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. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby 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 a heel counter to limit movement of the heel.

<CIT> discloses a footwear that is knitted seamlessly and includes a base knit fabric portion having a mixed section knitted using a first knitting yarn and a second knitting yarn interwoven along the first knitting yarn. The first knitting yarn is not a heat-fusible yarn, and the second knitting yarn is a heat-fusible yarn having thermal adhesiveness and heat-shrinkable properties.

Knitted fabrics are also known from <CIT> and <CIT>.

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 claim. In one aspect, the present disclosure provides an upper for an article of footwear according to the subject matter of claim <NUM>. This upper includes a first yarn and a second yarn, wherein the first yarn comprises a core with a sheath, the sheath being formed of a thermoplastic material having a melting temperature, a first layer having a first surface and a second layer having a second surface, and a fused area extending along the edge adjacent to the biteline of the upper but terminating adjacent a throat area of the upper.

The thermoplastic polymer material of the sheath may consist essentially of at least one thermoplastic polyurethane. The core of the first yarn may include at least one polyester.

The first layer may be integrally knit with the second layer.

The upper includes a throat area formed by the thermoplastic polymer material extending from an edge of the upper towards the throat area, where the fused area terminates adjacent to the throat area.

An auxiliary component may be formed by a material other than a knitted material and secured to the fused area via the thermoplastic polymer material.

The fused area extends along an edge adjacent to a biteline of the upper.

The fused area terminates adjacent a throat area of the upper.

In another aspect, the present disclosure provides a method of manufacturing an upper for an article of footwear.

The method may further include placing an auxiliary structure in contact with the knitted component and providing an amount of energy to at least one of the auxiliary structure and the knitted component to adhere the auxiliary structure to the knitted component.

The first layer may be at least partially formed on a first bed of a flat knitting machine and the second layer may be at least partially formed on a second bed of the knitting machine.

The relationship and functioning of the various elements may better be understood by reference to the following description. It also should be understood that the drawings are not necessarily to scale, and in certain instances, details may have been omitted that are not necessary for an understanding of aspects disclosed herein.

Certain aspects of the present disclosure relate to uppers configured for use in an article of footwear. The uppers may be used in connection with any type of footwear. Illustrative, non-limiting examples of articles of footwear include a basketball shoe, a biking shoe, a cross-training shoe, a global football (soccer) shoe, an American football shoe, a bowling shoe, a golf shoe, a hiking shoe, a ski or snowboarding boot, a tennis shoe, a running shoe, and a walking shoe. The uppers may also be incorporated into non-athletic footwear and shoes, such as dress shoes, loafers, and sandals.

With respect to <FIG>, an example of an article of footwear <NUM> is generally depicted as including a sole <NUM> and an upper <NUM>. The upper <NUM> may include a lateral side <NUM>, a medial side <NUM>, a heel region <NUM>, a mid-foot region <NUM>, and a toe region <NUM>. The area of the shoe where the sole <NUM> joins the outer edge of the upper <NUM> may be referred to as the biteline <NUM>. The upper <NUM> may be joined to the sole <NUM> in a fixed manner using any suitable technique, such as through the use of an adhesive, bonding, sewing, etc..

In some configurations, the sole <NUM> may include a midsole <NUM> and an outsole <NUM>. The article of footwear may additionally include a throat <NUM> and an ankle opening <NUM>, which may be surrounded by a collar <NUM>. The upper <NUM> may define a void <NUM> of the article of footwear that is configured to receive and accommodate the foot of a user or wearer. The throat <NUM> may generally be disposed in the mid-foot region <NUM> of the upper <NUM>. The mid-foot region <NUM> is depicted as a section of the upper <NUM> located between the heel region <NUM> and a toe region <NUM>.

In <FIG>, a tongue <NUM> is disposed in the throat <NUM> of the shoe, but the tongue <NUM> is an optional component, as is the lace <NUM>. Although the tongue <NUM> depicted in <FIG> is a traditional tongue, the tongue <NUM>, if included, 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 <NUM> may be joined together, for example.

The throat area <NUM> may include one or more loops <NUM> extending from the depicted tensile strands <NUM>. The tensile strands <NUM> are an optional component, and may form lace apertures (e.g., the aperture through the loops <NUM>) to receive a lace and/or may surround lace apertures formed in the layers of the knit element <NUM>. A tensile strand may be a yarn, a cable, a rope, or any other type of strand. A tensile strand may be flexible, but it also may have a substantially fixed length measured from a first end to a second end. As such, the tensile strand can be substantially inelastic. The one or more tensile strands may extend across the upper <NUM> in any direction. The tensile strands can be at least partially inlaid within the knit element <NUM>. The tensile strands may limit the stretch of the knit element. Also, in some aspects, portions of the tensile strands may be exposed from knit element. For example, portions of the tensile strands may extend out of the knit element in the throat region to form loops <NUM>. See, for example, <CIT>, <CIT>, and <CIT>. The tensile strands <NUM> may be placed between the layers of the knit element <NUM>, and/or may be incorporated primarily into any one of the layers at any location of the knit element <NUM>. The tensile strands <NUM> may be fixed within the fused area <NUM> in some configurations, though this is not necessary.

As described in further detail below, the upper <NUM> has a fused area <NUM> at least partially formed of a thermoplastic polymer material. In this description, the term "fused area" generally means an area of the upper <NUM> where distinct portions of material forming the upper (e.g., distinct individual strands or yarns of a knitted component) are partially or substantially bonded together. A "fused area" is not required to be formed by any specific process. In a non-limiting example, two or more separate yarns, including monofilament and/or multifilament yarn, may form a fused area when at least a portion of the separate yarns are bonded such that at least a portion of the separate yarns become continuous with one another. Further, after bonding to form a fused area, the material of the once-separate yarns may become visually or physically indistinguishable, or both.

The fused area <NUM> may have any suitable size and shape, and the upper <NUM> may have multiple fused areas <NUM>. The fused area(s) <NUM> defines a portion of a first surface <NUM> of the upper <NUM>, which is an outer surface. As depicted, a second surface <NUM> of the upper <NUM> is an inner surface at least partially defining the void <NUM> of the article of footwear, and the second surface <NUM> is located at least partially between the fused area <NUM> and the void <NUM> of the article of footwear (such that the fused area <NUM> is separated from the void at least at one location, for example). The fused area <NUM> extends from the biteline <NUM> towards the throat <NUM> and the collar <NUM>. The fused area <NUM> extends along substantially the entirety of the biteline <NUM> (e.g., substantially around the entire perimeter of the article of footwear). As described in more detail below, the fused area <NUM> may be water repellant, water resistant, and/or substantially waterproof.

Referring to <FIG>, the upper <NUM> (shown separate from other elements of the article of footwear of <FIG>) is formed at least partially of a knitted component <NUM> (and at least a portion of the knitted component may be referred to as a "knit element"). As depicted in <FIG>, the upper <NUM> may be substantially or entirely formed of the knitted component <NUM>. While the upper <NUM> is described herein as including the knitted component <NUM>, it 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. The knitted component <NUM> is a multi-layer knitted component. The knitted component <NUM> is a two-layer knitted component with a first layer forming the first surface <NUM> (e.g., outer surface) and a second layer forming the second surface <NUM> (e.g., inner surface) as described in further detail below. According to the claimed invention, the first and second layers both are knitted layers, and they will be referred to herein as the "first layer" and the "second layer.

The first surface <NUM>, which is formed of the first layer, includes at least one fused area <NUM>, and the fused area <NUM> may extend partially or continuously along a perimeter edge <NUM> from the heel region <NUM> on the lateral side <NUM>, around the toe region <NUM>, and back to the heel region <NUM> on the medial side <NUM>. The heel region <NUM> may be a region in the area near the tarsus of a foot of the wearer and does not necessarily have to extend behind the heel of the wearer. The fused area <NUM> may extend continuously along substantially the entirety of the perimeter edge <NUM> such that when the upper <NUM> is incorporated into an article of footwear, the fused area <NUM> provides the article of footwear with water repellence, water resistant, and/or substantially waterproof characteristics above (and also possibly below) the biteline <NUM>. The fused area <NUM> may extend any distance from the perimeter edge <NUM> towards the throat <NUM> and/or the collar <NUM>. In one exemplary embodiment, the fused area <NUM> extends a distance from the edge <NUM> such that the fused area <NUM> covers at least approximately <NUM> millimeters above the biteline <NUM> (see <FIG>) of an article of footwear. In other embodiments, the fused area <NUM> may provide more or less coverage, and it is contemplated that the fused area <NUM> may cover at least approximately <NUM> millimeters, <NUM> centimeter, <NUM> centimeters, or even more above the biteline <NUM>. It is further contemplated that the fused area <NUM> may terminate slightly inward from the terminus of the perimeter edge <NUM> of the upper <NUM>, which may be advantageous when non-fused portions of the upper <NUM> are more suitable for attachment to other elements of the article of footwear (e.g., a midsole). In other words, there may be a border of a non-fused area around at least a portion of the perimeter edge <NUM>.

As shown in exemplary <FIG>, a first yarn <NUM> forms at least a portion of the first (outer) surface <NUM> of the knitted component <NUM>. In this description, the first yarn <NUM> includes a yarn (or multiple yarns) that includes or incorporates a thermoplastic polymer material configured to form the fused area <NUM>. Illustrative, non-limiting examples of thermoplastic polymers include polyurethanes, polyamides, polyolefins, and nylons. In contrast to thermoset polymeric materials (described below), thermoplastic polymers melt when heated and return to a solid state when cooled. More particularly, a thermoplastic polymer transitions from a solid state to a softened or liquid state when subjected to temperatures at or above its melting point, and then the thermoplastic polymer transitions from the softened or liquid state to a solid state when sufficiently cooled below its melting point.

Any portion of the first yarn <NUM> may have one or more thermoplastic polymers (collectively "the thermoplastic polymer material"), and in some embodiments, substantially the entirety of the first yarn <NUM> may be formed of the thermoplastic polymer material. The first yarn <NUM> is a yarn with a polyester core and a thermoplastic polymer sheath. The thermoplastic polymer material of the sheath has a melting temperature less than the melting temperature or decomposition temperature of the polyester core. For example, the melting temperature of the thermoplastic polymer material may have a melting temperature of approximately <NUM> less than the melting temperature of the polyester core in some embodiments, though any other suitable difference in melting temperatures is contemplated. The melting temperature of the polyester core may be about <NUM>, and the decomposition temperature may be about <NUM> or greater. The melting temperature of the thermoplastic polymer 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 an exemplary embodiment, the first yarn <NUM> may include a sheath formed of a thermoplastic polyurethane. The first yarn <NUM> may specifically be a yarn marketed as a Dream-Sil ® thermoplastic polyurethane coated yarn manufactured by Sambu Fine Chemical Co.

The knitted component <NUM> also includes one or more yarns formed of material(s) other than the specific thermoplastic polymer material described above. The depicted second yarn <NUM> is substantially formed of a material that has a melting point (if it is a thermoplastic polymer material) or a decomposition point (if it is a thermoset material) that is higher than the melting point of the first yarn <NUM>. Illustrative, non-limiting examples of types of yarns that may form the second yarn <NUM> include yarns comprising thermoset polymeric materials and natural fibers, such as cotton, silk, and wool, or materials with a relatively high melting point. When subjected to moderate levels of heat, thermoset polymeric materials tend to remain stable. Moreover, when subjected to elevated levels of heat, thermoset polymeric materials and natural fibers may burn or otherwise degrade or decompose. As such, thermoset polymeric materials generally remain in a permanent solid state. In some embodiments, the melting point or decomposition temperature of the second yarn <NUM> is greater than about <NUM> based on atmospheric pressure at sea level. The second yarn <NUM> may also be formed of a material with a melting point higher than that of the first yarn <NUM>, and references to the first yarn as being formed of a thermoplastic polymer material herein do not limit the second yarn from being a separate thermoplastic polymer with a higher melting point, for example. One specific example is a polyester yarn, which may have a melting point of about <NUM>, and a boiling or decomposition point of about <NUM>. It is noted that the second yarn <NUM> may comprise one or multiple yarns with one or multiple properties including yarn(s) with different elasticity, breathability and/or durability characteristics or different visual characteristics, or a combination thereof, for example.

As described above, the knitted component <NUM> has more than one layer. At least a portion of the knitted component <NUM> has two layers: a first layer defining the first surface <NUM> and a second layer defining the second surface <NUM>. While more than two layers could be included, this description generally describes the knitted component <NUM> as having two layers for simplicity of description. Further, it is contemplated that different portions of the knitted component <NUM> could have a different number of layers (e.g., a portion corresponding to the fused area <NUM> may have multiple layers, while a portion corresponding to areas without the fused area <NUM> may have only one layer).

The first and second layers of the knitted component <NUM> are separately formed, and both layers are formed during a knitting manufacturing process. In one example, the first layer defining the first (outer) surface <NUM> and the second layer forming the second (inner) surface <NUM> are formed during a single knitting process (e.g., simultaneously on a knitting machine). The first and second layers are formed on a flat knitting machine with two needle beds. The first layer is primarily formed on a front needle bed, and the second layer is primarily formed on a back needle bed, or vice versa. The knitted component <NUM> has at least one location where the first layer and the second layer are separable and/or form a pocket therebetween, which may be filled with a filler material (e.g., a cushioning material). It is contemplated that the first layer and the second layer may be attached only at the edges of the knitted component <NUM> or the first and second layers may be attached at additional points by a tie stitch at any one or more points on the upper. Further, it is contemplated that the knitted component <NUM> may have some areas where the layers are substantially bound or attached together (in an indistinguishable manner, or not) and other areas where they are separable. Separable first and second layers may be formed by a tubular knitting process where the yarns forming the first layer are knitted only on one bed of a knitting machine and the yarns of the second layer are knitted only on a second bed of the knitting machine.

The first layer defining the first surface <NUM> of the knitted component <NUM> includes the first yarn <NUM> such that the first layer includes a thermoplastic polymer material, at least at locations of the first layer configured for forming the above-described fused area <NUM>. It is also contemplated that the thermoplastic polymer material may additionally be added to the first layer separate from a yarn (e.g., it could be sprayed on or otherwise applied after the knitting process). The first layer of the knitted component <NUM> is formed of the first yarn <NUM>, at least in areas corresponding to the fused area <NUM>. However, other yarns (like the second yarn <NUM>) are additionally or alternatively incorporated into the first layer at certain locations. The amount of the first yarn <NUM> incorporated into the first layer, and/or the quantity of the thermoplastic polymer material included in the first yarn <NUM>, is optimized such that a desirable amount of the thermoplastic polymer material is included at specific and desired areas, including areas corresponding to the fused area <NUM>. For example, if the area of the first layer includes both the first yarn <NUM> and the second yarn <NUM> (or some other combination such that both a thermoplastic polymer material and a different material are included), the ratio of the thermoplastic polymer material to non-thermoplastic polymer materials in that area may be from about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, about <NUM>:<NUM>, and about <NUM>:<NUM>. The first layer also includes areas that substantially exclude the first yarn <NUM> (e.g., in the throat area <NUM>, as depicted in <FIG>).

As shown in <FIG>, at areas corresponding to the fused area <NUM>, the second layer forming the second surface <NUM> of the knitted component <NUM> is formed of the second yarn <NUM>. In exemplary embodiments, the second yarn <NUM> is a polyester yarn. Several different types of yarns with varying properties (e.g., varying stretch, durability and/or breathability properties, deniers, and/or colors or a combination thereof) may be included. There are several advantages that are associated with a second layer being formed of the second yarn <NUM>. In one non-limiting example, the second surface <NUM>, which is configured to face the void <NUM> of the article of footwear, is formed of a yarn including a material that achieves a comfortable inner surface for contacting a foot of a wearer. The second layer may further be formed to have a high degree of elasticity such that selected portions of the article of footwear are relatively elastic, particularly at areas not corresponding with the fused area <NUM>.

When the first layer and the second layer are formed together on a knitting machine, it is contemplated that the two layers have an inverse composition of the thermoplastic polymer material configured to form the fused area and a second material. For example, in the fused area <NUM> (where thermoplastic polymer material is desired on the outer surface <NUM>), approximately <NUM>% or more of the thermoplastic polymer material at that location may be within the first layer forming the outer surface <NUM>, and approximately <NUM>% or less of the thermoplastic polymer material in the second layer forming the inner surface <NUM>. In another area, such as in the throat area <NUM>, most of the thermoplastic polymer material may instead be located in the second layer forming the inner surface <NUM>. Advantageously, the thermoplastic polymer material forms the fused area <NUM> at certain locations during heat processing (as described in more detail below), but the thermoplastic polymer material is shielded from heat applied to the outer surface <NUM> at other areas (such as the throat area <NUM>) thereby preventing fusing where it is not desirable.

The second layer of the knitted component <NUM> is located at least partially between the first layer with a fused area <NUM> and the void <NUM> (shown in <FIG>). This provides a knitted component <NUM> of an upper <NUM> that has the above-described fused areas <NUM> on one side (e.g., the first surface <NUM>), but does not have fused areas on the opposite side (e.g., second surface <NUM>). Advantageously, this knitted component <NUM> provides an article of footwear with both the desired features of the above-described fused area <NUM> (e.g., water repellence, water resistance, and water-proofing) while simultaneously providing advantages associated with the second yarn <NUM> including but not limited to comfort and elasticity. Further, all of the described advantages related to the second layer also apply to the first layer in areas where the fused area <NUM> is not present. It is also contemplated that thermoplastic polymer materials may exhibit advantageous characteristics associated with the second yarn <NUM> when not heat-processed.

The first yarn <NUM> is integrated into the second layer of the knitted component <NUM>. For example, during a knitting process where the first layer and the second layer are substantially formed on different needle beds of a knitting machine, the first yarn <NUM> is knitted on needles of the bed associated with the second layer at selected locations. This physically attaches and/or binds the first layer and the second layer together at one or more points. Additionally or alternatively, by tucking the first yarn <NUM> during the knitting process at a series of locations, a series of floats of the first yarn <NUM> may be formed that extend behind (e.g., inward of) the first layer. Advantageously, these described floats may enhance some of the desirable characteristics of the fused area <NUM> (e.g., water resistance). For example, the floats may reduce and/or eliminate pores within the fused area <NUM> by, for example, extending behind and filling certain areas that may otherwise be porous. It is also contemplated that a fused area may be desirable on the second layer in some instances.

Similarly, the second yarn <NUM> that is generally associated with the second layer of the knitted component <NUM> is knitted on or otherwise moved to the bed associated with the first layer of the knitted component <NUM> at selected locations. This may be advantageous, for example, in areas where the second yarn <NUM> has properties that may provide the first layer of the knitted component <NUM> with particular characteristics (e.g., elasticity, desirable aesthetics, durability, breathability and/or a combination thereof), and/or where the second yarn <NUM> is used to bind the first and second layers of the knitted component <NUM> together at one or more select points throughout the upper <NUM>.

When forming the first and second layers of the knitted component <NUM> on a knitting machine, any suitable knitting sequence may be used. One knitting sequence that has been found to be suitable is shown in <FIG>. Referring to <FIG>, the first pass in a series of knitting passes may include knitting the second yarn <NUM> on every other needle of the back bed <NUM> as shown in step A. Next, in a second pass as shown in step B, another second yarn <NUM> (which may be the same or may be a separate yarn than the one used in the first pass) may be knitted on the back bed <NUM> on the needles not used in step A. Providing two passes of the second yarn <NUM> rather than a single pass on the back bed may provide several advantages, such as a tight, non-porous structure, the ability to vary color configurations on the second surface <NUM> (<FIG>), the ability to control the elasticity of the knitted component <NUM>, and/or the ability to control the softness and other surface characteristics of the second surface <NUM>. The next depicted step, step C, may include knitting the first yarn <NUM> (e.g., the yarn comprising the thermoplastic polymer material) on all of the needles of the front bed <NUM> of the knitting machine. Each pass depicted in steps A-C may be performed in a first direction <NUM> along the needle bed. In step D, now moving in the second direction <NUM>, the first yarn <NUM> may be transferred to the back bed <NUM> on every other needle. Finally, in step E, again moving in the first direction <NUM>, the first yarn <NUM> may be transferred to the back bed on every other needle (on opposite needles with respect to step D). This knitting sequence may then be reversed and repeated as necessary. Again, the knitting sequence described in <FIG> is provided only as a non-limiting example, and any other suitable sequence may be used.

Referring to <FIG>, the upper <NUM> is shown as having a fused area <NUM> that extends from the biteline <NUM> (and/or the edge <NUM> of <FIG>) on the outer perimeter of the knitted component <NUM> towards the throat area <NUM>. The fused area <NUM> terminates adjacent to the throat area <NUM>, and the throat area <NUM> is substantially free of thermoplastic polymer material at least on an outer layer. The first layer at the throat area <NUM> is substantially formed of the second yarn <NUM>, which as described above may be a polyester yarn. This may advantageously provide the throat area <NUM> with desirable elasticity, which may allow the knitted component <NUM> of the upper <NUM> to stretch in the throat area <NUM> to thereby facilitate the entry and removal of a foot of a user within the void <NUM> of the article of footwear and provide a snug fit around the foot. The visual contrast between the throat area <NUM> and the fused area <NUM> may also be aesthetically advantageous.

In some embodiments, the amount and/or the density of the fused and/or non-fused thermoplastic polymer material present in one or more of the layers of the knitted component <NUM> varies. Hereinafter, the term "density" when referring to a fused area refers to the amount (i.e., mass) of fused material (e.g., fused thermoplastic polymer material) per a determined surface area. For example, in the embodiment depicted in <FIG>, the amount and/or density of thermoplastic polymer material included in the outer (first) layer of the knitted component <NUM> may decrease when moving from the biteline <NUM> towards a throat area <NUM> of the article of footwear <NUM>.

To illustrate, the first layer of the knitted component <NUM> is, as shown in <FIG>, fully be formed of a thermoplastic polymer material in an area adjacent to the biteline <NUM>, which is referred to as a first region. In a third region of the knitted component <NUM>, depicted in <FIG> as the transition area <NUM> located between the fused area <NUM> and the throat area <NUM>, the first layer may include a relatively reduced amount of the thermoplastic polymer material (which may be the result of some yarns formed of the thermoplastic polymer material being moved to the second or inner layer in that area). The transition area <NUM> may still include characteristics of the fused area <NUM> (e.g., water repellence, water resistance, water-proofing), but the degree of some of those characteristics may be relatively reduced when moving toward the throat area <NUM> and/or towards the collar <NUM>. A second region, such as the throat area <NUM> and an area adjacent to the collar <NUM> of the knitted component <NUM>, excludes thermoplastic polymer material.

It is also contemplated that instead of (or in addition to) varying the amount of the thermoplastic polymer at different areas of the knitted component <NUM>, different areas of the knitted component <NUM> having the thermoplastic polymer may be processed differently (e.g., more heat and/or pressure may be administered in one or more areas near the biteline <NUM> than near the throat <NUM> during a heat-pressing process). In some embodiments, some selected areas of the knitted component <NUM> having the thermoplastic polymer may not form a fused area at all. For example, while the knitted component <NUM> may comprise the first yarn <NUM> in an outer layer of certain areas where a fused area is not desired, there may be no additional processing (e.g. heat processing or the like) that would result in the formation of a fused area in those areas.

The fused area <NUM> may be water resistant or substantially waterproof. In one testing process performed by the inventors for evaluating one embodiment of an article of footwear with a fused area <NUM> in accordance with this description, the article of footwear was placed in a container of water filled to a level up to <NUM> millimeters above the biteline <NUM> of the article of footwear. The fused area <NUM> extended to above the water level. The article of footwear stayed in the container for two hours. After the two hour time period expired, the article of footwear was removed from the container. No water was detected to have passed through the fused area <NUM>.

Referring to <FIG>, in one non-limiting example, a thermoforming process such as a heat-pressing process may be performed to form the fused area <NUM> from a thermoplastic polymer material. More particularly, a thermoplastic polymer material may be incorporated into the knitted component <NUM> by knitting with above-described first yarn <NUM> having the thermoplastic polymer material.

<FIG> generally depict a heat press <NUM> and associated components. The heat press <NUM> may include a top plate <NUM> and a bottom plate <NUM>. Each of these plates has a surface that may or may not provide heat and may or may not contact a side of the upper <NUM>. The materials used to form the plates are not limited. In some aspects, the plates may include a metal and/or silicone or combination thereof. In some embodiments, the bottom plate <NUM> may be formed of silicone and the top plate <NUM> may be formed of a metal.

In some embodiments, an upper <NUM> may be disposed on the bottom plate <NUM>, and the top plate <NUM> may be lowered until a surface thereof contacts the upper <NUM>. An amount of pressure may be applied by the top plate and since the bottom plate is stationary, the upper <NUM> is at least partially compressed in one or more selected areas. In some aspects, after the top plate is lowered to contact the upper <NUM>, the top plate and the bottom plate remain separated and do not contact each other. The heat press may comprise a stopper (not shown) to prevent the top plate <NUM> and bottom plate <NUM> from making contact with each other.

As shown in <FIG>, a jig <NUM> may be used to hold and/or position the upper <NUM> during the heat pressing process. The jig <NUM> may be a separate element from the heat press <NUM> or the jig <NUM> may be disposed on the bottom plate <NUM> of the heat press <NUM>. The jig <NUM> may have a top section <NUM> and a bottom section <NUM>, which may be formed using any material, such as rubber or metal. If the material used to form the jig <NUM> has a melting temperature, the melting temperature should be above the typical temperature achieved during the heat-pressing process to ensure that the heat-pressing process does not disfigure, alter, damage or otherwise negatively affect the jig <NUM>. The shape and configuration of the jig <NUM> is also not limited. In <FIG>, the shape of the jig <NUM> is generally rectangular. The jig <NUM> may include a positioning device, in this case a plurality of spring-loaded pins <NUM> that is configured to position the upper <NUM>. Here, the shape of the plurality of spring-loaded pins <NUM> is substantially the same as the shape of an upper <NUM> such that it corresponds with the outer perimeter of the upper <NUM>. The upper <NUM> may include a plurality of apertures configured to receive the spring-loaded pins <NUM>, and/or the spring-loaded pins may penetrate through the upper <NUM> to hold the upper <NUM> in position upon and within the jig <NUM>.

The jig <NUM> may further include a pad <NUM> configured to prevent the upper <NUM> from sticking to the heat press <NUM>. The pad may be insulative and/or provide cooling, particularly when the desired fused area (e.g., fused area <NUM> of <FIG>) is located only on one side or one surface of the upper <NUM>. The pad <NUM> may generally be in the shape of the desired fused area of the upper <NUM>. The thickness of the pad <NUM> may reduce the amount of heat applied and even reduce or substantially prevent the areas of the upper <NUM> not corresponding to a fused area (e.g., the throat area) from being pressed, directly heated and/or burned. In one embodiment, the pad <NUM> is formed of Teflon and is approximately <NUM> thick, though any suitable thickness may be used. The spring-loaded pins <NUM> are configured to compress if necessary during the heat-pressing process such that they do not inhibit the pressure applied to the upper <NUM> (e.g., if the spring-loaded pins <NUM> are longer than the thickness of the upper <NUM>). In some embodiments, the jig <NUM> may be configured such that two or more uppers <NUM> can be processed simultaneously. A release paper <NUM> may be placed over the areas corresponding to the fused area of the upper <NUM>, as shown. The release paper is preferably constructed of a material that reduces or prevents the fused area of the upper from sticking to it and therefore, the release paper <NUM> may also prevent the fused area of the upper <NUM> from sticking to the jig <NUM>. The release paper <NUM> may be configured to allow heat to be conducted to the upper <NUM> directly through the release paper <NUM> and without interfering in the heating process.

Next, referring to <FIG>, the jig <NUM> may be closed and placed into the heat press <NUM>. The heat press <NUM> may be preheated to between about <NUM> and about <NUM> (or any other suitable temperature range). The press may then be activated. In one embodiment, the heat press may apply approximately <NUM>/cm^<NUM> of pressure at between about <NUM> and about <NUM> for a period of <NUM> seconds. When subjected to this heat and pressure, the thermoplastic polymer material of the upper <NUM>, such as the thermoplastic polymer material included with a yarn (i.e., the first yarn <NUM> described above), may at least partially melt. As a result, the material originally forming separate yarns of the upper <NUM> may become bonded and/or continuous to form a fused area. Therefore, any one or more areas where the upper <NUM> contains thermoplastic polymer material, and where that material is subjected to a suitable process (such as the heat-pressing process described herein), it is contemplated that a fused area <NUM> will be formed. A thermocouple (not shown) may measure the temperature of the upper <NUM> during this process. Once the upper <NUM> reaches a predetermined temperature (e.g., between about <NUM> and about <NUM>), the heat press <NUM> may open, and the upper <NUM> may be removed. While a heat-pressing process is described, any other suitable process may be used to form the fused areas.

Next, the heated upper <NUM> may go through a cooling process, such as a cold-pressing process. The cooling process may set the fused area of the upper <NUM> or otherwise bring the fused area into a state other than a melted state. Referring to <FIG>, the upper <NUM> may be placed in a cold press <NUM>. A silicon pad <NUM> (which may be any other suitable material) may be placed on one or both sides of the upper <NUM>, and particularly over the heated and/or partially melted areas, to ensure even pressure. The cold press <NUM> may include a refrigeration system, but in some embodiments the cold press <NUM> is at or about at room temperature. When activated, in one non-limiting example, the cold press <NUM> may apply approximately <NUM>-<NUM>/cm^<NUM> of pressure for about <NUM> seconds. During the cold-pressing process, the release paper <NUM> may remain attached to the upper <NUM> to prevent the upper <NUM> from sticking to the cold press <NUM>, though this is not required. Further, while shown without the use of a jig, the cold press <NUM> can be used in conjunction with a jig similar to the jig <NUM> described with respect to the heat-pressing process.

In some embodiments, a heat pressing process may be used to attach an auxiliary component to the upper <NUM>. While not shown, the auxiliary component, which may include a thermoplastic polymer material, may be placed in contact with the upper <NUM> such that it at least partially melts and thereby adheres to the upper <NUM> during the heat-pressing process. Alternatively, or in addition, an auxiliary component may be substantially free of a thermoplastic polymer and may be bonded to the upper <NUM> by placing the auxiliary component in contact with the heated thermoplastic polymer of the upper <NUM>. This may be done in conjunction with the process of forming the fused areas <NUM> (see <FIG>) or may be done at a different time. In one exemplary embodiment of an article of footwear, an auxiliary component <NUM> shown in <FIG> may be adhered to the upper <NUM> during a heat-pressing step. This auxiliary component may provide additional support in the toe area <NUM> of the article of footwear, for example.

Auxiliary components may additionally or alternatively be attached to the upper <NUM> by another suitable process. For example, auxiliary components may be attached with an adhesive, by sewing, by heat-processing, etc. In one example, a high-frequency welding process ("HF welding process") may be used. Referring to the article of footwear <NUM> shown in <FIG>, the plurality of second auxiliary components <NUM> may be attached to the upper using HF welding. The second auxiliary components <NUM> may, like the fused area <NUM>, be at least partially formed of a thermoplastic polymer material that at least partially melts when heated to a certain temperature. During the HF welding process, energy in the form of electromagnetic energy may be provided (for example, by an electrode, not shown) to the second auxiliary components <NUM> and/or the fused area <NUM> which may thereby cause the molecules within the materials of the second auxiliary components <NUM> and/or the fused area <NUM> to move at a high-frequency to generate heat. In one non-limiting example, the electromagnetic energy is supplied at about <NUM>. Any suitable amount of electromagnetic energy may be provided. For example, about <NUM> amperes to about <NUM> amperes may be provided for a period of approximately <NUM> seconds, though any suitable combination of current and time may be used. The generated heat may be sufficient to at least partially melt the second auxiliary components <NUM> and/or the fused area <NUM>. While not necessary, additional thermal energy (i.e., heat) may be provided in another form during the HF welding process. Once cooled, the second auxiliary components <NUM> may be secured to the fused area <NUM>. It is contemplated that the second auxiliary components <NUM> do not necessarily need to be HF welded to the fused area <NUM>, but may rather be HF welded or otherwise secured by mechanical or chemical means to another area of the upper <NUM>.

After the HF welding process (or other process), the upper <NUM> may go through a cooling process, such as the cold-pressing process described above. Other cooling processes may be used. Further, when an HF welding process is used, the HF welding process may be performed before, during, or after a heat-pressing process.

Auxiliary components may have several advantageous characteristics. For example, the auxiliary component <NUM> may provide additional support in the toe area <NUM> of the article of footwear. The second auxiliary components <NUM> may, in one example, provide a texture that is advantageous for gripping another object. An auxiliary component may be any suitable shape, size, and material, may be secured to the article of footwear using any suitable securement process, and may be configured for any function. In some embodiments, auxiliary components may be primarily for aesthetic purposes, including but not limited to design components, labels, tags and/or logos.

Claim 1:
An upper (<NUM>, <NUM>, <NUM>) for an article of footwear (<NUM>, <NUM>), the upper comprising:
a knitted component (<NUM>) having a first yarn (<NUM>) and a second yarn (<NUM>),
wherein the first yarn (<NUM>) comprises a core with a sheath, the sheath being formed of a thermoplastic material having a melting temperature,
wherein the second yarn (<NUM>) is free of the thermoplastic material, wherein the second yarn (<NUM>) has a melting point or decomposition temperature higher than the melting point of the first yarn (<NUM>),
wherein the knitted component (<NUM>) further comprises a first layer having a first surface (<NUM>) and a second layer having a second surface (<NUM>), wherein the first surface (<NUM>) forms an outer surface of the upper (<NUM>, <NUM>, <NUM>) when the upper (<NUM>, <NUM>, <NUM>) is incorporated into the article of footwear (<NUM>, <NUM>), wherein the first layer and the second layer are secured via a knit structure of the knitted component (<NUM>),
wherein the knitted component (<NUM>) further comprises a first region extending along an edge adjacent to a biteline (<NUM>) of the upper (<NUM>, <NUM>, <NUM>) when the upper (<NUM>, <NUM>, <NUM>) is incorporated into the article of footwear (<NUM>, <NUM>, <NUM>) and a second region extending along a throat area (<NUM>) when the upper (<NUM>, <NUM>, <NUM>) is incorporated into the article of footwear (<NUM>, <NUM>),
wherein the upper (<NUM>) is characterized in that the first region comprises the first surface (<NUM>) formed by the first yarn (<NUM>) and the second surface (<NUM>) formed by the second yarn (<NUM>), wherein the first layer excludes the first yarn (<NUM>) in the second region,
wherein a fused area (<NUM>, <NUM>) extending along the edge adjacent to the biteline (<NUM>) of the upper (<NUM>, <NUM>, <NUM>) when the upper (<NUM>, <NUM>, <NUM>) is incorporated into the article of footwear (<NUM>, <NUM>) is formed by the thermoplastic polymer material from the first layer in the first region, and wherein the fused area (<NUM>, <NUM>) terminates adjacent the throat area (<NUM>) of the upper (<NUM>, <NUM>, <NUM>) when the upper (<NUM>, <NUM>, <NUM>) is incorporated into the article of footwear (<NUM>, <NUM>).