Patent Description:
The objective technical problem to be solved may be considered to consist in overcoming or at least reducing the disadvantages according to the prior art. The problem is solved by the subject matter of the independent claims. A knitted component is provided according to the subject matter of claim <NUM>.

Background information useful for understanding the present claimed invention relates to an upper which may include a knit layer at least partially formed by a course of a first yarn type and having multi -bed construction. The knit layer may include a first surface, a cavity formed within the knit layer that is recessed relative to the first surface, and a first course of a second yarn type that may include a first knit stitch and a first float that extends across the cavity, wherein the first knit stitch may be integrally knit with the knit layer. The first float may have a first length and may be exposed, e.g., from a viewing perspective facing the first surface. The first course of the second yarn type may extend from a medial region to a lateral region, and may extend from one of the medial region and the lateral region to a throat region. The upper may further include a second course of the second yarn type that may include a second float that extends across a second cavity. The second course of the second yarn type may be spaced apart from the first course of the second yarn type by a first distance that is at least <NUM>. The second float may have a second length. The upper may further include a third course and a fourth course of the second yarn type that are spaced apart from each other by a second distance. The first and second courses of the second yarn type may be located in a first region of the upper and the third and fourth courses of the second yarn type may be located in a second region of the upper. The upper may further include a sole structure that is secured to the knit layer.

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

Other systems, methods, features and advantages of the present disclosure will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be within the scope of the present disclosure, and be encompassed by the following claims.

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.

Referring to <FIG>, a knitted component <NUM> suitable for a number of applications, e.g., footwear and apparel, 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. That is, a knitting process on a knitting machine 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.

Knitted component <NUM> may include at least a first layer <NUM> formed on one or more needle beds, e.g., a first needle bed and/or a second needle bed. The knitted component <NUM> may optionally include one or more additional knit layers that may overlap and may be coterminous in one or more dimensions with first layer <NUM>, e.g., to add cushioning, protection, or for other advantage. When the first layer <NUM> is formed on more than one needle bed, or when the knitted component <NUM> includes one or more additional layers that are formed on a different needle bed than the first layer <NUM>, then the resulting knitted component <NUM> has multi -bed knit construction. As used in this application, a first layer may form a first surface comprising a first plurality of knit loops, and second layer may form a second surface comprising a second plurality of knit loops. In examples with more than one layer, the first layer may overlap at least a portion of a second layer, and the first and second layers may be coterminous in one or more dimensions; however, the first and second layers need not be coterminous. At least a portion of the first layer may be freely separable from the second layer. In other words, the first layer and second layer may have opposite facing surfaces, thereby making at least a portion of the first layer freely separable from second layer. That is, the first layer may have a first surface generally facing a first direction, and a second surface generally facing the opposite direction. Likewise for the second area. Although the first layer may be freely separable from the second layer in certain areas, it need not be freely separable. For example, the knitted component may include one or more interlayer knit stitches (e.g., stitches formed between a first needle bed and a second needle bed). Such interlayer knit stitches may be formed by the same yarn(s) that forms the first and/or second layers, or a different yarn. A single course of material may form at least a portion of both first layer and second layer, e.g., a knit structure formed on both first and second needle beds that includes a first plurality of knit loops on the first surface and a second plurality of loops on the second surface. For example, in an interlock knit structure or similar structure with each course having loops formed on a first and a second needle bed, each course may form part of the first and second layers. Alternatively, different courses of material may form first and second layers, 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. In other examples, the knitted component may include additional layers, e.g., to add cushioning, protection, or for other advantage. In various applications, the first layer or second layer may correspond with 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 an exterior or interior layer of a component or product used in another application.

In <FIG>, first layer <NUM> may have a first surface <NUM> and a second surface <NUM>. First surface <NUM> may eventually correspond with an outer or inner layer of an article of apparel, an exterior or interior layer of an upper for an article of footwear, or other application. As first surface <NUM> may correspond with an outer or an inner surface of knitted component <NUM>, features of knitted component <NUM> that do not form part of the outer or inner surface may not form part of first surface <NUM>, even if formed by the same material(s) that form first surface <NUM>. For example, one or more cavities in knitted component <NUM> (described below) may be at least partially formed from the same material(s) that form first surface <NUM>, but the cavities themselves may not form part of first surface <NUM>, e.g., because they are set back relative to the outer or inner surfaces. Thus, first surface <NUM> may be a reference point for other features of knitted component <NUM>.

The first surface <NUM> is at least partially formed by a first yarn type <NUM>. The first surface <NUM> may include additional materials in addition to the first yarn type <NUM>. While first surface <NUM> is at least partially formed of courses of first yarn type <NUM>, not all courses of first yarn type <NUM>, or even all of a single course of first yarn type <NUM>, necessarily form part of first surface <NUM>. Consistent with the preceding paragraph, one or more courses of first yarn type <NUM> may form aspects of knitted component <NUM> that are recessed relative to first surface <NUM>. First yarn type <NUM> may be selected for different applications. For example, first yarn type <NUM> may be selected for durability, e.g., yarns with tensile strength ranging from approximately <NUM> N (<NUM>-f) to approximately <NUM> N (<NUM>-f). Additionally or alternatively, first yarn type <NUM> may have moderate stretch, e.g., yarns or strands (including elasticized yarns or strands) with approximately <NUM> percent to approximately <NUM> percent maximum elongation. Additionally, first yarn type <NUM> may be weatherized, such as yarns or strands having water repellent or resistant properties (e.g., due to a durable water repellent coating). These examples are non-limiting and are intended to illustrate the versatility of first yarn type <NUM>, which may be selected to provide advantageous properties to one or more layers, portions, areas and/or regions of a knitted component.

Referring still to <FIG>, first layer <NUM> includes one or more cavities (e.g., cavity <NUM>) that are recessed relative to first surface <NUM> and may be formed anywhere upon or within first layer <NUM>. The cavities may protect other aspects of knitted component <NUM>. Not all cavities necessarily have the same characteristics. Cavity <NUM> has the appearance of a depression having a depth, d, relative to first surface <NUM>, although in other examples, cavities may resemble a recess, blind hole, dent, slot, or similar feature with depth relative to first surface <NUM>, and may have a shape that is approximately square, rectangular, elliptical, hyperbolic, or irregular. Cavity <NUM> has a cavity surface <NUM> that generally corresponds with the extent of its depth. That is, the maximum depth of cavity <NUM> generally corresponds with the extent to which cavity surface <NUM> is recessed relative to first surface <NUM>, and may be at least <NUM>, and may range from approximately <NUM> to approximately <NUM>, e.g., between <NUM> and <NUM>, inclusive. Generally, the depth within a single cavity varies. In the embodiment according to the claimed invention of <FIG>, a knit component <NUM> includes a first surface <NUM> and a cavity <NUM> having a sloped cavity surface <NUM>. Consequently, the depth of cavity <NUM> is zero at one side of cavity <NUM> and gradually increases to a maximum depth at another side. A float <NUM> of a course <NUM> of a second yarn type extends across cavity <NUM> and interloops with knitted component <NUM> on either side of cavity <NUM>. In other examples not forming part of the claimed invention, cavity surfaces may be flat, contoured, or have another profile. Referring again to <FIG>, cavity <NUM> has a height, h, ranging from approximately <NUM> to approximately <NUM> or greater. Cavity <NUM> also has a width, w, that may be at least <NUM>, and may range from approximately <NUM> to approximately <NUM> or greater, e.g., between <NUM> and <NUM>, inclusive. Any of the foregoing dimensions may vary between cavities in the same or different embodiments or examples. For example, knit component <NUM> also includes cavity <NUM>, which has a different depth than cavity <NUM>.

Knitted component <NUM> includes a plurality <NUM> of cavities (e.g., cavities <NUM>, <NUM>) that extend in a course-wise direction (e.g., a single course of first yarn type <NUM> forms at least part of more than one cavity) and in a wale-wise direction (e.g., the plurality <NUM> is formed by more than one course of first yarn type <NUM>), forming a pattern. Along a single course of first yarn type <NUM> or between courses of first yarn type <NUM>, each cavity of the plurality <NUM> may have the same or different dimensions (i.e., depth, width, and height). In other embodiments, pluralities of cavities may form different patterns, e.g., patterns that extend diagonally relative to one or more edges of the knitted component, patterns that form geometric or irregular groups of cavities, etc..

As noted above, cavities may protect other aspects of knitted component <NUM>. In particular, each cavity (e.g., cavity <NUM>) may protect one or more portions of a course of a second yarn type <NUM> (such as floats) that extend across the cavity when knitted as described below. Second yarn type <NUM> may be selected to have relatively high tensile strength in order to impart additional strength and stretch resistance to knitted component <NUM>. Alternatively, second yarn type <NUM> may be knitted to have a relatively high degree of elasticity in order to impart resiliency to knitted component <NUM>. Additionally or alternatively, second yarn type <NUM> may be selected to have one or more different visual properties relative to first yarn type <NUM> or another useful property, e.g., reflectivity, a different color, a different texture, or other visual property. For example, suitable material for second yarn type <NUM> may include thermoplastic polymer yarns such as a reflective thermoplastic polyurethane yarn, multi -filament polyester yarns, monofilament strands, etc. Such yarns may be coated or treated to prevent fibrillation during the knitting process.

Knitted component <NUM> contains a plurality of courses of second yarn type <NUM> (e.g., a first course <NUM> and a second course <NUM>), each of which may be parallel to one or more other courses of second yarn type <NUM>. In some embodiments, the knitted component may include a first and second course of second yarn type that are spaced apart by a first distance (e.g., <NUM>-<NUM>), and may also contain third and fourth course that are spaced apart by a second distance, which may be the same or different from the first distance (e.g., <NUM>-<NUM>). In <FIG>, first course <NUM> and second course <NUM> are located near each other (in the same region of knitted component <NUM>), although in other examples, courses of second yarn type <NUM> may be located in different regions of the knitted component. If the knitted component includes one or more gores or wedges (not shown), then it is possible for courses of second yarn type <NUM> to have non -parallel orientations.

Referring still to <FIG>, courses of second yarn type <NUM>, <NUM> are knitted into knitted component <NUM>, i.e., interlooped with one or more other courses that form knitted component <NUM>. Referring to <FIG> for example, course <NUM> of second yarn type <NUM> may include at least one stitch, for example first stitch <NUM> and second stitch <NUM> (shown in hidden lines), that is integrally knitted with one or more courses of first yarn type <NUM>. Advantageously, knitting one or more courses of second yarn type <NUM> into knit component <NUM> fixes the course-wise position of at least a portion of that course. By comparison, an inlaid course of second yarn type <NUM> (without stitches), would be vulnerable to translating within the knitted component in course-wise directions. Stitches <NUM>, <NUM> are adjacent to floats <NUM>, <NUM> that are free of knit stitches as a result of skipping one or more needles. Each course of second yarn type <NUM> may alternate between stitches and floats, such that one or more floats is bounded by stitches. Each stitch of each course of second yarn type <NUM> (e.g., stitches <NUM>, <NUM>) may be formed on one or more needle beds, e.g., a first needle bed or a second needle bed. Forming stitches on the second needle bed with a float in between may cause the float to be recessed relative to the first surface, and may further cause the stitches to be concealed from a viewpoint facing first surface <NUM>. For example, stitches <NUM>, <NUM> may be formed on a second needle bed, and therefore are concealed from a viewpoint <NUM> facing first surface <NUM>.

Each float of second yarn type <NUM> (e.g., floats <NUM>, <NUM>) may have a float length that may be characterized as the distance along the float between bounding stitches or by the number of needles skipped. For example, float <NUM> has a float length that corresponds to the distance along float <NUM> between stitches <NUM>, <NUM>. Generally, the float length may range from two to ten needles or a greater number of needles, e.g., three, four, or five needles. Referring to <FIG>, floats may have a straight appearance (e.g., if taut) or a U-shaped appearance (e.g., if the float has slack and/or is not under tension). A straight float such as float <NUM> of <FIG>, <FIG> may advantageously increase the stretch resistance of the knitted component because it limits mechanical stretch (as compared to a knit stitch or a U-shaped float, which may allow mechanical stretch, i.e., straightening of the course due to application of a tensile force). However, a U-shaped float (such as float <NUM>) may also have advantages; for example, float <NUM> may nest within cavity <NUM>, where it is protected from snagging. More than one float may exist along a single course of second yarn type <NUM>, and those floats may have different float lengths. For example, course <NUM> includes floats <NUM> (with a first float length that is longer because it is U-shaped) and <NUM> (with a second, shorter float length because it is straight).

The cavities may protect the floats. For example, one or more floats (e.g., float <NUM>) extends across each cavity (e.g., cavity <NUM>). In other words, float <NUM> may pass across the void created by cavity <NUM> such that it is suspended above, or rests on, cavity surface <NUM>. This structure has at least two characteristics. First, float <NUM> may be exposed and visible from viewpoint <NUM>. This feature may reveal and accentuate the visual properties of second yarn type <NUM>, e.g., reflectivity or contrasting color. At the same time, because cavity <NUM> may not extend all the way through knitted component <NUM>, float <NUM> may not be visible from all viewpoints (e.g., a viewpoint facing second surface <NUM>). Although float <NUM> may be visible, stitches <NUM>, <NUM> of may not be visible from viewpoint <NUM>, especially if knitted on a needle bed other than the needle bed that formed the stitches that predominantly make up first surface <NUM>. In other embodiments, more than one float may extend across each cavity.

Another characteristic of this knit structure is that a float may potentially form part of first surface <NUM> if it is substantially coplanar with first surface <NUM> (e.g., coplanar with stitches of first yarn type <NUM> that form at least part of first surface <NUM>); this may occur if a float protrudes from a cavity (e.g., float <NUM> of <FIG>). Alternatively, a float may be recessed relative to first surface <NUM> by a distance that is less than the maximum depth of the cavity in which it resides. For example, float <NUM> is recessed relative to first surface <NUM> because it resides within cavity <NUM>. Advantageously, by knitting a float that extends across a cavity and is recessed relative to first surface <NUM>, that float may be visible from viewpoint <NUM>, yet protected. This feature may be useful regardless of whether second yarn type <NUM> has high durability, because an exposed float may be prone to snagging and breakage. A float may be further recessed within a cavity relative to first surface <NUM> if that float is adjacent to stitches of the same course that are formed on a needle bed other than the needle bed that formed the stitches that predominantly make up first surface <NUM>. For example, first surface <NUM> includes stitches formed on a front needle bed of a knitting machine, and stitches <NUM>, <NUM> of course <NUM> of second yarn type <NUM> are formed on a rear needle bed; as a result, float <NUM> may advantageously may be recessed deeper within cavity <NUM> than if stitches <NUM>, <NUM> were knitted on the first needle bed. In some embodiments, a float (e.g., float <NUM>) may nest within a cavity, i.e., fit compactly within or "bed down" within the cavity, rather than passing across a cavity in a straight configuration. Knitting slack into a float may accentuate this nested structure.

Referring now to <FIG>, an upper <NUM> for an article of footwear includes a knitted component <NUM> as described above having cavities and floats. Upper <NUM> resembles a U-shape in <FIG>, however, it shall be understood that the "horseshoe"-shape or "U-shape" shape is merely exemplary, and other knitted components embodying the disclosure of this application may be knitted with edges in different locations, for example a "C-shaped" knitted component or a multiple-piece knitted component. For reference purposes, upper <NUM> may be divided generally along a longitudinal direction (heel-to-toe) into three general regions: a forefoot region <NUM>, a midfoot region <NUM>, and a rearfoot region <NUM>. Forefoot region <NUM> may generally include portions that may eventually correspond (when incorporated into an article of footwear) with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region <NUM> may generally include portions corresponding with an arch area of the foot. Rearfoot region <NUM> may generally correspond with rear portions of the foot, including areas that cover the calcaneus bone (which comprises a portion of a wearer's heel). Additionally, rearfoot region <NUM> may cover some or all of the wearer's malleoli and talus (which comprise a portion of the ankle). Upper <NUM> may also include a medial side <NUM> and a lateral side <NUM>, which may extend through each of forefoot region <NUM>, midfoot region <NUM>, and rearfoot region <NUM>, and may correspond with opposite sides. More particularly, lateral side <NUM> may correspond with an outside area of the foot (i.e., the surface that faces away from the other foot), and medial side <NUM> may correspond with an inside area of the foot (i.e., the surface that faces toward the other foot). Forefoot region <NUM>, midfoot region <NUM>, rearfoot region <NUM>, medial side <NUM>, and lateral side <NUM> are not intended to demarcate precise areas of a knitted component, upper, or article, but rather are intended to represent general areas to aid in the following discussion.

Referring still to <FIG>, knitted component <NUM> includes a first layer <NUM> having a first surface <NUM> formed at least partially from a first yarn type <NUM>, and an opposite-facing second surface <NUM>. First surface <NUM> may correspond with an exterior surface, and second surface <NUM> may correspond with an interior surface when upper <NUM> is incorporated into an article of footwear. Knitted component <NUM> includes a first protected float area <NUM> located in rearfoot region <NUM> on lateral side <NUM>, a second protect float area <NUM> located in midfoot region <NUM>, and a third protected float area <NUM> located in forefoot region <NUM>. It shall be understood that knit structures present in any protected float area of upper <NUM> may also be suitable in other protected float areas and in other locations (including other regions and/or sides) of upper <NUM>.

Referring to <FIG>, B, first protected float area <NUM> includes a first plurality of cavities <NUM> (e.g., cavity <NUM>) and a first plurality of courses <NUM> of a second yarn type <NUM> (e.g., course <NUM>). At least some courses of second yarn type <NUM> have a diagonal orientation extending from a collar region <NUM> to a lateral edge region <NUM> (including a lateral edge <NUM>), and include at least one float and at least one knit stitch (concealed behind first surface <NUM>). At least one float of second yarn type <NUM> extends across a cavity of the first plurality <NUM>. At least one stitch of the first plurality of courses <NUM> of second yarn type <NUM> interloops with one or more courses of knitted component <NUM> (e.g., may interloop with one or more courses of first yarn type <NUM>), and each stitch may be concealed by first surface <NUM>. At least one float in first protected float area <NUM> has a relatively short float length fi, and at least two courses of second yarn type <NUM> are separated by a first distance di.

Referring to <FIG>, cavity <NUM> has a depth corresponding to the distance between first surface <NUM> and first cavity surface <NUM>. U-shaped float <NUM> of course <NUM> is nested deeply within cavity <NUM> (it has slack and fits compactly within cavity <NUM>) at a depth that approaches first cavity surface <NUM>, and thus float <NUM> may be visibly recessed relative to first surface <NUM>. Course <NUM> also includes a stitch <NUM> (concealed behind first surface <NUM>) that interloops with one or more yarns of knitted component <NUM>. Notably, courses of plurality <NUM> may not be parallel to courses of yarns in second and third protected float areas <NUM>, <NUM> due to the use of one or more wedges or gores <NUM> to vary the course-wise direction of knitted component <NUM> in rearfoot region <NUM>.

Referring to <FIG>, <FIG>, second protected float area <NUM> includes a second plurality of cavities <NUM> formed in knitted component <NUM>, along with a second plurality of courses <NUM> of a third yarn type <NUM> selected for high strength and oriented in a medial to lateral direction. At least some courses of third yarn type <NUM> include at least one float and at least one stitch that is interlooped with knitted component <NUM>. At least some floats in second protected float area <NUM> have a second float length <NUM> that is larger than first float length <NUM> of first protected float area <NUM>. At least some courses of third yarn type <NUM> in second protected float area <NUM> area separated from at least one other courses of third yarn type <NUM> by a second distance d2 that is greater than the first distance di of first protected float area <NUM>. At least some courses of third yarn type <NUM> include one or more stitches that interloop with knitted component <NUM>, thereby affixing the course-wise position of those courses. One or more courses of third yarn type <NUM> may extend from lateral edge region <NUM> (including lateral edge <NUM>) to a throat region <NUM> and/or to a medial edge region <NUM> (including a medial edge <NUM>). The floats and stitches that may exist in one or more courses of third yarn type <NUM> may alternate; this characteristic, along with the potential medial-lateral orientation of courses of third yarn type <NUM>, may advantageously inhibit medial-lateral movement of a wearer's foot when upper <NUM> is incorporated into an article of footwear. Second protected float area <NUM> also includes a plurality of optional apertures <NUM> that extend through upper <NUM> between courses of third yarn type <NUM>. Such apertures may have a number of different sizes and shapes, including elliptical, circular, square, rectangular, etc. Apertures of plurality <NUM> are exemplary, and may optionally exist in other protected float areas to improve breathability of upper <NUM>, improve visibility through knitted component <NUM>, and/or provide another technical advantage.

Referring to <FIG>, float <NUM> of course <NUM> may extend across a cavity <NUM> at a depth that is intermediate between first surface <NUM> and second cavity surface <NUM>, and therefore float <NUM> may be less recessed relative to first surface <NUM> than float <NUM> in first protected float area <NUM>. Course <NUM> may include first and second stitches 232a, b that interloop with one or more yarns of knitted component <NUM>.

Referring to <FIG>, <FIG>, third protected float area <NUM> includes a third plurality of cavities <NUM> formed in knitted component <NUM>, along with a third plurality of courses <NUM> of a fourth yarn type <NUM>. Each course of fourth yarn type <NUM> includes a plurality of floats, at least some of which may have different float lengths. For example, course <NUM> includes a plurality of floats, each with a different float length, such that floats nearer to lateral edge region <NUM> have a shorter float length than floats near to medial edge region <NUM>. However, the variation in float lengths may differ in other embodiments, e.g., by decreasing in the lateral to medial direction, by varying randomly, or in another manner. Courses of fourth yarn type <NUM> may be separated by one or more distances that may be greater than or less than first distance di and second distance d2. Notably, courses of fourth yarn type <NUM> in third protected float area <NUM> are not parallel to courses in first or second protected float areas <NUM>, <NUM> as a result of optional wedges or gores <NUM> to vary the course-wise direction of knitted component <NUM>. Referring to <FIG>, straight float <NUM> of course <NUM> may extend across cavity <NUM> at a depth that approaches first surface <NUM>. Course <NUM> includes stitch <NUM> that is interlooped with knitted component <NUM> and partially exposed through first surface <NUM>.

In <FIG> an article of footwear <NUM> is shown that incorporates an upper <NUM> at least partially formed from a knitted component <NUM> constructed as described above, with a first protected float area <NUM> in a midfoot region <NUM> and a second protected float area <NUM> in a rearfoot region <NUM>. Article <NUM> has a general configuration suitable for walking or running. Concepts associated with footwear, including the upper and knitted component, may also be applied to a variety of other athletic footwear types, including but not limited to baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, soccer shoes, sprinting shoes, tennis shoes, and hiking boots. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. The concepts disclosed herein apply, therefore, to a wide variety of footwear types. Furthermore, the concepts disclosed herein may apply to articles beyond footwear, such as accessories or apparel. In the embodiment of <FIG>, upper <NUM> may generally provide a comfortable and secure covering for a wearer's foot. As such, upper <NUM> may define a void <NUM> to effectively receive and secure a foot within article <NUM>. Moreover, an optional sole structure <NUM> may be secured to a lower area of upper <NUM> and may extend between the foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence the motions of the foot.

First protected float area <NUM> includes a first plurality of cavities <NUM> formed in knitted component <NUM> and a first plurality of courses <NUM> of a second yarn type <NUM>. Each course of second yarn type <NUM> includes a plurality of floats and knit stitches (concealed) and has a medial-lateral orientation. Some courses of second yarn type <NUM> may extend at least part- way from a lateral edge region <NUM> (including a lateral edge <NUM>) at or near sole structure <NUM>, across overfoot portion <NUM>, to a medial edge region (including a medial edge). For example, course <NUM> extends from sole structure <NUM> to fastening system <NUM>, which may be a lace, zipper, or similar structure. Course <NUM> may be secured to sole structure <NUM> and/or fastening system <NUM> with adhesive, a thermal bond, with one or more knit stitches, or by other means.

Second protected float area <NUM> includes a second plurality of cavities <NUM> and a second plurality of courses <NUM> of third yarn type <NUM> that extend in a horizontal direction around rearfoot portion <NUM> of article <NUM>. Second protected float area <NUM> may extend to a lateral border region <NUM> that is adjacent to first protected float area <NUM>, and may also extend from sole structure <NUM> to a collar region <NUM>. Courses of third yarn type <NUM> in second protected float area <NUM> are not parallel to courses of second yarn type <NUM> first protected float area <NUM> due to the use of one or more wedges or gores <NUM>.

Referring now to <FIG> a knitting sequence is illustrated that may be utilized to form integrally-knitted components 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>. The knitting sequence illustrates the formation of a protected float area that utilizes courses of a first yarn type <NUM> to form a first layer, including a plurality of cavities. The knitting sequence also utilizes courses of a second yarn type <NUM> that form a plurality of floats extending across the cavities, and knit stitches that interloop with the first layer.

At a first step <NUM>, the knitting machine forms courses <NUM>, <NUM> of first yarn type <NUM> on first and second needle beds <NUM>, <NUM> in order to form a portion of the first layer. In other words, first and second courses <NUM>, <NUM> have multi-bed construction. Courses <NUM>, <NUM> may have a number of configurations, such as an interlock structure with less-than-full gauge knitting on both first and second needle beds <NUM>, <NUM>. If courses knitted during step <NUM> knit a loop of first yarn type <NUM> on a needle of first needle bed <NUM>, then the corresponding needle on second needle bed <NUM> may be left free of loops in order to preserve those needles for transfers in a subsequent step.

At a second step <NUM>, the knitting machine forms a plurality of cavities in the knit layer by transferring one or more stitches of courses <NUM>, <NUM> from first needle bed <NUM> to second needle bed <NUM>. The cavity width may generally correspond with the number of transferred loops. When forming cavities, the knitting machine may not transfer all loops of courses <NUM>, <NUM> to second needle bed <NUM>, as those loops that remain on first needle bed <NUM> may form boundaries of the cavities. Therefore, the knitting machine may leave one, two, three, or more loops of courses <NUM>, <NUM> on first needle bed <NUM> in between transferred loops. In <FIG>, the knitting machine forms three cavities each having a three-needle width by transferring loops of courses <NUM>, <NUM> from the second, third, fourth, fifth, sixth, eighth, ninth, and tenth needles on first needle bed <NUM> to opposite needles on the second needle bed <NUM>, leaving loops of courses <NUM>, <NUM> on the third and seventh needles of first needle bed <NUM>. Following second step <NUM>, the knitting machine will have formed three cavities, each being separated by one stitch.

In a third step <NUM>, the knitting machine knits at least one course <NUM> of second yarn type <NUM> on second needle bed <NUM>. Specifically, course <NUM> includes a first float <NUM>, a first loop <NUM>, a second float <NUM>, a second loop <NUM>, and a third float <NUM>. Each float <NUM>, <NUM>, <NUM> skips three needles, i.e., has a three-needle float length. Additionally, each float extends across a cavity formed during second step <NUM>. Where first and second loops <NUM>, <NUM> are formed on second needle bed <NUM>, those loops <NUM>, <NUM> interloop with loops of course <NUM> of first yarn a type <NUM> knitted during first step <NUM>. As a result, loops <NUM>, <NUM> fix the course-wise position of course <NUM> within the knitted component.

In a fourth step <NUM>, the knitting machine forms courses <NUM>, <NUM> of first yarn type <NUM> on first and second needle beds <NUM>, <NUM> in order to continue forming the first layer, and also to interloop the first layer with course <NUM> of second r yarn type <NUM>. Courses <NUM>, <NUM> may form one boundary of the cavities formed during second step <NUM>. Following first through fourth steps <NUM>-<NUM>, the knitting machine will have formed a multi -bed first layer formed from a yarn type <NUM> and having a plurality of cavities that are recessed relative to a first surface, with a float of a second yarn type <NUM> extending across each cavity, and with at least one stitch of a course of the second yarn type <NUM> interlooped with the first layer.

Claim 1:
A knitted component, (<NUM>) comprising:
a course of a first yarn type (<NUM>) and a course (<NUM>, <NUM>, <NUM>) of a second yarn type (<NUM>);
a first surface (<NUM>) at least partially formed by the course of the first yarn type (<NUM>);
a cavity (<NUM>, <NUM>) formed within the knitted component (<NUM>) that is recessed relative to the first surface (<NUM>), wherein the cavity (<NUM>, <NUM>) has a sloped surface (<NUM>); and
a first float (<NUM>, <NUM>) formed by the course (<NUM>, <NUM>, <NUM>) of the second yarn type (<NUM>) that extends across the cavity (<NUM>, <NUM>) and is exposed, and
wherein the cavity (<NUM>, <NUM>) has a depth of zero at one side and gradually increases to a maximum depth at another side.