Patent Description:
Document <CIT> describes a last fitting knit upper for an article of footwear which is heat-shrinked around a last to achieve a skin-tight fit. The upper is continuously knit from any yarn suitable for machine knitting. Additionally, thick strands of thermoplastic yarn are incorporated into the knit upper such that they lie closely adjacent in longitudinal parallel relation. When placing the upper around the last and increasing the temperature the upper heat-shrinks around the last, providing a skin-tight fit.

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

The advantages and features of novelty characterizing aspects of the invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying figures that describe and illustrate various configurations and concepts related to the invention.

The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the accompanying figures.

The following discussion and accompanying figures disclose various concepts associated with knit component bonding.

A composite element <NUM> is depicted in <FIG> and <FIG> as including a knit component <NUM> and a bonded component <NUM>. Components <NUM> and <NUM> are secured together through knit component bonding. Although described in greater detail below, knit component bonding generally includes utilizing a fusible material (e.g., a thermoplastic polymer material) within knit component <NUM> to form a thermal bond that joins or otherwise secures components <NUM> and <NUM> to each other. That is, bonded component <NUM> is joined through thermal bonding to knit component <NUM> with the fusible material from knit component <NUM>. The various configurations of composite element <NUM> discussed below provide examples of general configurations in which knit component bonding may be implemented. As such, the various configurations of composite element <NUM> may be utilized in a variety of products, including many of the products discussed in the background above. In order to provide specific examples of the manner in which knit component bonding may be implemented, however, various articles of apparel, including a shirt <NUM> and an article of footwear <NUM>, are described below.

Knit component <NUM> is manufactured through a knitting process to have a generally planar configuration that defines a first surface <NUM> and an opposite second surface <NUM>. The knitting process forms knit component <NUM> from a non-fusible yarn <NUM> and a fusible yarn <NUM>, as depicted in <FIG>. That is, knit component <NUM> has a knitted structure in which yarns <NUM> and <NUM> are mechanically-manipulated together during the knitting process. Various types of knitting processes may be utilized to form knit component <NUM>, including hand knitting, flat knitting, wide tube circular knitting, narrow tube circular knit jacquard, single knit circular knit jacquard, double knit circular knit jacquard, warp knit tricot, warp knit raschel, and double needle bar raschel, for example. Moreover, any knitting process that may form a knitted structure from at least two yarns (e.g., yarns <NUM> and <NUM>) may be utilized to manufacture knit component <NUM>.

Whereas non-fusible yarn <NUM> is formed from a non-fusible material, fusible yarn <NUM> is formed from a fusible material. Examples of non-fusible materials include various thermoset polymer materials (e.g., polyester, acrylic) and natural fibers (e.g., cotton, silk, wool). When subjected to moderate levels of heat, thermoset polymer materials tend to remain stable. Moreover, when subjected to elevated levels of heat, thermoset polymer materials and natural fibers may burn or otherwise degrade. Examples of fusible materials include various thermoplasticpolymer materials (e.g., polyurethane, polyester, nylon). In contrast with thermoset polymer materials and natural fibers, thermoplastic polymer materials melt when heated and return to a solid state when cooled. More particularly, thermoplastic polymer materials transition from a solid state to a softened or liquid state when subjected to sufficient heat, and then the thermoplastic polymer materials transition from the softened or liquid state to the solid state when sufficiently cooled. In some configurations, the non-fusible material used for non-fusible yarn <NUM> may also be a thermoplastic polymer material, particularly where the melting temperature of the thermoplastic polymer material used for non-fusible yarn <NUM> is greater than the melting temperature of the thermoplastic polymer material used for fusible yarn <NUM>.

Thermoplastic polymer materials, as discussed above, melt when heated and return to a solid state when cooled. Based upon this property, the thermoplastic polymer material from fusible yarn <NUM> may be utilized to form a thermal bond that joins knit component <NUM> and bonded component <NUM>. As utilized herein, the term "thermal bonding" or variants thereof is defined as a securing technique between two components that involves a softening or melting of a thermoplastic polymer material within at least one of the components such that the components are secured to each other when cooled. Similarly, the term "thermal bond" or variants thereof is defined as the bond, link, or structure that joins two components through a process that involves a softening or melting of a thermoplastic polymer material within at least one of the components such that the components are secured to each other when cooled.

As general examples, thermal bonding may involve (a) the melting or softening of thermoplastic polymer materials within two components such that the thermoplastic polymer materials intermingle with each other (e.g., diffuse across a boundary layer between the thermoplastic polymer materials) and are secured together when cooled; (b) the melting or softening of a thermoplastic polymer material within a first component such that the thermoplastic polymer material extends into or infiltrates the structure of a second component to secure the components together when cooled; and (c) the melting or softening of a thermoplastic polymer material within a first component such that the thermoplastic polymer material extends into or infiltrates crevices or cavities of a second component to secure the components together when cooled. As such, thermal bonding may occur when two components include thermoplastic polymer materials or when only one of the components includes a thermoplastic polymer material. Additionally, thermal bonding does not generally involve the use of stitching, adhesives, or other joining techniques, but involves directly bonding components to each other with a thermoplastic polymer material. In some situations, however, stitching, adhesives, or other joining techniques may be utilized to supplement the thermal bond or the joining of components through thermal bonding.

More specific examples of thermal bonding that relate to composite element <NUM> will now be discussed. In general, bonded component <NUM> may be any element that is joined with knit component <NUM>, including textile elements (e.g., knit textiles, woven textiles, non-woven textiles), polymer sheets, polymer foam layers, leather or rubber elements, and plates, for example. In a configuration where bonded component <NUM> is formed from a textile element, thermal bonding may involve the melting or softening of a thermoplastic polymer material within fusible yarn <NUM> such that the thermoplastic polymer material extends into the textile element of bonded component <NUM> and around individual filaments, fibers, or yarns within the textile element to secure components <NUM> and <NUM> together when cooled. In a similar configuration where bonded component <NUM> is formed from a textile element incorporating a thermoplastic polymer material, thermal bonding may involve the melting or softening of thermoplastic polymer materials within each of fusible yarn <NUM> and the textile element of bonded component <NUM> such that the thermoplastic polymer materials intermingle with each other and are secured together when cooled. Moreover, in any configuration where bonded component <NUM> incorporates a thermoplastic polymer material (e.g., textiles, polymer sheets, polymer foam layers, leather or rubber elements, plates), thermal bonding may involve the melting or softening of thermoplastic polymer materials within each of fusible yarn <NUM> and bonded component <NUM> such that the thermoplastic polymer materials intermingle with each other and are secured together when cooled. Additionally, in a configuration where bonded component <NUM> is a polymer sheet, polymer foam layer, leather or rubber element, or plate, thermal bonding may involve the melting or softening of a thermoplastic polymer material within fusible yarn <NUM> such that the thermoplastic polymer material extends into crevices or cavities of bonded component <NUM> to secure components <NUM> and <NUM> together when cooled. Although many configurations of composite element <NUM> do not involve the use of stitching, adhesives, or other joining techniques, these joining techniques may be utilized to supplement the thermal bond or the joining of components <NUM> and <NUM> through thermal bonding.

Based upon the above discussion, knit component bonding generally includes utilizing a fusible material (e.g., a thermoplastic polymer material) within fusible yarn <NUM> of knit component <NUM> to form a thermal bond that joins or otherwise secures components <NUM> and <NUM> to each other. That is, bonded component <NUM> is joined through thermal bonding to knit component <NUM> with the fusible material from fusible yarn <NUM>. In order to form the thermal bond, the fusible material is often located in a portion of knit component <NUM> that is adjacent to bonded component <NUM>. Given that bonded component <NUM> is secured to first surface <NUM>, therefore, the fusible material is often located at first surface <NUM> to thereby form a thermal bond with bonded component <NUM> at first surface <NUM>. Referring to <FIG>, non-fusible yarn <NUM> effectively extends throughout knit component <NUM> and from first surface <NUM> to second surface <NUM>, whereas fusible yarn <NUM> is concentrated at first surface <NUM>. In this configuration, the fusible material of fusible yarn <NUM> is positioned to contact bonded component <NUM> and form the thermal bond between components <NUM> and <NUM> at first surface <NUM>. Any knit structure where a yarn (e.g., fusible yarn <NUM>) is concentrated or present at one or both surfaces may be utilized to achieve this configuration.

Although the configuration of <FIG> provides a suitable structure for forming a thermal bond between components <NUM> and <NUM>, a variety of other knitted structures may also form a thermal bond. Referring to <FIG>, for example, non-fusible yarn <NUM> effectively extends throughout knit component <NUM> and from first surface <NUM> to second surface <NUM>, whereas fusible yarn <NUM> is concentrated at both surfaces <NUM> and <NUM>. As another example, <FIG> depicts a configuration wherein the portion of fusible yarn <NUM> located at first surface <NUM> is plated with a portion of non-fusible yarn <NUM>. That is, yarns <NUM> and <NUM> run in parallel along first surface <NUM>. Another configuration wherein yarns <NUM> and <NUM> are plated is depicted in <FIG>, where yarns <NUM> and <NUM> run in parallel throughout knit component <NUM>. Accordingly, the configurations of yarns <NUM> and <NUM> within knit component <NUM> may vary considerably.

Referring again to <FIG>, fusible yarn <NUM> is concentrated at first surface <NUM> and forms loops that extend around sections of non-fusible yarn <NUM>. One consideration regarding this configuration relates to the potential for unraveling or releasing. When heated, the thermoplastic polymer material of fusible yarn <NUM> may soften or melt, which may effectively release the sections of non-fusible yarn <NUM>. That is, the melting or softening of the thermoplastic polymer material of fusible yarn <NUM> may allow the knitted structure of knit component <NUM> to unravel, become non-cohesive, or otherwise release because fusible yarn <NUM> is no longer forming loops that hold the knitted structure together. In order to prevent this occurrence, the configurations of <FIG> and <FIG> may be utilized. That is, yarns <NUM> and <NUM> may be plated so that they run in parallel. When fusible yarn <NUM> softens or melts, therefore, non-fusible yarn <NUM> remains intact and effectively holds the knitted structure together.

A further method of ensuring that the melting or softening of the thermoplastic polymer material in fusible yarn <NUM> does not release the knitted structure is to form portions of fusible yarn <NUM> from both fusible and non-fusible materials. Referring to <FIG>, for example, a portion of fusible yarn <NUM> is depicted as having various fusible filaments <NUM> and non-fusible filaments <NUM>. Even when fusible filaments <NUM> melt or soften, non-fusible filaments <NUM> are present to prevent the knitted structure from releasing. In a similar configuration, <FIG> depicts filaments <NUM> and <NUM> as forming a sheath-core structure. That is, fusible filaments <NUM> are located peripherally to form a sheath and non-fusible filaments <NUM> are located centrally to form a core. Similarly, <FIG> depicts a configuration wherein fusible filaments <NUM> spiral around a core formed by non-fusible filaments <NUM>.

Yet another method of ensuring that the melting or softening of the thermoplastic polymer material in fusible yarn <NUM> does not release the knitted structure is to form individual filaments within fusible yarn <NUM> from both fusible and non-fusible materials. Referring to <FIG>, for example, an individual filament <NUM> includes a fusible portion <NUM> and a non-fusible portion <NUM> in a sheath-core configuration. That is, fusible portion <NUM> is located peripherally to form a sheath and non-fusible portion <NUM> is located centrally to form a core. In another configuration, <FIG> depicts filament <NUM> as having one half formed from fusible portion <NUM> and another half formed from non-fusible portion <NUM>. Fusible yarn <NUM> may, therefore, be formed from multiple filaments <NUM> that will only partially melt or soften when exposed to heat.

The configuration of composite element <NUM> in <FIG> provides an example of the manner in which knit component bonding may be utilized to join components <NUM> and <NUM>. Given that knit component bonding may be utilized in various products, numerous aspects relating to composite element <NUM> may vary from the configuration depicted in <FIG>. Moreover, variations in either of components <NUM> and <NUM> may alter the properties of composite element <NUM>, thereby enhancing the products in which knit component bonding is utilized. Referring to <FIG>, for example, bonded component <NUM> is depicted as having a greater size than knit component <NUM>. <FIG> depicts a configuration wherein bonded component <NUM> forms a plurality of apertures <NUM>. When bonded component <NUM> is a polymer sheet, polymer foam element, or plate, for example, apertures <NUM> may be utilized to enhance the fluid permeability or flexibility of composite element <NUM>. Although both components <NUM> and <NUM> may have constant thickness, one or both of components <NUM> and <NUM> may also have a varying thickness. Referring to <FIG>, for example, bonded component <NUM> has a tapered configuration. Although both components <NUM> and <NUM> may be planar, one or both of components <NUM> and <NUM> may also have a contoured configuration. Referring to <FIG>, for example, components <NUM> and <NUM> are curved. In the configurations of <FIG> and <FIG>, fusible yarn <NUM> is concentrated at both surfaces <NUM> and <NUM>. This may provide the advantage of allowing bonded components <NUM> to be thermal bonded to either of surfaces <NUM> and <NUM>. For example, <FIG> depicts a configuration wherein one bonded component <NUM> is thermal bonded to first surface <NUM> and another bonded component <NUM> is thermal bonded to second surface <NUM>.

In addition to the various structural aspects of different configurations of composite element <NUM> depicted in <FIG>, some configurations of composite element <NUM> may provide aesthetic, informational, or other non-structural benefits. Referring to <FIG>, for example, bonded component <NUM> is a letter "A" that is secured to knit component <NUM> through knit component bonding. The letter "A" or other indicia may be utilized to impart information about a product, such as trademarks of the manufacturer. Similarly, <FIG> depicts bonded component <NUM> as being a placard having care instructions, as for an article of apparel.

Referring to <FIG> and <FIG>, fusible yarn <NUM> is located on both surfaces <NUM> and <NUM>. In these configurations, bonded component <NUM> may be secured to either of surfaces <NUM> and <NUM>. Referring to <FIG>, bonded component <NUM> may also wrap around knit component <NUM>, thereby being bonded to both of surfaces <NUM> and <NUM>. In another configuration, components <NUM> and <NUM> may be thermal bonded at their edges, as depicted in <FIG>, in order to replace stitching and form a seam between components <NUM> and <NUM>. Referring to <FIG>, various strands <NUM> may be located between and thermal bonded between components <NUM> and <NUM>. Strands <NUM> may, for example, resist stretch in directions corresponding with their lengths. As such, the combination of components <NUM> and <NUM> and strands <NUM> may be utilized in footwear, for example, as disclosed in <CIT>.

An advantage of composite element <NUM> is that properties from both components <NUM> and <NUM> combine to enhance the overall properties of composite element <NUM>. In configurations where bonded component <NUM> is a textile, bonded component <NUM> may have different textile properties than knit component <NUM>. The resulting composite element <NUM> may, therefore, exhibit the textile properties of both components <NUM> and <NUM>. When bonded component <NUM> is a polymer sheet, bonded component <NUM> may impart resistance to fluid permeability or wear resistance. If, for example, bonded component <NUM> is formed from a compressible material, such as a polymer foam element, then composite element <NUM> may be suitable for articles of apparel where cushioning (i.e., attenuation of impact forces) is advantageous, such as padding for athletic activities that may involve contact or impact with other athletes or equipment. Similar protective attributes may be present when bonded component is a plate.

The combination of properties from components <NUM> and <NUM> may also be present when methods other than knit component bonding (e.g., adhesives, stitching) are utilized to join components <NUM> and <NUM>. An advantage to knit component bonding however, is that no adhesives or other elements are present between components <NUM> and <NUM>. For example, some adhesives (e.g., hot melt) may impair fluid permeability through composite element <NUM>. Also, adhesives may be visible around edges of bonded component <NUM>, thereby decreasing the aesthetic appeal of a product. Moreover, forming stitching may be a time-consuming process, the stitches may compress either of components <NUM> and <NUM>, and the stitches may be visible from the exterior of composite element <NUM>. Accordingly, knit component bonding <NUM> may be utilized to alleviate the disadvantages discussed above, for example, in other joining methods.

Fusible yarn <NUM> may extend throughout knit component <NUM>. In addition to imparting the advantage of knit component bonding, fusible yarn <NUM> may have the effect of stiffening or rigidifying the structure of knit component <NUM>. More particularly, fusible yarn <NUM> may also be utilized to join one portion of non-fusible yarn <NUM> to another portion of non-fusible yarn <NUM>, which has the effect of securing or locking the relative positions of non-fusible yarn <NUM>, thereby imparting stretch-resistance and stiffness. That is, portions of non-fusible yarn <NUM> may not slide relative to each other when fused by fusible yarn <NUM>, thereby preventing warping or permanent stretching of knit component <NUM> due to relative movement of the knitted structure. Another benefit relates to limiting unraveling if a portion of knit component <NUM> becomes damaged or a portion of non-fusible yarn <NUM> is severed.

Although fusible yarn <NUM> may extend throughout knit component <NUM>, fusible yarn <NUM> may be limited to specific areas of knit component <NUM>. Referring to <FIG>, for example, an exploded perspective view of composite element <NUM> depicts knit component <NUM> as having a bonding area <NUM> and a peripheral area <NUM>. Bonding area <NUM> corresponds with the portion of first surface <NUM> where bonded element <NUM> is thermal bonded to knit component <NUM>. Moreover, fusible yarn <NUM> may be limited to bonding area <NUM>. That is, fusible yarn <NUM> may be absent from peripheral area <NUM>. In some configurations, an advantage may be gained by not joining one portion of non-fusible yarn <NUM> to another portion of non-fusible yarn <NUM> in peripheral area <NUM>. Accordingly, by placing fusible yarn <NUM> in specific areas of knit component <NUM>, knit component bonding may be performed in those areas, while reducing the effects of fusible yarn <NUM> in other areas. A similar configuration is depicted in <FIG>, wherein various bonding areas <NUM> are formed in the portion of first surface <NUM> where bonded element <NUM> is joined to knit component <NUM>. In some configurations, bonding areas <NUM> may be individual stitches where fusible yarn <NUM> is present and exposed on first surface <NUM>.

Knit component <NUM> may have a generally planar and continuous configuration. In some configurations, as depicted in <FIG>, the knitted structure of knit component <NUM> may define various indentations <NUM> or apertures <NUM>. That is, the knitted structure may be knit to form surface features or other elements by varying the knitted structure in specific locations. Alternately, indentations <NUM> or other surface features may be formed through embossing, for example. In addition to enhancing the aesthetic appeal of composite element <NUM>, indentations <NUM> and apertures <NUM> may increase properties such as fluid permeability and flexibility, while decreasing the overall mass of composite element <NUM>.

Based upon the above discussion, composite element <NUM> has a configuration wherein components <NUM> and <NUM> are secured together through knit component bonding. In general, knit component bonding includes utilizing a fusible material (e.g., a thermoplastic polymer material in fusible yarn <NUM>) within knit component <NUM> to form a thermal bond that joins or otherwise secures components <NUM> and <NUM> to each other. The various configurations of composite element <NUM> discussed above provide examples of general configurations in which knit component bonding may be implemented. As such, the various configurations of composite element <NUM> may be utilized in a variety of products to impart a range of benefits to those products.

The general process by which knit component bonding is performed will now be discussed in detail. As a preliminary aspect of the process, knit component <NUM> is formed through a knitting process. Generally, a knitting machine may be programmed to knit a textile (i.e., knit component <NUM>) with non-fusible yarn <NUM> and fusible yarn <NUM>. Moreover, the knitting machine may also locate fusible yarn <NUM> on at least one surface, such as first surface <NUM>. In effect, therefore, the knitting process may include concentrating fusible yarn <NUM> at first surface <NUM>. In some configurations, the knitting process may also extend fusible yarn <NUM> from first surface <NUM> to second surface <NUM> or plate yarns <NUM> and <NUM>. Hand knitting, rather than machine knitting, may also be utilized.

Once knit component <NUM> is formed, both of components <NUM> and <NUM> may be placed within a heat press <NUM>, as depicted in <FIG>. More particularly, bonded component <NUM> may be placed adjacent to a portion of first surface <NUM> where bonding is intended to occur, and both of components <NUM> and <NUM> may be located between opposing portions <NUM> and <NUM> of heat press <NUM>. Once positioned, portions <NUM> and <NUM> may translate toward each other to compress and apply heat to components <NUM> and <NUM>, as depicted in <FIG>. That is, components <NUM> and <NUM> may be compressed and heated to a temperature that causes the thermoplastic polymer material in fusible yarn <NUM> to melt or soften. Due to the compression from portions <NUM> and <NUM>, portions of the melted or softened thermoplastic polymer material may contact or otherwise engage bonded component <NUM>. Following sufficient heating and compression, portions <NUM> and <NUM> separate, as depicted in <FIG>, and components <NUM> and <NUM> may be removed. Following cooling, the thermoplastic polymer material from fusible yarn <NUM> securely forms a thermal bond that joins components <NUM> and <NUM> to each other.

Heat press <NUM> provides an advantage of simultaneously heating and compressing components <NUM> and <NUM>. In other bonding processes, components <NUM> and <NUM> may be heated prior to being compressed within heat press <NUM> or a cold press. Examples of heating methods that may be utilized include conduction, infrared, ultrasonic, high frequency, radio frequency, vibration heating, and steam heating.

Following the process of knit component bonding discussed above, composite element <NUM> may be incorporated into one of various products, including many of the products discussed in the Background above. As specific examples of products that may incorporate concepts associated with knit component bonding, two articles of apparel, a shirt <NUM> and an article of footwear <NUM>, will now be discussed.

An exemplary shirt <NUM>, not according to the claimed invention, is depicted in <FIG> as including a torso region <NUM> and a pair of arm regions <NUM> that extend outward from torso region <NUM>. Torso region <NUM> corresponds with a torso of a wearer and covers at least a portion of the torso when worn. Similarly, arm regions <NUM> correspond with arms of the wearer and cover at least a portion of the arms when worn. Torso region <NUM> and arm regions <NUM> may both be formed from a textile that is similar to knit component <NUM>. That is, the textile forming torso region <NUM> and arm regions <NUM> may be at least partially formed from a yarn incorporating a fusible material, which has properties similar to fusible yarn <NUM>. Moreover, the fusible material may be oriented to form at least a portion of the exterior surface of shirt <NUM>. The textile forming torso region <NUM> and arm regions <NUM> may also be at least partially formed from a yarn incorporating a non-fusible material, which has properties similar to non-fusible yarn <NUM>.

Given the configuration of shirt <NUM> discussed above, various components <NUM>-<NUM> may be secured to shirt <NUM> through knit component bonding. Referring specifically to <FIG>, two components <NUM> are secured to elbow areas of arm regions <NUM> and may be polymer or leather sheets that provide wear resistance to the elbow areas. Component <NUM> is also located around a neck opening of torso region <NUM> and may be a polymer sheet that enhances the stretch-resistance of the area around the neck opening. Additionally, two components <NUM> are bonded to side areas of torso region <NUM> and may be polymer foam elements that attenuate forces impacting the sides of the wearer during athletic activities. Accordingly, the general concepts of knit component bonding may be utilized in shirt <NUM> to impart a variety of benefits. Moreover, similar concepts may be applied to a variety of other types of apparel to impart similar benefits, including headwear, pants, undergarments, socks, and gloves.

An article of footwear <NUM>, according to the claimed invention, is depicted in <FIG> as including a sole structure <NUM> and an upper <NUM>. Although footwear <NUM> is depicted as having a configuration that is suitable for running, the concepts of knit component bonding may be applied to a wide range of athletic footwear styles, including basketball shoes, biking shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennis shoes, and walking shoes, for example. Concepts associated with knit component bonding may also be utilized with footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, and sandals. Accordingly, knit component bonding may be utilized with a wide variety of footwear styles.

Sole structure <NUM> is secured to upper <NUM> and extends between the foot and the ground when footwear <NUM> is worn. In general, sole structure <NUM> may have any conventional or non-conventional configuration. Upper <NUM> provides a structure for securely and comfortably receiving a foot of a wearer. More particularly, the various elements of upper <NUM> generally define a void within footwear <NUM> for receiving and securing the foot relative to sole structure <NUM>. Surfaces of the void within upper <NUM> are shaped to accommodate the foot and extend over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. In this configuration, at least an exterior surface of upper <NUM> is formed from a textile similar to knit component <NUM>. That is, the textile forming the exterior surface is at least partially formed from a yarn incorporating a fusible material, which has properties similar to fusible yarn <NUM>. Moreover, the fusible material is located on at least a portion of the exterior surface. The textile is also at least partially formed from a yarn incorporating a non-fusible material, which has properties similar to non-fusible yarn <NUM>.

Given the configuration of footwear <NUM> discussed above, various components <NUM>-<NUM> may be secured to the textile of upper <NUM> through knit component bonding. According to an embodiment, component <NUM> may be secured to a forefoot area of upper <NUM> and may be a polymer or leather sheet that forms a wear resistant toe guard extending from a lateral side to a medial side of footwear <NUM>. Component <NUM> is located around a heel region of footwear <NUM> and extends from the lateral side to the medial side of footwear <NUM> to form a heel counter that will resist lateral movements of the foot during walking, running, and other ambulatory activities. Although component <NUM> is secured to the exterior surface of upper <NUM>, component <NUM> may also be secured to the interior surface if a fusible material is present at the interior surface. Various polymer sheets and plates, for example, may be utilized for component <NUM>. Component <NUM> may also be a polymer or leather sheet that extends around a throat area of upper <NUM> to reinforce lace apertures due to tension in a lace. Additionally, three components <NUM> forming the characters "XYZ" are located on the lateral side of upper <NUM> to represent a trademark or other indicia. Accordingly, the general concepts of knit component bonding may be utilized in footwear <NUM> to impart a variety of benefits.

In the configuration of footwear <NUM> disclosed above, the textile forming the exterior surface of upper <NUM> is noted as being partially formed from a yarn incorporating a fusible material. In the configuration depicted in <FIG>, however, the exterior surface of upper <NUM> may be a base element formed from any material commonly utilized in footwear uppers. That is, the exterior surface of upper may or may not include a thermoplastic polymer material. Moreover, components <NUM>-<NUM> may be formed from a textile incorporating a yarn with a fusible material. In other words, components <NUM>-<NUM> may have the configuration of knit component <NUM> As such, the fusible material of components <NUM>-<NUM> may be utilized to form a thermal bond with upper <NUM>.

Claim 1:
An upper (<NUM>) for an article of footwear (<NUM>) comprising:
a knit component (<NUM>) forming at least a surface of the upper (<NUM>), wherein the knit component (<NUM>) comprises a first surface (<NUM>) and an opposite second surface (<NUM>), wherein the knit component (<NUM>) includes a non-fusible yarn (<NUM>) and a fusible yarn (<NUM>), the non-fusible yarn (<NUM>) extending throughout the knit component (<NUM>), characterised by the fusible yarn (<NUM>) being located on at least the first surface (<NUM>), and
a bonded component (<NUM>, <NUM>-<NUM>) adjacent to the first surface (<NUM>),
wherein the bonded component (<NUM>) is thermal bonded to the first surface (<NUM>) with a thermoplastic polymer material of the fusible yarn (<NUM>).