Patent Description:
A variety of articles are formed from textiles. As examples, articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats) are often at least partially formed from textiles. These textiles are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines. One particular object that may be formed from a textile is an upper for an article of footwear.

Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is secured to the sole structure and forms a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. In some articles of athletic footwear, for example, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. The outsole may be secured to a lower surface of the midsole and forms a ground-engaging portion of the sole structure that is formed from a durable and wear-resistant material.

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 area 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. 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 composite textile fabric that includes a first fabric layer and a second fabric layer that is formed concurrently with the first fabric layer in a plaited construction. The second fabric includes a plurality of anchored regions at which the second fabric layer is anchored to the first fabric layer. The second fabric layer also includes a plurality of floating regions, overlying and unattached to the first fabric layer, interspersed between the anchored regions.

<CIT> discloses a sheet of complex, multi-layer material. The material is produced by means of weaving or knitting. A structure is created having two stacked faces which are intermittently interconnected in such a way as to form pockets. One of the aforementioned layers shrinks under the effect of heat and the link between said layers is provided by the intermittent binding of a selection of threads in order to form the pockets.

<CIT> discloses a knitted fabric, which is knitted from a first yarn with a relatively high shrinkage property and has been shrunk after knitting, and a knitted fabric, which is knitted from a second yarn, lie opposite one another and are with one another connected, whereby a multi-layer knitted fabric is formed with an inner curvature and an outer curvature.

The embodiments will be further described in connection with the attached drawings. It is intended that the drawings included as a part of this specification be illustrative of the exemplary embodiments and should in no way be considered as a limitation on the scope of the present disclosure. Indeed, the present disclosure specifically contemplates other embodiments not illustrated but intended to be included in the claims.

The objective technical problem to be solved can 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 according to the independent claims. A knitted component for an upper of an article of footwear according to the claimed invention is defined in claim <NUM> and a method of knitting a textile for an upper of an article of footwear according to the claimed invention is defined in claim <NUM>.

Certain aspects of the present disclosure relate to articles at least partially formed from textiles. One example of an article is an article of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear, or the like). The article may be an upper configured for use in an article of footwear. The upper 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 upper may also be incorporated into a non-athletic shoe, such as a dress shoe, a loafer, and a sandal.

Referring to <FIG>, an article of footwear <NUM> may include an upper <NUM> secured to a sole structure <NUM>. The upper <NUM> includes a lateral side <NUM> and a medial side <NUM>. The area of the shoe where the sole structure <NUM> joins the upper <NUM> may be referred to as the biteline <NUM>. The upper <NUM> may be joined to the sole structure <NUM> in a fixed manner using any suitable technique, such as through the use of an adhesive, by sewing, etc. It is contemplated that the upper <NUM> may extend partially or completely around the foot of a wearer and/or may be integral with the sole, and a sockliner may or may not be used. In some embodiments, the sole structure <NUM> may include a midsole (not shown) and an outsole.

The article of footwear <NUM> may additionally include a throat area <NUM> and an ankle opening <NUM>, which may be surrounded by a collar <NUM> and may lead to a void <NUM>. The void <NUM> of the article of footwear <NUM> may be configured to accommodate a foot of a person. The throat area <NUM> may be generally disposed in a midfoot area <NUM> of the upper <NUM>. The midfoot area <NUM> is generally an area of the upper <NUM> located between a heel area <NUM> and a toe area <NUM>. In some embodiments, a tongue may be disposed in the throat area <NUM>, but a tongue is an optional component. The tongue may be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included, the lateral and medial sides of the throat area <NUM> may be joined together. As shown, in some embodiments, the article of footwear <NUM> may include an optional fastening element, such as a lace (which may be associated with the lace apertures <NUM>). Any suitable type of fastening element may be used.

The upper further includes one or more structures, including but not limited to, at least one raised structure <NUM>, sometimes referred to herein as a "welt" or "ottoman. " The raised structure is a generally elongated structure that extends in a direction that is generally perpendicular to the course-wise direction of the knitted component.

The raised structure <NUM> may be arranged at any suitable location on the article of footwear, such as in the heel area <NUM>, the medial side <NUM>, the lateral side <NUM>, the toe area <NUM>, and/or another location or combination thereof. The raised structure <NUM> may be advantageous for providing the article of footwear <NUM> with suitable cushioning, rigidity (e.g., without sacrificing flexibility in certain directions), durability, desirable aesthetic properties, or other properties. Any suitable number of raised structures <NUM> may be included. In some embodiments, a plurality of raised structures <NUM> may be included. In one non-limiting example, as shown in <FIG>, a plurality of elongated and parallel raised structures <NUM> may be present. As shown, the plurality of parallel raised structures <NUM> extend longitudinally between a heel area <NUM> and a toe area <NUM>. The course-wise direction of the knitted component extends between the lateral and medial sides of the upper such that the plurality of raised structures <NUM> (or at least a portion of the plurality of raised structure <NUM>) extend longitudinally between a heel area <NUM> and a toe area <NUM> are therefore perpendicular to the course-wise direction of the knitted component.

At least a portion of the upper <NUM>, and in some embodiments substantially the entirety of the upper <NUM>, is formed of a knitted component <NUM>, such as a weft-knitting process on a flat knitting machine, for example. The knitted component <NUM> may additionally form another element of the article of footwear, such as an underfoot portion, for example. The knitted component <NUM> may have a first side <NUM> forming an inner surface of the upper <NUM> (e.g., facing the void of the article of footwear) and a second side <NUM> forming an outer surface of the upper <NUM> (e.g. facing generally opposite the first side <NUM>). The first side <NUM> and the second side <NUM> of the knitted component <NUM> may exhibit different characteristics (e.g., the first side <NUM> may provide abrasion resistance and comfort while the second side <NUM> may be relatively rigid and provide water resistance, among other advantageous characteristics mentioned herein). The knitted component <NUM> may be formed as an integral one-piece element during a knitting process, such as a weft knitting process (e.g., with a flat knitting machine or circular knitting machine), a warp knitting process, or any other suitable knitting process. That is, the knitting process on the knitting machine may substantially form the knit structure of the knitted component <NUM> without the need for significant post-knitting processes or steps. Alternatively, two or more portions of the knitted component <NUM> may be formed separately as distinct integral one-piece elements and then the respective elements attached.

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

The yarns themselves and/or the knit structure formed by one or more of the yarns of the knitted component <NUM> are varied at different locations such that the knitted component <NUM> has two or more portions with different properties (e.g., a portion forming the throat area <NUM> of the upper <NUM> may be relatively elastic while another portion may be relatively inelastic). In the embodiments, the knitted component <NUM> incorporates one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light).

For example, the knitted component <NUM> may include yarns formed of a thermoplastic polymer material (e.g., polyurethanes, polyamides, polyolefins, and nylons) that transitions from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point and then transitions back to the solid state when cooled. The thermoplastic polymer material may provide the ability to heat and then cool a portion of the knitted component <NUM> to thereby form an area of fused or bonded or continuous material that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example.

The knitted component <NUM> may include a seamless portion extending from the toe area <NUM>, through a midfoot area <NUM>, and to a heel area <NUM> on at least one of a lateral side and a medial side of the upper. In some embodiments, the knitted component <NUM> may include a first edge and a second edge, which may be terminal ends of the knitted component <NUM> after the knitting process when the knitted component <NUM> is removed from the knitting machine. After the knitting process, the knitted component <NUM> may be folded or otherwise manipulated such that a first edge and the second edge are secured together at a seam <NUM> during formation of the upper <NUM>. The seam <NUM> may be located on the lateral side <NUM> of the upper <NUM>, on the medial side <NUM> of the upper <NUM>, and/or in another location (e.g., at the back of the heel area <NUM> of the upper as shown in <FIG>). Forming the upper <NUM> such that it is in an appropriate shape for inclusion in an article of footwear may further include lasting the upper <NUM>. An example of a lasting process is described in <CIT>, and issued as <CIT>.

When forming the knitted component <NUM>, the knitted component <NUM> may be oriented with respect to a needle bed of a knitting machine such that a feeder of the knitting machine is capable of moving in a single pass (i.e. , without changing its feed direction direction) to knit a first course <NUM> (see <FIG> and <FIG>) from the lateral side <NUM> to the medial side <NUM> of the knitted component. As such, as the courses are formed that are parallel to the first course <NUM>, the toe area <NUM> of the knitted component <NUM> will be formed first, followed by the midfoot area <NUM> of the knitted component <NUM>, and then the heel area <NUM> of the knitted component <NUM> (and/or vice versa, such that it is formed from heel to toe). Thus, when the knitted component <NUM> is formed and removed from the knitting machine, the first course <NUM> (which may include one or more yarns dispensed from a feeder during the single pass) may extend at least partially between the medial side and the lateral side of the knitted component.

In some embodiments, the first course <NUM> may include a continuous strand of yarn that extends between the lateral and medial side of the upper <NUM>. Additionally or alternatively, one or more strands of yarn forming at least a portion of the first course <NUM> may extend less than the full length of the first course <NUM>. For example, it is contemplated that a strand of yarn may extend from one side of the upper (such as a lateral or a medial side) to the other side of the upper, but may terminate within the first course <NUM> prior to reaching the other side. In one non-limiting example, one strand of yarn may extend from a lateral side towards a medial side when forming a course but terminate before it reaches the medial side. The course may continue in an uninterrupted manner towards the medial side, but with an additional or alternative strand of a different second yarn picking up where the first yarn terminated. Alternatively, a first and second strand can be combined such that the course is knitted with a combination of the first and second strand of yarn.

As shown in <FIG> (and as described in further detail below), the courses of the knitted component at least partially form the raised structure <NUM> of the knitted component <NUM> and/or portions of the knitted component <NUM> without raised structures (i.e., such that the course-wise direction extends generally across, or along the width, of the raised structures <NUM>. <FIG> shows a close-up, cross-sectional view of a portion of the knitted component <NUM>. While <FIG> (and <FIG>) show a partial view of the knitted component <NUM> before being subjected to a stimulus (including but not limited to steam heat, for example), <FIG> (and <FIG>) show a partial view of the knitted component <NUM> after being subjected to a post-manufacture process or stimulus treatment, including, but not limited to steam.

As shown in <FIG>, the upper <NUM> has a first layer <NUM>, a second layer <NUM>, with a pocket <NUM> formed between the first layer <NUM> and the second layer <NUM>. In other portions of the upper, the first layer <NUM> and the second layer <NUM> are coextensive and/or overlapping, but do not form a pocket there between. The pocket <NUM> may be filled with another element (e.g., a filler material, such as foam, down, or another suitable material or object), but this is not required, and in exemplary embodiments, the pocket <NUM> may be empty and/or filled with just air.

The first layer <NUM> and the second layer <NUM> are both formed by knit structures of the knitted component <NUM> such that the raised structure <NUM> is primarily formed on a knitting machine with the rest of the knitted component <NUM>.

When the knitted component <NUM> is included in an upper, the second layer <NUM> may form an external surface of an upper and the first layer <NUM> may form an inner surface of the upper. The first course <NUM> may extend along a direction that herein defines "a first direction" (which is illustrated as lateral to medial direction, generally along an x-axis as shown in <FIG>). The first direction may be approximately horizontal when the knitted component <NUM> is incorporated into an upper, for example, and/or when the knitted component <NUM> is being formed on a knitting machine (such that the "first direction" is parallel to the needle bed). The length of at least one raised structure <NUM> (or the length of a plurality of raised structures) may extend longitudinally in a second direction, where the second direction may be generally angled with respect to the first direction. In one non-limiting example, the second direction may be generally perpendicular to the first direction.

In such an arrangement, at least one raised structure <NUM> and/or a plurality of the raised structures <NUM> extend in a heel to toe direction, generally along a y-axis as shown in <FIG>. This may be referred to herein and by one of skill as a "vertical ottoman" structure. In other words, the raised structure <NUM> or ottoman extends between the heel and toe and angled with respect to the course-wise direction of the knitted upper. In one non-limiting example, being angled with respect to the course-wise direction may include the raised structure <NUM> being generally perpendicular to the course-wise direction. Thus, as the upper <NUM> is being formed by consecutive knit courses that extend in a lateral to medial direction (the first direction), the upper <NUM> may be coming off the knitting machine with either the heel region or toe region first, and the vertical ottoman structure extending longitudinally, generally in a heel-to-toe direction (the second direction). In other embodiments, certain raised structures <NUM> may extend diagonally between the heel and toe such that one or more of the raised structures <NUM> are not totally parallel with the y-axis but rather, are angled and/or extend diagonally relative to the y-axis, generally in a heel-to-toe direction. In one embodiment as shown in <FIG>, one or more of the raised structures <NUM> may extend generally along the y-axis in a toe area <NUM> and/or midfoot area <NUM> and as the raised structure extends towards the heel area <NUM>, it may angle upwards or diagonally and/or angled with respect to the y-axis. It is also contemplated that one or more of the raised structures <NUM> extend in respective different directions from one another.

A raised structure <NUM> includes a length <NUM> along the second direction (e.g., heel-to-toe in <FIG> ) and a width <NUM> along the first direction (e.g., medial-to-lateral in <FIG>). The length is greater than the width. It is contemplated that, with a high length-to-width ratio, the raised structure <NUM> can be given appropriate characteristics for forming a suitable ottoman knit structure (sometimes also referred to as a "welt" knit structure) where the second layer <NUM> is raised or bulged and extends outwardly and away from the first layer <NUM>, as shown in <FIG> and by the vertically pointing arrows in <FIG>. In some embodiments, the length <NUM> of the raised structure <NUM> may be at least <NUM>% larger than the width <NUM>, at least <NUM>% larger than the width <NUM>, at least twice the width <NUM>, at least five times the width <NUM>, or greater than five times the width <NUM>. The length of raised structure <NUM> on a single article can vary, or each raised structure <NUM> on a single article can have the same length.

A variety of processes are contemplated for creating the raised structure <NUM> (i.e. a vertical ottoman), and these processes may occur during or after the knitting process for forming the knitted component <NUM>. For example, the upper may be knit on a knitting machine having a front bed and a back bed. In one example, a yarn knit on the back bed may ultimately form the first side <NUM> forming an inner surface of the upper <NUM> (e.g., facing the void of the article of footwear). A yarn knit on the front bed may ultimately form the second side <NUM> forming an outer surface of the upper <NUM> (e.g. facing generally opposite the first side <NUM>), as shown in <FIG>.

One or more yarns may be used when knitting the knitted component. In one non-limiting example, a first yarn is used to form at least a portion of the first side <NUM> of the knitted component forming an inner surface of an upper. The first yarn may include, for example a relatively elastic yarn. One or more ends of the first yarn may be used, such as one end, two or more ends. Preferably, in this example, one end of the first yarn may be used. In one non-limiting example, the first yarn may be an"E04"-type yarn supplied by Unifi, Inc. of Greensboro, North Carolina, which preferably has a relatively high elasticity compared to other yarns that may be used to form the knitted component. The first yarn may comprise a spandex core (i.e. Lycra) wrapped with polyester. It may have a denier range of <NUM>-<NUM>, and a tensile strength of ><NUM> and an elongation of <NUM>-<NUM>. Such as when it is desirable for the first yarn to reduce in size during the manufacturing process, the shrinkage rate of the first yarn is higher relative to other yarns used to form the knitted component when subjected to heat (or another stimulus). In other words, when subjected to heat (e.g., via steam), the first yarn shrinks more, and/or at a higher rate, than the other yarns used to form the knitted component. Features associated with a relatively-high shrinkage rate are described in more detail below.

A second yarn is used to form at least a portion of the second side <NUM>, or outer surface, of the knitted component. The second yarn is different from the first yarn. The second yarn used to form at least a portion of the second side <NUM> of the knitted component (which forms at least a portion of the outer surface of the upper) is a yarn that has different properties relative to the first yarn. In one example, the second yarn is a relatively inelastic yarn. One or more ends of the second yarn may be used, such as one end, two ends or more than two ends. For example, four ends of the second yarn may be used. This second yarn may be referred to as"P16" provided by Unifi, Inc. of Greensboro, North Carolina, which may have a relatively low elasticity compared to other yarns that may be used to form the knitted component. The second yarn may be formed primarily of a strand, or multiple strands, of textured polyester. It may have a denier range of approximately 155D to approximately 180D, a tensile strength of about <NUM> to <NUM> and an elongation of <NUM>-<NUM>. The shrinkage rate of the second yarn is lower relative to other yarns used to form the knitted component. In other words, when subjected to a similar amount of heat, (e.g., such as via steam), the second yarn shrinks much less if at all, and/or at a lower rate, than the other yarns used to form the knitted component.

In addition to the first and second yarn used to form the knitted component, a third yarn may be used to form the knitted component. The third yarn may be the same as the first yarn and/or the second yarn, or it may be different. In one example, the third yarn used to form at least a portion of the knitted component comprises a yarn that is different than the first yarn and the second yarn. In one example, the third yarn is relatively less elastic than the first yarn (E04) but is relatively more elastic than the second yarn (P16). The third yarn may be a combination of materials or strands. In one example, the third yarn may comprise a combination of a polyester yarn with an elastic core and a yarn formed of a thermoplastic polymer material, sometimes referred to as a "fusible yarn. " The polyester yarn with an elastic core may be referred to as"P15" (which, in one example, is a strand of the P16 mentioned above, air tacked to a strand of spandex). The yarn formed of a thermoplastic polymer material, or fusible yarn may be a polyester that melts at about <NUM>. In one non-limiting example, the fusible yarn may be approximately <NUM> denier, comprising <NUM> continuous filaments. Thus, the third yarn may be a combination of a polyester yarn (i.e. P15) and a yarn formed of a thermoplastic polymer material, or "fusible yarn. " The combination of materials, such as the polyester yarn and the fusible yarn that together form the third yarn may be achieved by twisting, winding, braiding, and or wrapping on about the other and the like, and/or the yarns may be a core/sheath configuration, and/or the yarns may be tacked along their length at a plurality of points.

One or more ends of the third yarn may be used, such as one end, two ends or more than two ends. Preferably, in this example, the third yarn comprises a combination of four ends of P15 and one end of a fusible yarn. The elastic (i.e. Lycra) core of the P15 allows the third yarn to have a greater elasticity than the second yarn (i.e. P16 yarn), but a lower elasticity than the first yarn (the elastic E04 yarn). The third yarn may have a denier range of approximately 160D to approximately 190D, a tensile strength of about <NUM> to <NUM> and an elongation of <NUM>-<NUM>. The shrinkage rate of the third yarn may be lower relative to the first yarn and greater relative to the second yarn used to form the knitted component when subjected to heat or another stimulus. In other words, when subjected to a similar amount of heat (e.g., via steam), the third yarn may shrink relatively more than the second yarn and relatively less than the first yarn used to form the knitted component.

During or after the knitting process, a stimulus, such as heat, may be applied to at least a portion of, or to the entirety of the upper. This heat may be in the form of steam, such as by a steam-providing device, for example. One or more effects may result from the exposure of the knitted component to steam.

In one example, the steam may cause one or more of the yarns used to form the knitted component to shrink at different relative rates, thus forming the raised structure <NUM>. For example, the steam may cause the first yarn (e.g. the relatively highly elastic E04 yarn) to shrink at a higher degree and/or rate than the second and third yarns used to form the knitted component. The third yarn (or P15 yarn), which is relatively less elastic than the first yarn but relatively more elastic than the second yarn, may also shrink in response to the steam heat stimulus, but less so than the first yarn. The second yarn (i.e. P16) which is a relatively inelastic yarn has relatively little or insignificant shrinkage in response to the steam heat stimulus.

In one non-limiting example relating to relative shrinkage rates, three different test swatches were knitted, each swatch knitted exclusively from one type of yarn. In this example, the test swatches were each knitted in a jacquard structure and then exposed to a steam heat stimulus. The first swatch was knitted entirely of the first yarn, or 'E04" type yarn. The second swatch was knitted entirely of the second yarn, or"P16" type yarn. The third swatch was knitted entirely of the third yarn, of"P15" type yarn. After steaming, the shrinkage rates were as follows, with the percentage (%) representing the percentage of shrinkage of the width of the original swatch:.

In another example, the steam may also activate thermoplastic polymer materials in the third yarn. Once this heat is removed and the article cools, the thermoplastic material present in the third yarn (i.e. the one end of "fusible yarn" present in the third yarn) may at least partially fuse together with adjacent yarns in its proximity to within the knitted component. When the thermoplastic material transitions back to a solid state upon cooling, this may cause the fused yarns to remain fixed in (or at least have a tendency to remain fixed in) a desirable position and orientation. Heat-processing the fusible material of the fusible yarn may also enhance the rigidity, strength, and other mechanical properties of the knitted component at least in select locations.

As shown in <FIG>, the first yarn is used to form at least a portion of the first side <NUM> of the knitted component forming an inner surface of an upper (e.g., facing a void). The second yarn is used to form at least a portion of the second side <NUM>, or outer surface, of the knitted component. Prior to exposing the knitted component to a stimulus, the second side <NUM> may be generally flat, overlapping and generally coextensive to the first side <NUM> as shown in <FIG>. Alternatively, prior to exposing the knitted component to a stimulus, the raised structure <NUM> may be partially visible as shown in <FIG>, but not as pronounced and/or defined as shown in <FIG> which illustrates one example of the knitted component after exposure to a stimulus. When exposed to a stimulus, such as steam, the first yarn of the first side <NUM> shrinks, while the second yarn on the second side <NUM> of the knitted component has relatively little or insignificant shrinkage. The shrinkage of the first yarn causes the second yarn to buckle or bulge outward as shown in <FIG> and by the vertically oriented arrows in <FIG> to form a raised structure <NUM> that extends outwardly and away from the first side <NUM> of the knitted component. In other words, the relative difference in shrinkage among the different yarns used to form the knitted component upon exposure to a stimulus results in the formation of a raised structure <NUM> or "ottoman.

As shown in <FIG>, the third yarn (i.e. the P15 combined with fusible yarn) forms at least a portion of the second side <NUM>, or outer surface of the knitted component. The third yarn may be located between one or more of the raised structures <NUM>. In other words, the third yarn may form a valley <NUM> between one or more of the raised structures <NUM> on the second side <NUM> as shown in <FIG>. As noted above, the third yarn (P15 + fusible) has a relatively higher degree of shrinkage as compared to the second yarn (P16). This may be at least partially attributable to the tendency of the material forming the third yarn to shrink when subjected to heat or another stimulus. Therefore, when the knitted component is exposed to a stimulus such as steam, the resulting shrinkage of the third yarn may help to "pinch" together and define the sides of the raised structure <NUM> or ottoman. Furthermore, the thermoplastic material component (i.e. the fusible yarn component of the third yarn) may transition from a solid state to a softened or liquid state when subjected to certain temperatures at or above its melting point during steaming, and then transition back to the solid state when cooled. As such, the third yarn may be at least partially fused to the first yarn which forms the first side <NUM>, or inner surface of the knitted component. In one example, the presence of the third yarn on the second side <NUM>, or outer surface of the knitted component, may therefore serve to form a valley <NUM> located between raised structures <NUM> to better define the loft of the raised structure <NUM>. Furthermore, by fusing to the first yarn of the first side <NUM>, the third yarn may provide enhanced stability, lock down, rigidity and or stability to the knitted component when formed into an upper for an article of footwear.

Turning now to <FIG>, a knit program used to form a knitted component comprising one or more raised structures <NUM> ("welts" or "ottomans") as identified herein will be described. First, looking to <FIG>, a program view of the vertical ottomans ("welts") formed on at least a portion of the second side <NUM>, or outer surface of the knitted component is illustrated. As shown there, a series of vertical regions or stripes are depicted. When viewed in color, the red vertical regions (or, when in black and white, the darker vertical stripe) represent a raised structure <NUM> (i.e. a "welt" or "ottoman") formed on the second side <NUM> or outer surface of the knitted component. The yellow (or lighter when viewed in black and white) vertical regions or stripes represent a valley <NUM> located between each of the raised structures <NUM>. Thus, it can be seen that there is one valley <NUM> comprised of the third yarn located between each of the raised structures <NUM> formed of the second yarn.

Next, looking to <FIG>, a knit diagram illustrating the "technical view of the vertical welts" is shown. It is noted that the knit diagram of <FIG> is an enlarged portion of the process view of vertical welts (i.e. raised structures or ottomans) shown in <FIG>. In other words, this knit diagram of <FIG> and <FIG> represents the formation of at least a portion of the knitted component on a knitting machine having two needle beds, a front bed and a back bed.

Looking specifically to <FIG>, the front needle bed is represented by the series of dots (needles) on the bottom row of each course, while the back needle bed is represented by the series of dots (needles) on the top row of each course. The portion of the knitted component shown in <FIG> has at least seven courses comprising at least two raised structures <NUM> and at least two "valleys" <NUM> located between the raised structures <NUM>.

Looking to the first course <NUM>, the first yarn (E04) is knit on the back needle bed only, while the front needle bed of the first course <NUM> remains empty. As shown, the first yarn is knit on every other needle of the back bed to form at least a portion of the first side <NUM>, or inner surface of the knitted component. Using every other needle on the back bed (as opposed to all needles on the back bed) may help to avoid the first side <NUM> from becoming too rigid and/or brittle, and it may provide empty needles that can be utilized for other knit actions (e.g., knitting loops of the second and/or third yarns on the back needle bed to couple the second layer <NUM> to the first layer <NUM> (see <FIG>) at the valleys <NUM> between the raised structures <NUM>).

Next, looking to the second course <NUM> of <FIG>, the third yarn (P15) is knit on both the front and back needle beds. Specifically, as shown, the third yarn is knit on two needles, then skips two needles on the front bed. The third yarn is knit on every third needle on the back bed. It is noted that where the third yarn is present on the front needle bed, the second yarn (P16) is absent. As such, this results in the formation of raised structures <NUM> of the second yarn separated by "valleys" <NUM> formed by the third yarn on the second side <NUM> or outer surface of the knitted component. Where the third yarn is present on every fifth needle on the back bed (forming a portion of the first side <NUM> or inner surface of the knitted component), the thermoplastic material component of the third yarn may fuse with the first yarn (E04) also present on the first side <NUM> when the knitted component is heat processed (e.g., after knitting). This may help form the "valley" <NUM> between raised structures <NUM>, further pinch and/or close the sides of the adjacent raised structure <NUM>, and define the raised structure and provide additional stability to the knitted component when it is formed into an upper <NUM>.

Next, looking to the third course <NUM> depicted in the knit diagram, the second yarn (P16) is knit on both the front and back needle beds. Specifically, as shown, the second yarn is knit on two needles, then skips two needles on the front bed. The second yarn is knit on every fifth needle on the back bed. By pulling the second yarn to the back bed to knit the second yarn on at least one needle at regular and space apart intervals (such as every fifth needle of the back needle bed as shown) the second yarn can be locked to the first side <NUM> or inner surface of the knitted component. As noted above, where the second yarn is present on the front needle bed, the third yarn (P15) is absent. As such, this results in the formation of raised structures <NUM> formed by the second yarn separated by the valleys <NUM> formed by the third yarn. Upon steaming or other application of heat, the second yarn knitted on the front needle bed (forming the second or outer surface) will warp, bulge, and/or buckle as the first yarn knitted on the back needle bed (forming the first or inner surface) shrinks. The shrinkage of the first yarn allows the raised structure <NUM> or ottoman to form and extend away from the first side <NUM> (inner surface).

Next, looking to the fourth course <NUM>, the first yarn (E04) is again knit on every other needle of the back bed, while leaving the front needle bed empty. This is a repeat of the knitting pattern of the first course <NUM> described above. Knitting the fourth course <NUM> of the first yarn forms a portion of the first side <NUM> or inner surface of the knitted component. When the knitted component is subjected to a stimulus such as steam, the shrinkage of the first yarn of the fourth course <NUM> allows the second yarn of the third and/or sixth course to buckle or bulge outwardly, forming a raised structure <NUM> formed from the second yarn.

Next, looking to the fifth course <NUM>, the third yarn (P15) is again knit on both the front and back needle beds. As shown, the third yarn is knit on two needles and then skips two needles on the front bed. On the back needle bed, the third yarn is knit on every fifth needle. The fifth course <NUM> of yarn forms at least part of the valley <NUM> located between the raised structure or ottoman formed by the second yarn of the third course <NUM> and the additional raised structure or ottoman formed by the second yarn of the next (or sixth) course <NUM> described below.

Next, looking to the sixth course <NUM>, the second yarn (P16) is again knit on both the front and back needle beds. As shown, the second yarn is knit on two needles and then skips two needles on the front bed. On the back needle bed, the second yarn is knit on every fifth needle. By pulling the second yarn to the back bed at regular and space apart intervals (such as every fifth needle as shown) the second yarn can be locked to the first side <NUM> or inner surface of the knitted component. The sixth course <NUM> of yarn forms another raised structure <NUM> (or ottoman or welt) adjacent to the raised structure <NUM> (or ottoman or welt) formed by the third course <NUM> described above. The "valley" <NUM> formed by the third yarn of the fifth course <NUM> mentioned above is located on one side of the raised structure <NUM> formed by this sixth course <NUM>.

Next, looking to the seventh course <NUM>, the first yarn is again knit on every other needle of the back bed, while leaving the front needle bed empty. This is a repeat of the knitting pattern of the first course <NUM> and fourth course <NUM> described above. Knitting the seventh course <NUM> of the first yarn forms a portion of the first side <NUM> or inner surface of the knitted component. When the knitted component is subjected to a stimulus such as steam, the shrinkage of the first yarn of the seventh course <NUM> allows the second yarn of the sixth course <NUM> to buckle or bulge outwardly, forming a raised structure <NUM> formed from the second yarn knitted by the sixth course <NUM>.

The knit sequence of <FIG> may be repeated, as necessary, to form a knitted component with a suitable size. Further, it is noted that the sequence(s) may be varied to incorporate different features by changing certain knit structures, by varying yarn types, by increasing or decreasing the number of courses at each step, or by any other suitable adjustment to the knitting process or materials used. Further, other sequences may be used before, after, or between the sequences of <FIG>.

The embodiments of the raised structure <NUM> and other features are described generally herein with reference to an upper <NUM> for an article of footwear. Knitted raised structures <NUM> may be included in articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats).

Claim 1:
A knitted component (<NUM>) for an upper (<NUM>) of an article of footwear (<NUM>), the knitted component comprising:
a first layer (<NUM>),
a second layer (<NUM>),
a raised structure (<NUM>) formed by the second layer, the raised structure extending away from the first layer, the raised structure including a length (<NUM>) extending along a heel-to-toe direction when the knitted component is incorporated into the article of footwear, the raised structure including a width (<NUM>) along a lateral-to-medial direction when the knitted component is incorporated into the article of footwear, wherein the length is greater than the width,
wherein the first layer is at least partially formed from a first yarn having a first shrinkage rate and wherein the second layer is at least partially formed by a second yarn having a second shrinkage rate, and wherein the shrinkage rate of the first yarn is greater than the shrinkage rate of the second yarn when subjected to heat.