or a second needle bed. When one or both of first and second layers <NUM>, <NUM> are formed on more than one needle bed, or when first and second layers <NUM>, <NUM> are formed on different needle beds, then resulting knit element <NUM> is a multi-bed knit element. As used in this application, first layer <NUM> may form a first surface <NUM> comprising a first plurality of knit loops, and second layer <NUM> may form a second surface <NUM> comprising a second plurality of knit loops. First layer <NUM> may overlap at least a portion of second layer <NUM>, and first and second layers <NUM>, <NUM> may be coterminous in one or more dimensions; however, first and second layers <NUM>, <NUM> do not need to be coterminous. At least a portion of first layer <NUM> may be freely separable from second layer <NUM>. In other words, first layer <NUM> and second layer <NUM> may have one or more portions with opposite facing surfaces, thereby making those portions of first layer <NUM> freely separable from second layer <NUM>. That is, first surface <NUM> may generally face a first direction, and second surface <NUM> may generally face the opposite direction. Although first layer <NUM> may be freely separable from second layer <NUM> in certain areas, it does not need to be freely separable. For example, knit element <NUM> may include one or more interlayer knit stitches (e.g., stitches formed during the same knitting process and extending between a first needle bed and a second needle bed). Such interlayer knit stitches may be formed by the same yarn(s) that forms first and/or second layers <NUM>, <NUM>, or a different yarn.

In one example, at least one course of yarn may form a portion of both first layer <NUM> and second layer <NUM>, e.g., a knit structure formed on both first and second needle beds that includes the first plurality of knit loops on first surface <NUM> and the second plurality of loops on second surface <NUM>. For example, in an interlock knit structure or similar structure that includes one or more courses having loops formed on both a first and a second needle bed, each course may form at least a part of both first and second layers <NUM>, <NUM>. Alternatively, different courses of yarn may form first and second layers <NUM>, <NUM>, e.g., a first course may form a single jersey first layer on a first needle bed and a second course may form a single jersey second layer on a second needle bed, where at least a portion of the single jersey first layer is separable from the single jersey second layer (e.g., see section B, surfaces <NUM>, <NUM> of <FIG>). Knit element <NUM> may receive additional layers, e.g., to enhance strength, provide cushioning protection, or for other advantages. In various non-limiting applications, first layer <NUM> or second layer <NUM> may correspond with at least part of an outer or inner layer of an article of apparel or industrial textile, an exterior or interior layer of an upper for an article of footwear, or a layer of another application.

First and second layers <NUM>, <NUM> may each include one or more materials selected to impart advantageous properties to knit element <NUM>. For example, first layer <NUM> may eventually correspond with an exterior layer of an article of footwear, such as when the article has been assembled and is configured to accommodate the foot of a wearer, and therefore may include courses of a relatively inelastic first yarn providing abrasion resistance, water resistance and/or durability. Suitable materials for first layer <NUM> may include polyester yarns, e.g., polyester yarns having a maximum tensile strength of at least approximately <NUM>-f (e.g., ranging from approximately <NUM>-f to approximately <NUM>-f) and a linear density of at least approximately <NUM> denier (e.g., ranging from approximately <NUM> to approximately <NUM> ,<NUM> denier). First layer <NUM> may also be weatherized, e.g., it may be formed from yarns having water repellant and or resistant properties or it may have a durable water repellent finish.

Second layer <NUM> may eventually correspond with an interior layer of an article of footwear, such as when the article has been assembled and is configured to accommodate the foot of a wearer, and therefore, second layer <NUM> may include one or more courses of yarn having a relatively soft hand, for example a yarn having a napped finish or otherwise provide breathability and comfort to the wearer.

Additionally or alternatively, second layer <NUM> may include one or more elasticized yarns to give resiliency to knit element <NUM>. The examples are non-limiting and are intended to illustrate the versatility of first and second layers <NUM>, <NUM> which may be formed from the same yarn(s) or different yarns or a combination thereof to provide advantageous properties to the respective layers, and/or different portions, areas or regions of the respective layers, as necessary or desired.

Referring still to <FIG> and also to the representative cutaway view of <FIG> (and it is noted that, in practice, the layers may not be capable of being separated as depicted in <FIG>), knitted component <NUM> may include one or more yarns located between first and second surfaces <NUM>, <NUM> (and also potentially between the first and second layers <NUM>, <NUM> if/when they are included) to reinforce knitted component <NUM>, improve strength (e.g., tensile strength), to impart directional stretch resistance, to enhance compressibility, to create an attractive appearance, to increase resistance to penetration, and/or for other advantages. When incorporated into an upper of an article of footwear, the one or more yarns located between first and second layers <NUM>, <NUM> may assist with securing the upper around the foot, limit deformation in areas of upper (e.g., imparts stretch-resistance), and/or provide cushioning protection to selected areas of the upper, etc. For example, the depicted knitted component <NUM> includes a first inlaid yarn <NUM>, a second inlaid yarn <NUM>, and a third inlaid yarn <NUM>. It will be appreciated that <FIG> is representative; although the optional first layer <NUM> is illustrated as separated from the optional second layer <NUM> (e.g., in order to illustrate the inlaid yarns <NUM>-<NUM>), first layer <NUM> does not need to be freely-separable from second layer <NUM>. Further, the inlaid yarns <NUM>-<NUM> may be formed between first and second surfaces <NUM>, <NUM> as a result of the same process that forms knit element <NUM>. In other words, inlaid yarns <NUM>-<NUM> may be part of the same, integrally-formed knitted component <NUM>. Although inlaid yarns <NUM>-<NUM> generally extend along courses within knit element <NUM>, inlaid yarns <NUM>-<NUM> may also (or alternatively) extend along wales within knit element <NUM>.

Inlaid yarns <NUM>-<NUM> may each include one or more cushioning yarns inlaid within the knit element <NUM>. A cushioning yarn 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 (<NUM>. 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 may be inlaid such that it is placed in front of loops of some yarns and behind others (e.g., between loops formed on a first and a second needle bed). For example, an inlaid cushioning yarn may be placed in front of loops of a second yarn being held on a first needle bed, and behind loops of the second yarn (or a third yarn) being held on a second needle bed. As another example, an inlaid cushioning yarn may be placed in front of first layer <NUM> and behind second layer <NUM>; in such cases, first layer <NUM> and second layer <NUM> may or may not be freely separable. Subsequently, one or more yarns held on the first and second needle beds may be interlooped with additional courses of yarn and/or tucked on another needle bed, thus closing or securing the inlaid yarn within knit element <NUM> and effectively integrating the inlaid yarn into the integrally-knitted structure of knitted component <NUM>. In this way, an inlaid yarn may have portions that are not interlooped with other yarns of knitted component <NUM>, i.e., the inlaid yarn may have portions that may appear to extend straight through at least part of knit element <NUM>. This may be accomplished on a knitting machine, e.g., with a combination feeder or an inlay feeder, for example as described in <CIT>.

The courses of the knit element <NUM> that hold segments of an inlaid cushioning yarn may have a spaced relationship (where a "segment" in this context means a portion of the inlaid cushioning yarn extending through one course). In some examples, a cushioning yarn may be inlaid within two consecutive courses of the knit element <NUM> (e.g., two courses that have intermeshed loops) In other embodiments, at least one course of the knit element <NUM> may be located between segments of an inlaid cushioning yarn, such as one, two, three, four, five, six, seven, eight, nine, ten, or even more courses. For example, when a first segment of a cushioning yarn is inlaid in between loops of a first course of the knit element <NUM>, and when a second segment of that same cushioning yarn is inlaid between loops of a second course of the knit element <NUM> (when no other segments are located between the first and second segments), the first course and the second course may be consecutive, and thus the first course may have loops that are intermeshed with loops of the second course. Alternatively, the first course and the second course may be separated by one, two, three, four, five, six, seven, eight, nine, ten, or even more courses of the knit element <NUM>.

In some embodiments, an inlaid cushioning yarn may extend through the entirety of the knit element <NUM>. For example, first inlaid yarns <NUM> (which is depicted as two yarns inlaid together, each having <NUM> inlaid segments) may extend from first edge <NUM> to second edge <NUM>. Alternatively, some inlaid yarns may extend only partially through the knit element <NUM>, such as second inlaid yarn <NUM> (depicted as one yarn having <NUM> inlaid segments). Further, each inlaid segment of the cushioning yarn may be formed by one continuous yarn (such as inlaid segments 28a and 28b of first inlaid yarn <NUM>, which extends across at least a portion of knit element <NUM> in a snake-like or zig-zag pattern), or by distinct, individual ends of yarn (such as inlaid segments 30a and 30b of third inlaid yarn(s) <NUM>). In either case, one or more segments of cushioning yarn(s) may extend beyond one or more edges of knit element <NUM>, such as inlaid segments 28a and 28b (which form a loop or hair-pin-like turn, for example, to extend back through the knit element <NUM> two or more times in such a pattern) and inlaid segments 30a and 30b.

Suitable yarns forming the courses of the knit element <NUM> (e.g., the loops forming the first layer <NUM> and/or the second layer <NUM>) may include polyester and other compositions formed into yarns having a tenacity in the range of at least approximately six grams-force per denier, e.g., approximately <NUM>-<NUM> grams-force per denier. For example, polyester yarns having linear densities ranging from approximately <NUM>-<NUM> denier and a maximum tensile strength of at least <NUM> ,<NUM> grams-force may be appropriate.

As shown in <FIG>, the knitted component <NUM> is depicted with two areas where the first surface <NUM> and the second surface <NUM> are secured (herein referred to as"secured areas") shown as section A and section C. The secured areas where first surface <NUM> and second surface <NUM> are not separable may be formed with a double jersey knit structure or another knit structure where yarns are manipulated by needles of two needle beds. The inlaid yarn <NUM> may extend through the double jersey knit structure or other suitable structure such that it is relatively secured in place with respect to the first and second surfaces <NUM>, <NUM>. Section B, representing an area of tubular construction where the first surface <NUM> and second surface <NUM> are separable (thus forming a cavity <NUM> therebetween), is depicted between the two secured areas section A and section C. As shown, each of a set of first loops <NUM> forming the first surface are located on a first side of the inlaid yarn <NUM>, and the first loops <NUM>, and the first loops <NUM> are all formed in sequence from the same continuous yarn. Similarly, each of a set of second loops <NUM> forming the second surface <NUM> are located on an opposite second side of the inlaid yarn <NUM>, and the second loops <NUM> are all formed in sequence from the same continuous yarn. The yarns forming the first loops <NUM> and second loops <NUM> may alternate between the first and second sides of the inlaid yarn <NUM> in the secured areas (e.g., section A, C, as shown). The secured areas of knitted component <NUM> (e.g., sections A, C) may be positioned at the sides or edges of the knitted component <NUM>, and additionally or alternatively, may be positioned adjacent to and/or around the unsecured area (e.g., section B).

Inlaid portions of cushioning yarn <NUM> located between first and second surfaces <NUM>, <NUM> may pass from the secured areas (sections A and C) and through the tubular structure in section B. One or more cushioning yarns <NUM> may be inlaid together (e.g., one cushioning yarn <NUM> as shown in <FIG>, or more than one cushioning yarn <NUM> as shown in 3B). In the unsecured area, cushioning yarn(s) <NUM> may be substantially free to expand to, or remain in, a lofted or expanded state such that a maximum diameter may be reached. That is, in the tubular structure of Section B, inlaid segments of cushioning yarn <NUM> have the freedom to extend radially outward to reach their respective maximum diameters. This may push first and second surfaces <NUM>, <NUM> radially outward to form a "pillow-like," and the interior volume or cavity <NUM> between first and second surfaces <NUM>, <NUM> may be filled with the material of the cushioning yarn <NUM>. In contrast, portions of cushioning yarn <NUM> that are located in the secured areas (e.g., sections A, C) are in a relatively restricted or compressed state such that the maximum diameter of the cushioning yarn is not reached. The degree of restriction/compression may be varied by varying the stitch density of the knit element, by varying the elasticity of the yarns forming the knit element <NUM>, etc. In some embodiments, the diameter of the cushioning yarn <NUM> in the unsecured areas (e.g., section B) is at least <NUM>% larger than its diameter in the secured areas (e.g., section A, C), such as twice as large, <NUM> times as large, <NUM> times as large, or even larger. In other words, in the depicted embodiment, the portions of cushioning yarn <NUM> located within the unsecured areas (e.g., section B) are free to expand into a first diameter within the interior volume formed between first and second surfaces <NUM>, <NUM>, while portions of cushioning yarn <NUM> located within the secured areas (e.g., sections A, C) are restricted by the knit element <NUM> to a smaller second diameter. In this manner, the unsecured areas (e.g., section B) may protrude from the secured areas (e.g., sections A, C) that are adjacent to or at least partially surrounding the unsecured areas in a visible manner (e.g., <FIG>).

For example, referring to <FIG>, which show first surface <NUM> and second surface <NUM>, the unsecured areas (e.g., section B) may protrude at least <NUM>/<NUM>" (e.g., <NUM>/<NUM>", <NUM>/<NUM>", or even more) from at least one of first surface <NUM> and second surface <NUM> in the unsecured areas (e.g., section B). In secured areas (e.g., section A and section C), the knitted component <NUM> may be substantially flat on both surfaces <NUM>, <NUM>, and it may appear identical or similar to a knitted component without inlaid cushioning yarns at all (since the cushioning yarns are compressed within the knit element <NUM>).

The ability of inlaid cushioning yarns to reach their respectively-expanded diameters imparts a compressible aspect to the unsecured area (e.g., section B), such that the inlaid cushioning area may be formed. By having the unsecured area surrounded by or adjacent to secured areas, the unsecured area is positioned within a certain zone in the knitted component <NUM>. Further, referring back to <FIG>, while the inlaid cushioning yarns <NUM> may be relatively secured in place with respect to the first and second surfaces <NUM>, <NUM>, the inlaid cushioning yarns <NUM> have some freedom to move relative to first and second surfaces <NUM>, <NUM> within the unsecured area. An advantage of this configuration is that an inlaid cushioning area may be integrally formed within the one-piece knitted component <NUM> during the same process as the entire remainder of the one-piece knitted component <NUM>, without the need for inserting a separate cushioning component into the knitted component <NUM> after knitting processes. Integrally formed knitted components with inlaid cushioning areas provide a variety of advantages over conventional cushioning constructions.

As noted above, conventional cushioning constructions are formed by inserting separate cushioning components into voids within previously formed knitted components. Conventional cushioning components may be composed of foam materials, fluid-filled bladders, or other cushioning elements used singularly or in combination with other elements. As the number and type of cushioning components and voids within knitted components increases, the time and expense associated with transporting, stocking, cutting, and joining (e.g., stitching, bonding) the cushioning components and the voids within knitted components may also increase. Moreover, knitted components with a greater number of separately joined (e.g., inserted) cushioning components may be more difficult to recycle than knitted components with inlaid cushioning yarns. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and type of cushioning components and voids within knitted components increases. By integrally forming a knitted component with inlaid cushioning areas, waste may be decreased, recyclability may be simplified, manufacturing efficiency may be increased, and manufacturing costs may be reduced.

<FIG> shows a knitting sequence that may be utilized to form the integrally-knitted component <NUM> as described above, such as through a weft knitting process (e.g., with a flat knitting machine with one, two, or more needle beds). The non-limiting sequence of <FIG> is illustrated on a weft knitting machine having a first needle bed <NUM> and a second needle bed <NUM>. Loops formed on the first needle bed <NUM> may generally form first surface <NUM> (e.g., as shown in <FIG>) and loops formed on the second needle bed <NUM> may generally form the second surface <NUM> (e.g., <FIG>). The loops may be formed with a yarn <NUM> (e.g., a polyester yarn), and an inlaid yarn <NUM> may be inlaid within the loops. The inlaid yarn <NUM> may be a cushioning yarn as described above. Sections A, B, and C may correspond with like-named sections above (e.g., in <FIG>).

In a first step <NUM> , the machine may form loops of yarn <NUM> on both the first and second needle beds <NUM>, <NUM> with a double jersey knit structure in section A, only on the second needle bed <NUM> in a single jersey knit structure in section B, and then again on both needle beds <NUM>, <NUM> in section C. Next, in a second step <NUM>, the machine may inlay the cushioning yarn <NUM> between the first needle bed <NUM> and second needle bed <NUM>. In a third step <NUM>, another course of yarn <NUM> (which may be a common continuous yarn) may be formed that is similar to the course of first step <NUM> except in section B, the loops of the yarn <NUM> are located on the first needle bed <NUM>. In a fourth step <NUM>, another cushioning yarn <NUM> (or multiple cushioning yarns) may again be inlaid such that the cushioning yarns <NUM> are inlaid in consecutive courses. When these steps are repeated (e.g., steps <NUM>-<NUM> are the same as steps <NUM>-<NUM>, respectively), the resulting knitted component will have two secured areas corresponding with sections A, C where the yarn <NUM> is substantially secured with respect to the first and second surfaces <NUM>, <NUM> (e.g., <FIG>). In section B, the knitted component will have a tubular construction since the loops on the first needle bed <NUM> and the second needle bed <NUM> do not interlock, thereby forming an unsecured area (e.g., cushioning area) in accordance with the above description.

The knit structures formed by the sequence of <FIG> are for illustration only and may differ in the number of needles used, the number of skipped needles, the specific knit structures (e.g., tucks vs. loops), the size of certain sections/areas, etc. By using various knit structures, knitted component <NUM> may incorporate various inlaid cushioning areas with varying dimensions and shapes, thereby imparting specific properties and advantages to different areas of knitted component <NUM>. For example, by varying the number of courses and/or wales of yarn <NUM> within the unsecured area (e.g., section B), the dimension and shape of the cushioning areas may be varied accordingly. Referring to <FIG>, knitted component <NUM> shows various inlaid cushioning areas D-H having different knit structures, different dimensions and shapes, and different degrees of cushioning. For example, cushioning areas D, E, F are similarly in the shape of an ellipse, while cushioning area D has a larger dimension than cushioning areas E and F by incorporating a larger tubular structure in the course-wise direction (e.g., through utilizing more unsecured loops along the courses) within cushioning area D. As another example, cushioning area FI has a larger dimension than cushioning area E by incorporating a larger number of wales and courses within cushioning area Fl. As yet another example, cushioning areas FI and G have different dimensions and shapes by using varying tubular knit constructions or structures with different numbers of wales, different numbers of courses, and/or different numbers of loops.

Moreover, by combining various cushioning yarn types with the knit structures, knitted component <NUM> may impart a range of cushioning and/or stiffness to different areas. In some embodiments, the type of cushioning yarns used for forming inlaid cushioning areas extending between first and second surfaces <NUM>, <NUM> may be varied. For example, by varying the thickness of the cushioning yarns used to form inlaid cushioning areas, the amount or degree of cushioning may be similarly varied. In some cases, by inlaying a thinner cushioning yarn into knit element <NUM>, a smaller degree of compressibility and/or resiliency may be provided between first and second surfaces <NUM>, <NUM> in the cushioning area, thereby making the inlaid cushioning area easier to compress. In other cases, by inlaying a thicker cushioning yarn into knit element <NUM>, a larger degree of compressibility and/or resiliency may be provided between first and second surfaces <NUM>, <NUM> in the cushioning area, thereby making the inlaid cushioning area harder to compress and providing additional or increased padding and/or cushioning.

Additionally or alternatively, the number of cushioning yarns used for forming inlaid cushioning areas extending between first and second surfaces <NUM>, <NUM> may be varied. For example, more than one end of the cushioning yarn may be inlaid together (optionally in a twisted configuration, or not) within a course of knit element <NUM>. By varying the number of cushioning yarns used to extend through each course of the knit element <NUM>, the amount or degree of cushioning may be similarly varied. In some cases, by extending a smaller number of cushioning yarns through each course of the knit element <NUM>, a smaller degree of compressibility and/or resiliency may be provided between first and second surfaces <NUM>, <NUM> in the unsecured area, thereby making the inlaid cushioning area easier to compress. In other cases, by extending a greater number of cushioning yarns through each course of the knit element <NUM> in the unsecured area, a larger degree of resiliency may be provided between first and second surfaces <NUM>, <NUM> in the unsecured area, thereby making the inlaid cushioning area harder to compress and providing additional or increased padding and/or cushioning. Referring back to <FIG>, the inlaid cushioning area (section B) is depicted to illustrate a relatively high degree of cushioning, at least in part, due to more than one cushioning yarn (in this case four) being inlaid through the course of the knit element <NUM> and extending together through the cavity of the unsecured area (section B).

When knitted component <NUM> is incorporated into an upper of an article of footwear, different types of yarns may be selected to impart varying stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, color, and moisture-wicking to different areas of knitted component <NUM>, thereby imparting proper properties and advantages to different areas of the upper. For example, the upper may include inlaid cushioning areas with different levels of cushioning/stiffness at selected locations with respect to the skeletal structure and other anatomy of a wearer's foot to provide cushioning protection and/or stability for the wearer's foot. For example, cushioning areas with a lesser relative stiffness in compression may be positioned at locations most likely to experience impact loads during running and like activities. Cushioning areas with a greater relative stiffness in compression may be positioned at locations where impact loads are unlikely and greater resistance is needed to stabilize the running motion. Cushions of the type described above may be located in any suitable location, such as in a toe area of the upper, a medial and/or lateral side of the upper in a midfoot area, a heel area, a throat area, an ankle area and/or collar area, an external or internal surface layer, etc. Several non-limiting examples are described below for purposes of illustration.

<FIG> show an example of an article of footwear that may be formed with a knitted component <NUM> having cushioning areas, forming cushions <NUM>, <NUM>, <NUM>. The cushions <NUM>, <NUM>, <NUM> may be formed in accordance with the aspects above, and thus the knitted component <NUM> may be integral and have inlaid cushioning yarns that fill a cavity formed within a tubular knit construction of the cushions <NUM>, <NUM>, <NUM>.

As shown in <FIG>, the knitted component <NUM> may include a first layer <NUM> (e.g., an outer layer forming an exterior surface <NUM> of the upper <NUM> ) and a second layer <NUM> (e.g., an inner layer forming an interior surface <NUM> of the upper <NUM> ). The first layer <NUM> may include the first cushion <NUM>. The first cushion may extend along the heel area <NUM> of the upper <NUM> from a lateral side <NUM> to a medial side <NUM> , and the first cushion <NUM> may be exposed and visible on the exterior surface <NUM>. The first cushion <NUM> may also protrude towards the void <NUM>, as shown.

The second layer <NUM> may include the second cushion <NUM> and the third cushion <NUM>. The second and third cushions <NUM>,<NUM> may be located for communication with ankles of a wearer when the article of footwear <NUM> is in use (as depicted by <FIG>). In other embodiments, the second and third cushions <NUM>,<NUM> may be located for communication with the achilles tendon. That is, the second cushion <NUM> may be located just laterally with respect to an achilles of a wearer, and the third cushion <NUM> may be located just medially of the achilles. Advantageously, the second cushion <NUM> and the third cushion <NUM> may provide a comfortable, snug fit (e.g., particularly in the heel area) and may provide enhanced achilles support with respect to other embodiments.

The first layer <NUM> and the second layer <NUM> may overlap such that they are at least partially coextensive. For example, referring to <FIG>, the second layer <NUM> may be inverted with respect to the first layer <NUM> (as described in more detail below), and thus the first cushion <NUM> may contact at least one of the second cushion <NUM> and the third cushion <NUM>. This may be advantageous for providing enhanced cushioning characteristics to the second cushion <NUM> and the third cushion <NUM> since they may be forced, by the first cushion <NUM>, to protrude towards the void <NUM>. In other embodiments, at least one of the second cushion <NUM> and the third cushion <NUM> may be offset with respect to the first cushion <NUM>, and/or at least one of the first cushion <NUM>, the second cushion <NUM> and the third cushion <NUM> may not be included.

<FIG> shows an example of a knitted component <NUM> similar to the knitted component <NUM> of <FIG>, but in a flat orientation (e.g., as it may appear when it is initially removed from a knitting machine and prior to being folded or otherwise manipulated into a shape for use in an article of footwear). Like the above-described knitted component of <FIG>, the knitted component <NUM> of <FIG> includes a first cushion <NUM>, a second cushion <NUM>, and a third cushion <NUM>. The second and third cushions <NUM>, <NUM> are positioned for communication with an achilles tendon of a user, and the first cushion <NUM> is positioned to be exposed on an exterior surface <NUM> (as described above).

The first cushion <NUM> is located in a first layer <NUM>, and the second and third cushions <NUM>, <NUM> are located in a second layer <NUM>. It is noted that the first layer <NUM> and the second layer <NUM> may be knitted at different times, and each have their own sub-layers (e.g., when two needle beds are used, as described above). Thus, the first cushion <NUM> may have a tubular construction with separable surfaces forming an unsecured area, and/or cavity, such that a cushioning yarn can expand into its full diameter. Areas <NUM>, <NUM> may be secured areas that also include the inlaid cushioning yarn (but in a secured configuration where the cushioning yarn's diameter is restricted/compressed by knitted loops). The second cushion <NUM> and/or the third cushion <NUM>, and corresponding areas surrounding the same, may have a similar construction.

As shown, the first layer <NUM> and the second layer <NUM> may be formed with the same integral knitted component <NUM> (e.g., formed together in the knitting machine without being connected via a seam afterwards), and thus the first layer <NUM> and the second layer <NUM> may share a common yarn. The common yarn may be an inlaid yarn and/or a yarn forming knitted loops. For example, the common yarn may form knitted loops at a boundary region <NUM>. The boundary region <NUM> may be the point where the first layer <NUM> meets the second layer <NUM>. Further, the knitted component <NUM> may be folded at the boundary region <NUM> when being manipulated to form an upper for an article of footwear such that the second layer <NUM> becomes inverted with respect to the first layer <NUM>. As a result, the first layer <NUM> and the second layer <NUM> may become coextensive and overlap, and the second cushion <NUM> and/or the third cushion <NUM> may contact the first cushion <NUM> (as shown in <FIG>).

When the knitted component <NUM> is manipulated into its wearable shape, the boundary region <NUM> may be located at the collar <NUM> (see, e.g., boundary region <NUM> of <FIG>). The edge <NUM> of the first layer <NUM> and the edge <NUM> of the second layer <NUM>, which may be terminal edges, may extend towards a sole structure and/or the bottom of the void. In some embodiments, the edge <NUM> of the first layer <NUM> may end proximate a biteline of the article of footwear, and the edge <NUM> of the second layer <NUM> may end near or at the bottom of the void of the article of footwear, though other edge locations are also contemplated.

Optionally, the knitted component <NUM> may include an additional
portion <NUM> with a fourth cushion <NUM>. The additional portion <NUM> may be shaped and positioned (or otherwise configured) to form another surface of the upper, for example a side medial surface, a tongue, a bottom surface, etc. Thus, the fourth cushion <NUM> may be located at a variety of positions of the upper to provide cushioning and/or support in a variety of places. In the depicted embodiment of <FIG>, the additional portion <NUM> may extend to the throat area of the upper, and thus the fourth cushion <NUM> may provide cushioning in the throat area.

In some embodiments, such as the embodiment depicted in <FIG> , an upper <NUM> may include separate knitted components <NUM>, <NUM> that are sewn or otherwise secured together to complete the upper <NUM>. While not shown, additional non-knit elements (and/or additional knitted components) may also be included to complete the shape of the upper. For example, a first knitted component <NUM> (with two layers configured to overlap, similar to the embodiment of <FIG>) may be knitted separately from a second knitted component <NUM>. The second knitted component <NUM> may generally be configured to form a throat area and/or a tongue of the upper, and it may include a throat-area cushion <NUM>. The throat-area cushion <NUM> may have features and characteristics of any of the cushions described above, and may be advantageous for providing a comfortable fit and/or for protecting the top surface of the foot. Other knitted components with cushions for being located in other areas may also be included.

As shown in <FIG>, an upper <NUM>, which may or may not be formed of a knitted component, may be attached to a separate knitted component <NUM> that includes a cushion <NUM> in accordance with the embodiments above. The knitted component <NUM> may be secured to the rest of the upper <NUM> by sewing, using an adhesive, or by any other suitable method. While the knitted component <NUM> can be located at any suitable location, it may be advantageous to locate the knitted component <NUM> in the heel area <NUM> of the article of footwear (as depicted) such to provide enhanced heel cushioning. In other embodiments, the knitted component <NUM> may have more than one cushion (e.g., it may include a pair of achilles cushions, as described above with reference to <FIG>).

<FIG> shows another embodiment of a knitted component <NUM> for forming an upper <NUM>. The knitted component <NUM> includes a lateral underfoot portion <NUM> and a medial underfoot portion <NUM> shaped and positioned to connect at their respective edges <NUM>, <NUM>, therefore forming an underfoot portion of the upper that will be located under the void (and foot of the wearer) when the upper is in use.

Other configurations may also provide an underfoot area.

Claim 1:
A knitted component (<NUM>) for use in articles of footwear, comprising:
a knit element (<NUM>) having a first surface (<NUM>) and an opposite second surface (<NUM>);
an inlaid yarn (<NUM>, <NUM>, <NUM>, <NUM>) extending through the knit element and between the first surface and the second surface;
a secured area where the first surface and the second surfaces are secured together, and where the inlaid yarn is secured by loops (<NUM>, <NUM>) forming the first surface (<NUM>) and the second surface (<NUM>); and
a cushioning area,
wherein the cushioning area includes a tubular construction such that the first surface and the second surface are separable, forming a cavity (<NUM>) therebetween,
wherein the inlaid yarn extends through the cavity formed between the first surface and the second surface, and
wherein the inlaid yarn has a first diameter in the cushioning area, wherein the inlaid yarn has a second diameter in the secured area, and wherein the first diameter is larger than the second diameter.