Patent Description:
<CIT> discloses a knitted component for an article of footwear having a vertically inlaid tensile element. The inlaid tensile element extends along a direction that is vertical or at an angle to the direction of the knitting process of the knitted component. A method of knitting the knitted component includes placing a quantity of a tensile element into an auxiliary element of the knitted component and vertically inlaying a tensile element by using needles of a knitting machine to hold the tensile element by loops while the remaining portion of the knitted component is formed. As the knitted component is formed along a horizontal direction on the needles of the knitting machine, the tensile element spools out from within the auxiliary element to form the inlaid tensile element.

<CIT> discloses an article of footwear including an upper incorporating a knitted component. An inlaid strand extends through the knitted component. In manufacturing the knitted component, a feeder inlays the strand when the feeder arm is in the extended position, and the strand is absent from the knitted component when the feeder arm is in the retracted position.

<CIT> discloses an article of footwear including an upper with a knitted component formed of unitary knit construction. The knitted component has a first edge and a second edge. The second edge is joined to the first edge at a seam. The seam has a first end and a second end, wherein the first end is located generally at the rim of a collar on one of a medial side and a lateral side of the upper. The second end is spaced from the first end.

<CIT> discloses an article of footwear including an upper incorporating a knitted component formed of unitary knit construction. The knitted component includes portions having extended floated portions to distribute forces acting on the knitted component and resist stretching of the knitted component.

<CIT> disclosed knitted fabrics with inserted warp and weft threads starting and ending within the fabrics to give local shaping or patterning effects with multiple threads being inserted at a time.

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 of the independent claims. According to one aspect of the present disclosure, a knitted component is provided according to the subject matter of claim <NUM>. At least one course of the first plurality of inlaid courses of the high tenacity yarn may have a diameter of less than or equal to <NUM>. The first plurality of courses of the high tenacity yarn may include at least five courses of the high tenacity yarn. Each course of the first plurality of inlaid courses of the high tenacity yarn may have a linear density of at least <NUM> tex (<NUM>,<NUM> denier), with <NUM> tex corresponding to <NUM> denier. Each course of the first plurality of courses of the high tenacity yarn may have a maximum tensile strength of at least <NUM>,<NUM> grams-force. The knitted component may further include a second plurality of inlaid courses of the high tenacity yarn having a tenacity of at least six grams-force per denier. At least one course of the first plurality of inlaid courses may extend from a first edge toward a second edge, and at least one course of the second plurality of inlaid courses may extend from the second edge toward a third edge. At least one course of the first plurality of inlaid courses may extend from a first edge toward a second edge, and at least one course of the second plurality of inlaid courses may extend from the second edge toward the first edge. At least one course of the first plurality of inlaid courses may extend part way to the second edge, and at least one course of the second plurality of inlaid courses may extend part way to the first edge. At least one course of the first plurality of inlaid courses may extend past the at least one course of the second plurality of inlaid courses. The at least one course of the first plurality of inlaid courses may extend from the first edge to the second edge. The first knit layer may conceal one or more of the plurality of inlaid courses. The first knit layer and the second knit layer may be at least partially formed from the first yarn. At least one course of the plurality of inlaid courses may be secured to at least one of the first and second knit layers with a tuck stitch. The high tenacity yarn and the first yarn may have at least one different visual property, for example different colors. The knitted component further includes a plurality of openings formed in the first knit layer, through which an exposed portion of the plurality of inlaid courses of the high tenacity yarn is visible from a first viewpoint facing the first knit layer. The exposed portion is recessed relative to a first surface of the first knit layer. The plurality of openings forms a pattern, at least a portion of which has an orientation other than a course-wise direction.

According to another aspect of the present disclosure, a method of forming a knitted component is provided according to the subject matter of claim <NUM>.

An article of footwear may include a knitted component defining at least part of a void and joined with a sole structure. The knitted component may be configured according to the subject matter of claim <NUM>. At least one course of the plurality of inlaid courses of the high tenacity yarn may have a diameter of less than or equal to <NUM>. The high tenacity yarn may have a tenacity of at least six grams-force per denier. The plurality of inlaid courses may be at least partially located on at least one of a lateral side and a medial side of the article. The plurality of inlaid courses may be at least partially located in a midfoot region of the article, and/or at least partially located adjacent to a throat region of the article, and/or at least partially located in a forefoot region of the article, and/or at least partially located on the lateral side and the medial side of the article, and/or at least partially located in a rearfoot region. The plurality of inlaid courses may extend from a lateral edge to a medial edge. The plurality of inlaid courses may extend substantially throughout the knitted component. The plurality of inlaid courses may be at least partially located in at least one of a heel region and a toe box region of the article, and/or at least partially located on at least one of a medial side and a lateral side of the article, and/or may extend from the heel region to the toe box region.

An article of footwear may include a knitted component according to the subject matter of claim <NUM> defining at least part of a void and a sole structure joined with the knitted component. The article may include a second plurality of courses of the high tenacity yarn inlaid between the interior knit layer and the exterior knit layer, which may be located in a different location of the knitted component from the first plurality. At least one of the first plurality and the second plurality of courses of the high tenacity yarn may be at least partially located on at least one of a medial side and a lateral side of the article. At least one of the first plurality and the second plurality of courses of the high tenacity yarn may be at least partially located in a rearfoot region of the article. At least one of the first plurality and the second plurality of courses of the high tenacity yarn may be at least partially located in a heel region of the article. At least one of the first plurality and the second plurality of courses of the high tenacity yarn may be at least partially located in a midfoot region of the article. At least one of the first plurality and the second plurality of courses of the high tenacity yarn may be at least partially located in a forefoot region of the article. At least one of the first plurality and the second plurality of courses of the high tenacity yarn may be at least partially located in a toe box region of the article. At least one course of at least one of the first plurality and the second plurality of courses of the high tenacity yarn may be secured to the sole structure. A plurality of lace apertures may extend through at least one of the first plurality and second plurality of courses of the high tenacity yarn. The exterior knit layer may include a plurality of openings, through which an exposed portion of at least one of the first plurality and the second plurality of courses of the high tenacity yarn may be visible. The exterior knit layer may include a plurality of elongate and parallel knit structures.

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. Moreover, in the figures, like-referenced numerals designate corresponding parts throughout the different views.

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

Knitted component <NUM> includes at least a first layer <NUM> and a second layer <NUM>. First layer <NUM> and second layer <NUM> may be formed on one or more needle beds of a knitting machine, e.g., a first needle bed and/or a second needle bed. When one or both of first and second layers <NUM>, <NUM> are formed on more than one needle bed, or when first and second layers <NUM>, <NUM> are formed on different needle beds, then resulting knitted component <NUM> is a multi-bed knitted component. As used in this application, first layer <NUM> forms a first surface <NUM> comprising a first plurality of knit loops, and second layer <NUM> forms a second surface <NUM> comprising a second plurality of knit loops. First layer <NUM> overlaps at least a portion of second layer <NUM>, and first and second layers <NUM>, <NUM> may be coterminous in one or more dimensions; however, first and second layer <NUM>, <NUM> need not be coterminous. At least a portion of first layer <NUM> may be freely separable from second layer <NUM>. In other words, first layer <NUM> and second layer <NUM> have one or more portions with opposite facing surfaces, thereby making those portions of first layer <NUM> freely separable from second layer <NUM>. That is, first surface <NUM> generally faces a first direction, and second surface <NUM> generally faces the opposite direction. Although first layer <NUM> may be freely separable from second layer <NUM> in certain areas, it need not be freely separable. For example, knitted component <NUM> may include one or more interlayer knit stitches (e.g., stitches formed during the same knitting process and extending between a first needle bed and a second needle bed). Such interlayer knit stitches may be formed by the same yarn(s) that forms the first and/or second layers <NUM>, <NUM>, or a different yarn. In one example, at least one course of yarn may form a portion of both first layer <NUM> and second layer <NUM>, e.g., a knit structure formed on both first and second needle beds that includes the first plurality of knit loops on the first surface <NUM> and the second plurality of loops on the second surface <NUM>. For example, in an interlock knit structure or similar structure that includes one or more courses having loops formed on both a first and a second needle bed, each course may form at least a part of both the first and second layers <NUM>, <NUM>. Alternatively, different courses of yarn may form the first and second layers <NUM>, <NUM>, e.g., a first course may form a single jersey first layer on a first needle bed and a second course may form a single jersey second layer on a second needle bed, where at least a portion of the single jersey first layer is separable from the single jersey second layer (as in <FIG>). Knitted component <NUM> may include additional layers, e.g., to add cushioning, protection, or for other advantages. In various applications, first layer <NUM> or second layer <NUM> may correspond with at least part of an outer or inner layer of an article of apparel or industrial textile, an exterior or interior layer of an upper for an article of footwear, or other application.

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

The second layer <NUM> may eventually correspond with an interior layer of an article of footwear, such as when the article has been assembled and is configured to accommodate the foot of a wearer, and therefore, the second layer <NUM> may include one or more courses of yarn having a relatively soft hand, for example a yarn having a napped finish or otherwise provide breathability and comfort to the wearer. Additionally or alternatively, second layer <NUM> may include one or more elasticized yarns to give resiliency to the knitted component. The examples are non-limiting and are intended to illustrate the versatility of first and second layers <NUM>, <NUM> which may be formed from the same yarn(s) or different yarns or a combination thereof to provide advantageous properties to the respective layers, and/or different portions, areas or regions of the respective layers, as necessary or desired.

Referring still to <FIG> and also to the representative cutaway view of <FIG>, knitted component <NUM> includes one or more pluralities of courses of yarn located between the first and second layers <NUM>, <NUM> to reinforce the knitted component, improve strength (especially tensile strength), directional stretch resistance, to create an attractive appearance in certain embodiments, to increase resistance to penetration, and/or for other advantages. Knitted component <NUM> includes a first plurality of courses <NUM>, a second plurality of courses <NUM>, and a third plurality of courses <NUM>. It will be appreciated that <FIG> is representative; although first layer <NUM> is illustrated as separated from second layer <NUM> in order to reveal pluralities of courses <NUM>-<NUM>, first layer <NUM> need not be freely-separable from second layer <NUM>. Pluralities of courses <NUM>-<NUM> may be formed between first and second layers <NUM>, <NUM> as a result of the same process that forms first and second layers <NUM>, <NUM>; in other words, pluralities of courses <NUM>-<NUM> are part of the same, integrally-formed knitted component <NUM>.

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

Exemplary inlaid yarns are shown in <FIG>. In <FIG>, knitted component <NUM> includes a first yarn <NUM> that forms a plurality of intermeshed loops defining multiple horizontal courses and vertical wales. An inlaid yarn <NUM> extends along one of the courses and alternates between being located (a) behind loops formed from first yarn <NUM> and (b) in front of loops formed from first yarn <NUM>. Although first yarn <NUM> forms each of the courses in this configuration, additional yarns may form one or more of the courses or may form a portion of one or more of the courses. Another example of a suitable configuration for a portion of knitted component <NUM> is depicted in <FIG>. In this configuration, knitted component <NUM> includes first yarn <NUM> and a second yarn <NUM> defining multiple courses and wales. As with the configuration in <FIG>, inlaid yarn <NUM> extends along one of the courses and alternates between being located (a) behind loops formed from yarns <NUM>, <NUM> and (b) in front of loops formed from yarns <NUM>, <NUM>.

Generally, the courses of each plurality of courses of high tenacity yarn have a spaced relationship. In one example, the plurality of inlaid courses may be closely spaced and in other examples the inlaid courses may be spaced relatively further from each other. The plurality of inlaid courses may be uniformly spaced from each other or the spacing may vary, with some inlaid courses spaced closely to adjacent inlaid courses while other inlaid courses are spaced further apart from adjacent inlaid courses.

As used in this application, two courses of high tenacity yarn are closely spaced if separated by no more than ten courses of other yarns. In some examples, adjacent courses of inlaid high tenacity yarn are spaced apart by no more than five, four, three, two, one, or zero courses of another yarn. For example, a first course and a second course of high tenacity yarn are closely spaced if the first course is inlaid in between loops of a first course of a second yarn, the second course of high tenacity yarn is inlaid between loops of a second course of the second yarn, and the first and second courses of the second yarn are separated by one, two, three, four, five, six, seven, eight, nine, or ten courses of the second yarn. As another example, first and second courses of high tenacity yarn are closely spaced (in fact, they are consecutive) if the first course of high tenacity yarn is inlaid in between loops of a first course of a second yarn, the second course of high tenacity yarn is inlaid between loops of a second course of the second yarn, and the first and second courses of the second yarn are adjacent (i.e., not separated by any courses).

The number of courses of high tenacity yarn may vary. For example, some examples may include one or more pluralities of high tenacity yarn, each having at least two, three, four, five, six, seven, eight, nine, ten, or a greater number of courses of high tenacity yarn. For example, first plurality of high tenacity courses <NUM> of <FIG> includes more than ten courses <NUM> of high tenacity yarn (including courses 28a, b) that extend substantially through knitted component <NUM>. Second plurality of high tenacity courses <NUM> includes fewer than ten courses (including course 29a). Alternative examples may include greater or fewer pluralities of courses of high tenacity yarn. A greater number of courses of high tenacity yarn may provide greater reinforcement to the knitted component, and may correlate positively with the strength of the knitted component <NUM>, and may also correlate with the stretch resistance of the knitted component <NUM> in directions approximately parallel to the direction of the courses of high tenacity yarn. Generally, at least some courses of high tenacity yarn may be full courses, such as courses 28a, b of first plurality <NUM>, that extend from a first edge <NUM> of knitted component <NUM> to a second edge <NUM>. Other knitted components may include courses extending both from a first edge to a second edge, and other courses extending from the second edge to a third edge. Alternatively, at least some courses of high tenacity yarn may be partial courses (i.e., extending an intermediate distance across a portion of the knitted component <NUM> or to a third edge in other examples), such as course 29a of second plurality <NUM>. A knitted component may include both full and partial courses of high tenacity yarn. Further, each course of high tenacity yarn may be formed by one continuous yarn (such as courses 28a, b of first plurality <NUM>, which extend across at least a portion of knitted component <NUM> in a snake-like or zig-zag pattern), or by distinct, individual ends of yarn (such as courses 30a, b of third plurality <NUM>). In either case, one or more courses of high tenacity yarn may extend beyond one or more edges of knitted component <NUM>, such as courses 28a, b (which form a loop or hair-pin-like turn, for example, to extend back through the knitted component two or more times in such a pattern) and courses 30a, b.

Suitable high tenacity yarns may include polyester and other compositions formed into yarns having a tenacity in the range of at least approximately six grams-force per denier, e.g., approximately <NUM>-<NUM> grams-force per denier. For example, polyester yarns having linear densities ranging from approximately <NUM>-<NUM> denier and a maximum tensile strength of at least <NUM>,<NUM> grams-force may be appropriate. To facilitate knitting, in some examples, each course of the high tenacity yarn may have a maximum diameter of less than or equal to approximately <NUM>, e.g., less than or equal to <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or a smaller diameter. One suitable high tenacity yarn is a <NUM> denier polyethylene terephthalate yarn having a maximum tensile strength of <NUM>,<NUM> grams-force and thus, a tenacity of <NUM> grams-force per denier. Each course of high tenacity yarn may utilize a single yarn or strand. Or, each course of high tenacity yarn may comprise a plurality of yarns or strands such that each course of high tenacity yarn has greater maximum tensile strength and denier, and therefore higher tenacity. Referring to <FIG>, course <NUM> of high tenacity yarn extends in between first and second layers <NUM>, <NUM> and includes a single end of high tenacity yarn, e.g., a single end of <NUM>-denier high tenacity yarn having a <NUM>,<NUM> grams-force maximum tensile strength. By comparison, <FIG> illustrates a single course <NUM> of high tenacity yarn that includes four ends of high tenacity yarn, e.g., four ends of <NUM>-denier, <NUM>,<NUM> grams-force yarns of high tenacity yarn. Although <FIG> are representative, according to the claimed invention, each course of high tenacity yarn includes at least two, hence, two, three, four, five, six, ten, or a greater number of yarns of high tenacity yarn. The multiple ends of high tenacity yarn may be twisted, braided, formed in a core/sheath relationship, or otherwise combined together to form a course of high tenacity yarn. As yet another example, a course of high tenacity yarn may utilize three ends of <NUM> denier yarn, with each yarn having a maximum tensile strength of <NUM>,<NUM> grams-force, thereby forming a course of high tenacity yarn having an <NUM> denier and maximum tensile strength of <NUM>,<NUM> grams-force. As yet another example, a course of high tenacity yarn may utilize four ends of <NUM> denier yarn, each yarn having a maximum tensile strength of <NUM>,<NUM> grams-force, producing a course of high tenacity yarn having <NUM>,<NUM> denier and maximum tensile strength of <NUM>,<NUM> grams-force. Altogether, each course of high tenacity yarn (including all yarns utilized to form the course) may have a total linear density of at least approximately <NUM> denier (e.g., at least <NUM>,<NUM> denier) and a maximum tensile strength of at least approximately <NUM>,<NUM> grams-force (e.g., at least <NUM>,<NUM> grams-force).

In the embodiment of <FIG>, a knitted component <NUM> includes a first layer <NUM>, a second layer <NUM>, a first plurality of courses of high tenacity yarn <NUM> (e.g., course 63a) and a second plurality of courses of high tenacity yarn <NUM> (e.g., course 64a). First layer <NUM> includes a first plurality of apertures <NUM> (e.g., aperture 66a) and a second plurality of apertures <NUM>. First plurality of apertures <NUM> extends in a course-wise direction, and each aperture of first plurality <NUM> has, as one example, a longest dimension that is oriented in the course-wise direction, as shown in detail view <FIG>. At least an exposed portion of at least one course of high tenacity yarn (e.g., exposed portion <NUM> of course 63a) is exposed through each aperture of the first plurality <NUM>. If the high tenacity yarn has a different color and/or other different visual property relative to the yarn(s) that form first layer <NUM>, then the exposed portions of high tenacity yarn may provide an appealing visual appearance. The exposed portion of high tenacity yarn is recessed relative to a first surface <NUM> of knitted component <NUM> (e.g., which may correspond with an outermost or exterior surface of the knitted component <NUM>), or the exposed portion of high tenacity yarn may protrude through one or more of the plurality of apertures <NUM>.

The second plurality of apertures <NUM> forms a pattern that extends diagonally relative to first and second edges <NUM>, <NUM> of knitted component <NUM>. Each aperture of second plurality <NUM> has an elongate shape extending in a course-wise direction; thus, each aperture has a different orientation than the second plurality <NUM> as a whole. Accordingly, the second plurality of apertures <NUM> provides a visual impression that the high tenacity yarn extends in the direction(s) of the pattern (i.e., diagonally in <FIG>), when in fact each course of high tenacity yarn extends in another direction (i.e., a course-wise direction). In other words, in <FIG>, the high tenacity yarn appears to extend diagonally, although each course (e.g., course 64a) of high tenacity yarn has a course-wise orientation that is not diagonal.

The knitted components described above have a wide range of useful applications, including footwear, apparel, and industrial textiles. As one non-limiting example, <FIG> illustrates an article of footwear <NUM> that includes an upper <NUM> at least partially formed with a knitted component <NUM> as described above. Article of footwear <NUM> has a general configuration suitable for walking or running. Concepts associated with footwear, including upper <NUM> and knitted component <NUM>, 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. In the example 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 a wearer's 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.

For reference purposes, article <NUM> may be divided generally along a longitudinal direction (heel-to-toe) into three general regions: a forefoot region <NUM> including a forefoot edge region <NUM> and a toe box <NUM>, a midfoot region <NUM>, and a rearfoot region <NUM> including a heel region <NUM>. Forefoot region <NUM>, in particular toe box <NUM>, may generally include portions of upper <NUM> that may eventually cover (when incorporated into an article of footwear) 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, and may include a throat region <NUM>. Rearfoot region <NUM>, in particular heel 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, in some examples, rearfoot region <NUM> may cover some or all of the wearer's malleoli and talus (which comprise a portion of the ankle). Rearfoot region <NUM> may coincide with a collar region <NUM>. Upper <NUM> may also include a medial side <NUM> having a medial edge region <NUM> (including a medial edge <NUM>), and a lateral side having a lateral edge region (including a lateral edge). Each of the medial side <NUM> and lateral sides 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 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 are not intended to demarcate precise areas of upper <NUM> or knitted component <NUM>, but rather are intended to represent general areas to aid in the following discussion.

In <FIG> representing background knowledge useful for understanding the claimed invention, knitted component <NUM> of article <NUM> includes an exterior layer <NUM>, and interior layer <NUM>, and a plurality of courses of high tenacity yarn <NUM> (shown in hidden lines, e.g., 158a, b) formed between exterior and interior layers <NUM>, <NUM>. Plurality of courses <NUM> advantageously reinforce knitted component <NUM>, for example by increasing its strength and increasing stretch resistance in a particular direction, such as the medial-lateral direction and/or a forefoot-rearfoot direction, and improve lock-out of a wearer's foot such as during athletic activities that require side-to-side cutting movements (e.g., basketball and soccer). In <FIG>, the plurality of courses <NUM> (e.g., <NUM> a, b) of high tenacity yarn extends substantially throughout upper <NUM> on both the lateral side and medial sides <NUM>, extending from rearfoot region <NUM>, to midfoot region <NUM>, to forefoot region <NUM>. In other examples, one or more pluralities of courses of high tenacity yarn (including one or more pluralities of courses of high tenacity yarn) may exist in one or more regions, areas, portions, sides, or other locations of the upper, including those described above. Exterior and interior layers <NUM>, <NUM> may conceal at least a portion of the plurality of courses of high tenacity yarn <NUM>, although in other examples, apertures in the exterior and interior layers may expose a portion of the plurality of courses of high tenacity yarn. In other examples, the exterior layer may include one or more features other than apertures, for example raised knit structures forming a pattern (e.g., elongate and parallel knit structures, which may extend in a number of directions, e.g., diagonally relative to sole structure <NUM>), depressions, etc. The plurality of courses of high tenacity yarn <NUM> may also interact with a fastening system <NUM>. In particular, apertures of fastening system <NUM> may extend through the plurality of courses <NUM>, thereby adding strength to fastening system <NUM>. In one example, a looped portion <NUM> of high tenacity yarn may loop around one or more lace apertures <NUM>, such that when a lace is fed through the aperture(s), it also extends through the loop formed by the high tenacity yarn.

Referring still to <FIG>, course 158a of high tenacity yarn is a partial course that extends from medial edge region <NUM> to throat region <NUM> in a medial-lateral orientation. By comparison, course 158b is a full course of high tenacity yarn that extends from the lateral side to medial side <NUM>, i.e., from the lateral edge region to medial edge region <NUM>. In other examples, courses of high tenacity yarn may exist in one or more localized portions of the upper, e.g., in midfoot region <NUM>, forefoot region <NUM>, and/or rearfoot region <NUM>. Likewise, in other examples, courses of high tenacity yarn may have orientations other than the medial-lateral orientation. For example, the courses of high tenacity yarn may be oriented in a direction in which it is desirable to increase stretch resistance in that same direction, e.g., a forefoot-rearfoot direction or a direction oblique to sole structure <NUM>.

<FIG> show an alternative article of footwear <NUM> representing background knowledge useful for understanding the claimed invention that includes an upper <NUM> joined with an optional sole structure <NUM>, the upper <NUM> being at least partially formed with a knitted component <NUM> that is constructed according to the claimed invention. Knitted component <NUM> includes an exterior layer <NUM>, and interior layer <NUM>, and a first plurality of courses <NUM> of high tenacity yarn formed in between the exterior layer <NUM> and the interior layer <NUM>. The first plurality <NUM> is located in a midfoot region <NUM> on a medial side <NUM>, and a second plurality of courses <NUM> of high tenacity yarn located in a forefoot region <NUM> spanning into both the medial side <NUM> and a lateral side <NUM>. The locations and dimensions of first and second pluralities <NUM>, <NUM> are merely exemplary; other embodiments may include one or more pluralities of high tenacity yarn with various dimensions that at least partially occupy one or more of any of the regions discussed above. The first and second pluralities <NUM>, <NUM> of courses of high tenacity yarn form part of a first and a second high tenacity zone <NUM>, <NUM>, respectively, i.e., localized areas of article <NUM> that each include a plurality of courses of high tenacity yarn and other structures for the benefits of reinforcement, added strength, and increased stretch resistance provided by the high tenacity yarn. In other embodiments, greater or fewer high tenacity zones may exist in the same or different locations than those locations shown in <FIG>.

In <FIG>, the high tenacity yarn utilized in the first plurality of high tenacity yarns <NUM> has at least one different visual property than the material(s) utilized to form exterior layer <NUM> (e.g., reflectivity, and/or a different color or texture). First high tenacity zone <NUM> includes a first plurality of apertures <NUM> formed in exterior layer <NUM> that together extend in a diagonal direction relative to sole structure <NUM> on medial side <NUM> and overlap with the first plurality <NUM> of courses of high tenacity yarn. Each aperture of the first plurality of apertures <NUM> has a medial-lateral orientation. In other embodiments, one or more pluralities of apertures may extend in a number of directions or form a number of different patterns. Each aperture of the first plurality of apertures <NUM> exposes a portion of at least one course of the first plurality of courses <NUM> of courses of high tenacity yarn. Consequently, the exposed portion of high tenacity yarn (which has at least one different visual property relative to exterior layer <NUM>) is visible through the first plurality of apertures <NUM>. In other embodiments, the exposed portion of high tenacity yarn may be recessed relative to a first surface of the exterior layer (which may correspond with an outermost surface of the article of footwear). The first plurality of apertures <NUM> provides a visual impression that the first plurality <NUM> of courses of high tenacity yarn extends in a diagonal direction, when in fact each course of high tenacity yarn extends in a medial-lateral direction. This is the result of the first plurality of apertures <NUM> being formed in a generally diagonal orientation as shown in <FIG>, where each consecutive aperture exposes at least a portion of one or more courses of high tenacity yarn. In other words, each consecutive aperture in a particular diagonal line of apertures exposes a different course of high tenacity yarn.

Second high tenacity zone <NUM> includes a second plurality of apertures <NUM> formed in exterior layer <NUM> and located in forefoot region <NUM> that together form an "X" or diamond pattern and coincide with the second plurality <NUM> of courses of high tenacity yarn. The apertures are shown as oblong or oval, and may have a variety of orientations, and dimensions as desired in other embodiments. Because each aperture of the second plurality <NUM> of apertures exposes a portion of at least one course of the second plurality <NUM> of courses of high tenacity yarn, knitted component <NUM> provides a visual impression that the second plurality <NUM> of courses of high tenacity yarn extends in diagonal directions forming an "X" or diamond pattern, when in fact each course of high tenacity yarn of the second plurality <NUM> extends in a medial-lateral direction. In other embodiments, different aperture arrangements in the exterior layer and different visual properties of the exterior layer and of the portion of high tenacity yarn that is exposed through one or more of the apertures may produce a wide range of different patterns and visual effects.

<FIG> illustrates a knitting sequence that is utilized to form integrally-knitted components as described above, 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 first layer, an overlapping second layer, and a plurality of courses of high tenacity yarn <NUM> in between. The exterior layer and interior layers are at least partially formed from a first yarn <NUM> and a second yarn <NUM>. Notably, it is not necessary to utilize both first and second yarns <NUM>, <NUM>, as a single yarn could form both the first and second layers; however, different yarns are illustrated to better communicate spacing between courses of high tenacity yarn <NUM>. The knitting process forms a plurality of courses of high tenacity yarn, advantageously increasing the strength and course-wise stretch resistance of the resulting knitted component. Furthermore, the non-limiting sequence of <FIG> includes forming a plurality of apertures in the first layer to expose the high tenacity yarn <NUM>.

In a first step <NUM>, the machine forms a course <NUM> of first yarn <NUM> on both the first and second needle beds <NUM>, <NUM> (forming part of the first and second layers), and executes transfers <NUM> to form apertures in the first layer. To prepare for the transfers <NUM>, course <NUM> does not knit any loops on needles of second needle bed <NUM> that correspond with locations where apertures will later be formed in the first layer. Subsequent to course <NUM>, transfers <NUM> move knit loops formed on first needle bed <NUM> in course <NUM> to second needle bed <NUM>.

In a second step <NUM>, a course <NUM> of high tenacity yarn <NUM> is inlaid between loops previously formed on first and second needle beds <NUM>, <NUM> during course <NUM>. As discussed above, course <NUM> includes one or more ends of high tenacity yarn <NUM>. Following second step <NUM>, first step <NUM> and second step <NUM> may be repeated as desired to make the knitted component larger by adding more courses to the first and second layers and by inlaying additional courses of high tenacity yarn <NUM>.

In a third step <NUM>, the knitting machine knits three courses <NUM>, <NUM>, <NUM> of second yarn <NUM> on first and second needle beds <NUM>, <NUM>, thereby making the knitted component larger. At course <NUM>, the machine forms tucks of second yarn <NUM> on first needle bed <NUM> at locations corresponding to the front-to-rear transfers executed at first step <NUM>, thereby securing inlaid course <NUM> of high tenacity yarn formed during second step <NUM> within the knitted component.

Following third step <NUM>, first through third steps <NUM> - <NUM> may be repeated as necessary to make the knitted component larger and to inlay additional courses of high tenacity yarn <NUM>. The location of transfers and tucks may be altered to adjust the location of apertures formed in the first layer; alternatively, the transfers and tucks may be eliminated if no apertures are desired, although the tucks may advantageously secure the inlaid courses of high tenacity yarn. Regardless, the resulting knitted component would include first and second layers and a plurality of inlaid courses of high tenacity yarn <NUM>. The courses of high tenacity yarn <NUM> in <FIG> are closely spaced because a course of high tenacity yarn <NUM> is inlaid on top of each of course of first yarn <NUM> which, in this case, are separated by just three courses of second yarn <NUM>. In other embodiments, courses of high tenacity yarn may have closer spacing, e.g., inlaid after every course (consecutive). Alternatively, courses of high tenacity yarn may be spaced apart to a greater degree without deviating from the present disclosure, e.g., spaced apart by up to four, five, six, seven, eight, nine, or ten courses of yarn. In other embodiments, the size of the apertures may be greater to increase the exposed portion of high tenacity yarn, e.g., by transferring knit loops from two, three, or more consecutive needles on the first needle bed to the second needle bed.

Claim 1:
An integrally formed knitted component (<NUM>, <NUM>), comprising:
a first knit layer (<NUM>) comprising a first yarn (<NUM>), a second knit layer (<NUM>) comprising the first yarn (<NUM>), and a first plurality of inlaid courses (<NUM>, <NUM>, <NUM>) of a high tenacity yarn forming a first tenacity zone (<NUM>) having a tenacity of at least six grams-force per <NUM> tex (<NUM> denier), the inlaid courses extending in a course-wise direction;
wherein the first plurality of inlaid courses of the high tenacity yarn comprise at least three courses of high tenacity yarn, each of which is separated from an adjacent course of the first plurality of courses by no more than five courses of the first yarn,
wherein the first knit layer (<NUM>) comprises a plurality of openings (<NUM>, <NUM>, <NUM>, <NUM>), through which an exposed portion of the plurality of inlaid courses (<NUM>, <NUM>, <NUM>) of the high tenacity yarn is visible from a first viewpoint facing the first knit layer,
the knitted component being characterized in that
each course of the first plurality of inlaid courses comprises at least two ends of high tenacity yarn and
each opening of the plurality of openings (<NUM>, <NUM>, <NUM>, <NUM>) has an elongate shape extending in a course-wise direction, the plurality of openings forming a pattern, at least a portion of which has an orientation other than a course-wise direction, such that each opening of the plurality of openings (<NUM>, <NUM>, <NUM>, <NUM>) has an orientation different than the plurality of openings as a whole, thereby providing a visual impression that the high tenacity yarn extends in a direction of the pattern.