Patent Description:
Conventional articles of footwear generally include two primary elements: an upper and a sole structure. The upper is generally secured to the sole structure and may form a void within the article of footwear for comfortably and securely receiving a foot. The sole structure is generally 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 may form 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 and in some instances under the foot. Access to the void in the interior of the upper is generally provided by an ankle opening in and/or adjacent to a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate other structures such as, for example, a heel counter to provide support and limit movement of the heel.

<CIT> discloses a three-dimensional double-faced fabric which is produced on a weft knitting machine. The fabric comprises two external faces which are connected by means of rows of binding threads. Said fabric comprises hollow zones in which: the thread from a first external face works with the second external face; and the binding thread works with only one of the two external faces.

<CIT> discloses an insulating fabric which is formed by knitting a two ply fabric on a circular or flat machine and by laying yarns or rovings in the fabric between the two plies. The insulating fabric is formed by knitting one ply on the needles of one bed and the other ply on the needles of the other bed and by laying the yarns or rovings in between the plies by feeding them to the backs of the needles. The two plies are secured together by knitting the same yarn simultaneously by selected needles of both beds. The selection can be made to achieve a quilting effect in the fabric.

<CIT> discloses an article of footwear which has an upper and a sole structure secured to the upper. The upper includes a knitted component and a polymer layer. The knitted component is formed of unitary knit construction and extends along a lateral side of the upper, along a medial side of the upper, over a forefoot region of the upper, and around a heel region of the upper. The polymer layer is bonded to the knitted component and may form a majority of an exterior surface of the upper. The polymer layer may be formed from a thermoplastic polymer material and the knitted component comprises doublelayered structures including inlaid yarns.

The objective technical problem to be solved may be considered to consist in overcoming or at least reducing the disadvantages according to the prior art. The problem is solved by the subject matter of the independent claims. In one aspect, the claimed invention provides an article formed of a knitted component according to the subject matter of claim <NUM>. The knitted component comprises a first surface and a second surface, the first surface facing opposite the second surface. A pod has the first surface formed by a first layer and the second surface formed by a second layer, and an edge region has the first surface and the second surface, where the edge region at least partially demarcates the pod. In a precursor knitted component, a first yarn forms the first surface of the pod, where the first yarn is a fusible yarn comprising a first material that is a fusible thermoplastic polymer material. A second yarn forms the second surface of the pod, and the second yarn forms the first surface of the edge region. The pod includes a pocket formed between the first layer and the second layer and a third yarn is laid within the pocket between the first layer and the second layer. The first surface within the pod is heat-processed during manufacturing such that the first yarn is fused and forms a fused area of a first material.

The claimed invention also provides a method according to claim <NUM>.

This method includes forming an article formed of a knitted component having a first surface and a second surface utilizing a flat knitting machine, wherein the first surface faces opposite the second surface, the method comprising knitting a first layer having the first surface on a first needle bed using a first yarn comprising a first material that is fusible, wherein the first material is a thermoplastic polymer material, knitting a second layer having the second surface on a second needle bed using a second yarn such that a pocket of a pod is formed between the first layer and the second layer, wherein a third yarn is inlaid within the pocket, and knitting an edge region at least partially demarcating the pod having the first surface and the second surface with the second yarn on the first needle bed and the second needle bed, and heat-processing the first surface within the pod to form a fused area of the first material during manufacturing.

Certain aspects of the present disclosure relate to uppers configured for use in an article of footwear and/or other articles, such as articles of apparel. When referring to articles of footwear, the disclosure may describe basketball shoes, running shoes, biking shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennis shoes, and/or walking shoes, as well as footwear styles generally considered non-athletic, including but not limited to dress shoes, loafers, and sandals.

<FIG> is an illustration showing an article of footwear <NUM>, and <FIG> is a top view of the article of footwear <NUM>. Referring to <FIG>, the article of footwear <NUM> may include an upper <NUM>, where the upper <NUM> is substantially formed as a textile component. The textile component is formed as a knitted component. As shown, the upper <NUM> may be secured to a sole structure <NUM>. The upper <NUM> may include a lateral side <NUM> and a medial side <NUM>. The area where the sole structure <NUM> joins the upper <NUM> may be referred to as a 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. The upper <NUM> may extend partially or completely around a foot of a wearer and/or may be integral with the sole structure <NUM>, 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 upper <NUM> may extend under the foot of a wearer and form an underfoot portion, which may be in place of the sole structure <NUM>, if desired.

The upper <NUM> may additionally include a throat area <NUM> extending from and an ankle opening <NUM> leading to the void <NUM>, and a collar <NUM> may at least partially surround an ankle opening <NUM>. The void <NUM> of the article of footwear <NUM> may be configured (e.g., sized and shaped) to receive and 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> of the upper <NUM> may be located between a heel area <NUM> and a toe area <NUM>. In some embodiments, an optional tongue (such as the tongue <NUM> shown in <FIG>) may be disposed at least partially in the throat area <NUM>, but no tongue is depicted in <FIG>. If a tongue is included, 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 depicted in <FIG>, an outer surface <NUM> of the upper <NUM> be subdivided into two or more generally defined areas referred to as pods <NUM>. The pods <NUM> are at least partially demarcated by edge regions <NUM> of the upper <NUM>. The edge regions <NUM> may substantially or completely surround at least some of the pods <NUM>. Within a given pod <NUM>, the outer surface <NUM> may be formed primarily of a fused area of material that is heat-processed during the manufacturing of the article of footwear <NUM>. Herein a "fused area" is an area where distinct portion(s) of material forming the upper (e.g., distinct individual strands or yarns formed of thermoplastic polymer material) are partially or substantially melted and then cooled such that the material is bonded together. A fused area is not required to be formed by any specific process. More specific constructions of the pods <NUM> and the surrounding edge regions <NUM> are described in further detail below.

At least a portion of the upper <NUM> is formed by a knitted component <NUM> (and at least a portion of the knitted component may be referred to as a "knit element"). <FIG> shows the knitted component <NUM> as it may appear after knitting (e.g., on a flat knitting machine) but before being lasted or otherwise manipulated into a wearable shape in the depicted article of footwear <NUM> of <FIG>. While the upper <NUM> is described herein as being formed primarily of the knitted component <NUM>, it additionally could include a textile component formed by a process other than knitting (e.g., weaving) and may also include other materials including but not limited to leather, plastics, rubbers, and any other materials suitable for incorporation into the upper of an article of footwear.

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, 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> may be 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 some embodiments, the knitted component <NUM> may incorporate one or more materials with properties that change in response to a stimulus (e.g., temperature, moisture, electrical current, magnetic field, or light). According to the claimed invention, the knitted component <NUM> includes yarns formed of one or more thermoplastic polymer materials (including material composites) that transition 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(s) may provide the ability to heat and then cool a portion of the knitted component <NUM> to thereby form an area of bonded or continuous material (herein referred to as a "fused area") that exhibits certain advantageous properties including a relatively high degree of rigidity, strength, and water resistance, for example. Non-limiting examples of thermoplastic polymer materials are polyurethanes, polyamides, polyolefins, and/or nylons.

As shown in <FIG>, the knitted component <NUM> substantially forms the pods <NUM> and the surrounding edge regions <NUM>. When thermoplastic polymer material is included and configured to be fused during a heat-processing step, the thermoplastic polymer material is exposed on the outer surface <NUM> of the knitted component <NUM> only at the pods <NUM>, and other materials is used to form the outer surface <NUM> at the edge regions <NUM>. Thus, once heat is applied to the outer surface <NUM> during a heat-processing step (e.g., steaming or otherwise applying heat after knitting), the result of this process may be the formation of a "shell" on the outer surface <NUM> of the pods <NUM>. The shell may enhance the stiffness, strength, rigidity, durability, and other characteristics of the article of footwear <NUM>. The enhanced characteristics may provide additional support and structure and may bolster or replace other structural elements (such as a heel counter, brio cables, etc.).

In some embodiments, the heat-processing of the outer surface <NUM> of the pods <NUM> may cause the melted thermoplastic polymer material to flow over the edge regions <NUM> such that the edge regions <NUM> are at least partially covered by fused material once it has cooled. Alternatively, the fused material may be isolated on the outer surface <NUM> only adjacent to the pods <NUM> and may terminate adjacent to the edge regions <NUM> leaving at least a portion of the outer surface <NUM> free of the fused material at the edge regions <NUM>. Thus, at least after heat-processing, the edge regions <NUM> may have a first degree of flexibility, the pods <NUM> may have a second degree of flexibility, and the first degree of flexibility may be substantially greater than the second degree of flexibility (which may be at least partially attributed to the lack of fused material on the edge regions <NUM>). Similarly, the edge regions <NUM> may have a first degree of stiffness, the pods <NUM> may have a second degree of stiffness, and the first degree of stiffness may be substantially less than the second degree of stiffness. The relative degrees of flexibility and stiffness may be compared by applying a force to the respective components and then measuring the amount of displacement through those same components.

Different pods <NUM> may have identical dimensions, but at least some of the pods <NUM> may have dimensions that are substantially different. Similarly, the edge regions <NUM> may be about the same size throughout the knitted component <NUM>, but alternatively the edge regions <NUM> may vary in size. The sizes and locations of the pods <NUM> and/or the edge regions <NUM> may thus be selected to provide the upper <NUM> with strength, rigidity, protection, and other characteristics where desired, while also providing suitable flexibility, stretchability, and other characteristics at other zones or locations. To illustrate, the pods <NUM> in a first zone <NUM> may be larger, on average, than the pods <NUM> located in a second zone <NUM>, where the first zone <NUM> is located closer to the heel area <NUM> and the second zone <NUM> is located closer to the toe area <NUM>. Thus, the edge regions <NUM> may be more prevalent in the second zone <NUM> than the first zone <NUM> per unit area. As a result, the first zone <NUM> may have a higher degree of strength, rigidity, durability, and stiffness (along with other characteristics associated with the pods <NUM>) while the second zone <NUM> may have a higher degree of flexibility, stretchability, and other characteristics associated with the edge regions <NUM>. It is also contemplated that different pods <NUM> may have different material compositions such that, even correcting for size, the pods <NUM> provide differing degrees of the associated characteristics. To illustrate, a first pod may have a greater density of a thermoplastic polymer material on the outer surface <NUM> than a different second pod, and as a result, the first pod may have a greater degree of stiffness than the second pod.

While not required in all embodiments, it is contemplated that the substantial entirety of the heel area <NUM> may be constructed in a manner similar to the construction of the pods <NUM> (e.g., such that one large pod <NUM> forms the majority of the heel area <NUM>). Similarly, substantially the entirety of the toe area <NUM> may be formed by a large pod <NUM>. Advantageously, the heel area <NUM> and/or the toe area <NUM> may bolster or replace heel counter and/or toecap elements to thus offer a degree of desirable rigidity, strength, and structural support to a wearer etc. that is desirable in certain applications. In contrast, other portions such as the collar <NUM> may be formed with an elastic knit structure, and/or may not be heat-processed, such that the collar <NUM> is configured to stretch when receiving a foot.

Whether formed of the knitted component <NUM> or not, the upper <NUM> may have a single layer or multiple layers. For example, as shown in <FIG> (showing a side cutout view of one of the pods <NUM>), at least one pod <NUM> of the upper <NUM> may include a first layer <NUM> and a second layer <NUM>, where the first layer <NUM> is an outer layer and the second layer <NUM> is an inner layer nearer the void when incorporated into the article of footwear <NUM>. The knitted component also has the first surface <NUM> formed by the first layer <NUM> (which may include the outer surface <NUM> of <FIG>) and the second surface <NUM> formed by the second layer <NUM>. The second surface <NUM> and the first surface <NUM> face in opposite directions. For example, the first surface <NUM> may face outward (e.g., such that it is exposed for viewing when the article of footwear <NUM> is in use), and the second surface <NUM> may face the void, or interior of the article of footwear <NUM>.

The first layer <NUM> may include the above-described fused area, such that it can be considered to have formed a "shell" for providing protection and other desirable properties for the outer surface <NUM>, and the second layer <NUM> may be formed of a material (e.g., elastane, cotton, or polyester) having desirable comfort-related characteristics for contacting a foot or sock of a wearer, such as a desirable elasticity, absorption and/or anti-abrasiveness. A third layer <NUM> is located in a pocket <NUM> that is formed between the first layer <NUM> and the second layer <NUM>. As described in more detail below, if the upper <NUM> is formed of a knitted component <NUM>, the third layer <NUM> may include an inlaid material located at least partially between the first layer <NUM> and the second layer <NUM>, where the first layer <NUM> and the second layer <NUM> are both knitted layers. The third layer <NUM> may be substantially bonded to the first layer <NUM> due to heat processing of the material of the first layer <NUM>, but this is not required. More or fewer than three layers are also contemplated. For example, as shown in <FIG>, a fourth layer <NUM> may be located between the second layer <NUM> and the third layer <NUM>, but the fourth layer <NUM> may alternatively be located in any other location.

The fused material forming the first layer <NUM> is transparent (at least after heat-processing) such that when a viewer looks at the first surface <NUM>, he or she can detect the visual characteristics of the underlying third layer <NUM>. The third layer <NUM> can be formed/manipulated during the manufacturing process to provide desirable visual effects without limitation, as the third layer <NUM> may not have the necessity of providing structural characteristics (which may instead be substantially provided by the first layer <NUM>). However, it is also contemplated that the third layer <NUM> may provide certain structural or other functional characteristics, if desired, such as cushioning. Similarly, the fourth layer <NUM> may provide cushioning and/or other characteristics, such as additional stiffness, or alternatively, such as a water resistant layer, for example, that may be desired in the upper <NUM>. In some embodiments, the thermoplastic polymer material of the first layer <NUM> may not be transparent prior to the heat-processing step, and instead may have a color or may be opaque (e.g., white) and may hide or otherwise obscure the third layer <NUM> from view. This may be advantageous where it is beneficial to easily view the position of the material forming the first layer <NUM> during manufacturing to ensure quality standards are met.

<FIG> is an illustration showing a detailed side-cutout view of a multi-layer knitted component <NUM> forming the upper <NUM>. The depicted knitted component <NUM> has a first pod <NUM>, a second pod <NUM>, and a third pod <NUM>. The first pod <NUM> and the second pod <NUM> are separated by a first edge region <NUM>, and the second pod <NUM> and the third pod <NUM> are separated by a second edge region <NUM>. For illustration purposes, in <FIG>, four yarns (e.g., yarn types having one or more strands) are included: a first yarn <NUM>, a second yarn <NUM>, a third yarn <NUM>, and a fourth yarn <NUM>.

While the yarns <NUM>, <NUM>, <NUM> can be made of any suitable material, the first yarn <NUM> is at least partially formed with a thermoplastic polymer material having a suitable melting point that is substantially lower than the melting point and decomposition point of the second yarn <NUM> (for example, <NUM> lower or more) and also substantially lower than the melting point and decomposition point of the third yarn <NUM> and fourth yarn <NUM>. Illustrative, non-limiting examples of suitable thermoplastic polymer materials include polyurethanes, polyamides, polyolefins, and nylons. In some embodiments, substantially the entirety of the first yarn <NUM> may be formed of the thermoplastic polymer material, but alternatively the first yarn <NUM> may be a yarn with a thermoplastic polymer sheath with a relatively low melting point surrounded by a core that remains stable at higher temperatures. The melting temperature of the thermoplastic polymer material may be, for example, between about <NUM> and about <NUM>, such as from about <NUM> to about <NUM> based on atmospheric pressure at sea level. In another embodiment, the thermoplastic polymer may be a nylon co-polymer with a melting point of between about <NUM> and about <NUM>, such as about <NUM>. Additionally or alternatively, the first yarn <NUM> may include a thermoplastic polyurethane. Additionally or alternatively, the thermoplastic polymer material may be formed of a material that becomes translucent or transparent when raised above its melting point and then cooled.

The second yarn <NUM> is made from a yarn substantially formed of polyester or a polyester in combination with elastane. Such a yarn may provide elasticity and anti-abrasion that is well suited for forming the inner surface of an upper. The melting point or decomposition point of the material(s) forming the second yarn <NUM> may be relatively high (e.g., above <NUM> or higher, such as <NUM> or higher for certain polyesters) such that the material remains stable during heat processing of the knitted component <NUM>.

Like the second yarn <NUM>, the depicted third yarn <NUM> is formed of a material that remains stable during heat processing. In one embodiment, the third yarn <NUM> may comprise a plurality of polyester yarns having different colors. Advantageously, the third yarn <NUM> may provide a desirable visual effect when the first yarn <NUM> forms a transparent shell on the first surface <NUM> (as described in more detail below). Optionally, the third yarn <NUM> may additionally or alternatively be formed of a material that provides loft within the pockets <NUM> to provide the knitted component <NUM> with a visually-appealing texture where the pods <NUM> extend outward with respect to the edge regions <NUM>. In one non-limiting embodiment, the third yarn <NUM> may include a bulking material that expands in size after the knitting process (e.g., in response to a stimulus, such as heat), thus enhancing the optional loft provided within the pod <NUM>. Such yarns are described in detail in <CIT>, published as <CIT>.

The fourth yarn <NUM> may be a monofilament yarn, which may be advantageous for providing a durable and inelastic tie (as described in more detail below). Monofilament yarns are formed of a single elongated, continuous filament of a synthetic polymer material. Some monofilament yarns, such as those made of a single filament of an inelastic synthetic polymer material may have substantially no elasticity, or very little, elasticity. For example, a monofilament yarn made of an inelastic synthetic polymer material may have maximum elongation of less than <NUM>% (e.g., the maximum length of the yarn when subjected to a tensile force approaching its breaking force is less than <NUM>% of its length when not subjected to a tensile force), and it is contemplated that a such a yarn could have a maximum elongation of <NUM> %, <NUM>%, or even less.

Referring to the knit construction illustrated in <FIG>, the knitted component <NUM>, including each of the depicted pods and edge regions, includes the first surface <NUM> (e.g., an outward-facing surface) and the second surface <NUM>. Referring to the second pod <NUM>, the first surface <NUM> is formed by the first yarn <NUM> such that, when heat-processed, the fusible material of the first yarn <NUM> fuses to form a rigid first surface <NUM>. In contrast, the first surface <NUM> of the first edge region <NUM> is formed by the second yarn <NUM>. If the second yarn <NUM> is substantially free of fusible material, and/or the material of the second yarn <NUM> has a melting point that is higher than a melting point of the first yarn <NUM>, the edge regions <NUM>, <NUM> remain relatively flexible with respect to the first pod <NUM> after heat processing (at least on the first surface <NUM>). Similarly, the first surface <NUM> of the second edge region <NUM> is formed of the second yarn <NUM> and also remain relatively flexible with respect to the second pod <NUM> and third pod <NUM> after heat processing (at least on the first surface <NUM>).

The second surface <NUM> of the knitted component is formed of the second yarn <NUM> throughout the depicted pods and edge regions. Advantageously, when the second yarn <NUM> is a polyester yarn, for example, the second layer <NUM> may have characteristics that are desirable for facing a void. For example, the second surface <NUM> may have relative softness and/or other comfort-related characteristics that are suitable and desirable for contacting the foot or sock of a wearer. As described in more detail below, this construction may be achieved by utilizing a knitting process that forms a multi-layer structure. For example, within the first, second, and/or third pods <NUM>, <NUM>, <NUM>, the first layer <NUM> having the first surface <NUM> is formed on a first needle bed of a flat knitting machine, and the second layer <NUM> having the second surface <NUM> is formed on a second bed of the flat knitting machine such that the pocket <NUM> is formed between the first layer <NUM> and the second layer <NUM>. At least a portion of the second yarn <NUM> is knit with the first needle bed at the edge regions <NUM>, <NUM>. Other suitable knitting processes are also contemplated (e.g., a technique utilizing transfers between both needle beds). A specific knitting process is described in more detail below with reference to <FIG>.

The third yarn <NUM> is a yarn that is inlaid between the first layer <NUM> and the second layer <NUM>. While only one third yarn <NUM> is depicted in <FIG>, a plurality of yarns may be inlaid between the first layer <NUM> and the second layer <NUM>, and thus the depicted third yarn <NUM> may represent a plurality of yarns in reality (e.g., a plurality of yarn types, and/or a plurality of individual yarns of the same type). The third yarn <NUM> may have one or more visual characteristics to provide the knitted component <NUM> with desirable visual properties. For example, when the knitted component <NUM> is viewed from a perspective looking towards the first surface <NUM>, the third yarn <NUM> may be visible within at least one of the pods <NUM>, <NUM>, <NUM> due to the transparency of the material of the heat-treated first yarn <NUM>. Thus, it is contemplated that the third yarn <NUM> may include a variety of colors, visual textures, patters, or other visual properties that may be deemed visually appealing. A material (e.g., a material other than a yarn) may be included within the pocket <NUM> in addition to the third yarn <NUM>. Such a material may enhance the padding or cushioning-related characteristics of the pod. Alternatively, such material may enhance the rigidity or stiffening characteristics of the pod to provide greater structure to the particular region. Once the first yarn <NUM> is heat-processed, the thermoplastic polymer material of the first yarn <NUM> may be at least partially bonded to the third yarn <NUM>.

Optionally, the fourth yarn <NUM> may be included to provide a tie (e.g., a structural connection) between the first layer <NUM> and the second layer <NUM> within the pods <NUM>, <NUM>, <NUM>. The fourth yarn <NUM> may thus be advantageous for providing the pods <NUM>, <NUM>, <NUM> with structural integrity and/or for reducing movement of the third yarn <NUM> within the pod. In some embodiments, and as described above, the fourth yarn <NUM> may be a monofilament yarn or strand. Advantageously, since monofilament strands are often relatively small in diameter and formed of a transparent material while still having relatively high tenacity and strength, the fourth yarn <NUM> may provide an adequate tie between the layers <NUM>, <NUM> without interrupting the visual characteristics provided by the inlaid third yarn <NUM>. The resulting knit structure of the knitted component <NUM> may have suitable strength, durability, rigidity, and other desirable structural characteristics. In other embodiments, the fourth yarn <NUM> may be excluded such that the first layer <NUM> and the second layer <NUM> are separable at the pods <NUM>, <NUM>, <NUM>.

<FIG> illustrates exemplary knit diagrams for the pod and edge regions, respectively, and one skilled in the art would know how to accomplish it based on the diagrams alone. In one example, the sequence identified as "A" on the left side of <FIG> illustrates one embodiment of a knitting sequence that may be used for the pods <NUM>, <NUM>, <NUM> of the knitted component <NUM> as shown in <FIG>. Similarly, the sequence identified as "B" on the right side of <FIG> illustrates a knitting sequence that may be used to form the edge regions <NUM>, <NUM> of the knitted component <NUM>. As is apparent to a person of ordinary skill in the art, the types of yarns and manner of knitting each yarn may differ between different areas of the knitted component <NUM>, and the sequences depicted and described herein can be slightly or substantially altered to form similar structures.

Referring to sequence "A" of <FIG>, step <NUM> represents one or more knitting passes of knitting the first yarn <NUM> on every other needle of a first needle bed (e.g., a front bed). In step <NUM>, the third yarn <NUM> is inlaid between the first needle bed and a second needle bed of the knitting machine. As described in more detail above, the third yarn <NUM> may represent a plurality of strands or yarns which are inlaid with one pass or multiple passes. For example, in an exemplary embodiment, the third yarn <NUM> may include eight (<NUM>) inlaid polyester yarns having selected colors or other visual characteristics. In step <NUM>, the fourth yarn <NUM> may be knit to anchor or secure (e.g., "tie") the first layer <NUM> to the second layer <NUM> using tuck stitching. In step <NUM>, the second yarn <NUM> is knitted on every other needle of the back bed, as shown, with the second yarn <NUM> again being knitted in step <NUM> on the alternate needles of the back bed. In step <NUM>, the third yarn <NUM> is again inlaid. In step <NUM>, the fourth yarn <NUM> may again be knit to tie the first layer <NUM> to the second layer <NUM>, using tuck stitches. Finally, in step <NUM>, the first yarn <NUM> is knit on every other needle of the front bed that was not used in step <NUM>. The resulting structure may be similar to at least one of the pods <NUM>, <NUM>, <NUM> depicted in <FIG>.

Referring sequence "B" of <FIG>, which may represent the formation of one of the edge regions <NUM>, <NUM> (shown in <FIG>), step <NUM> includes inlaying the first yarn <NUM>. In step <NUM>, the third yarn <NUM> is inlaid. In step <NUM>, the fourth yarn <NUM> may be knit to anchor the adjacent yarns using tuck stitching. In step <NUM>, the second yarn <NUM> is knitted on the back bed, as shown, with the elastic yarn again knitted in step <NUM> on the front bed. In step <NUM>, the third yarn <NUM> is again inlaid. In step <NUM>, the fourth yarn <NUM> may again be knit to tie yarns using tuck stitches. Finally, in step <NUM> the first yarn <NUM> is inlaid as shown.

<FIG> is an illustration showing a top perspective view of another embodiment of an article of footwear <NUM>. As shown, the article of footwear <NUM> may include an upper <NUM> that is formed of a knitted component <NUM>. The upper <NUM> may include a tongue <NUM> extending through a throat area <NUM> of the upper <NUM>. The tongue <NUM> may be formed as a portion of the knitted component <NUM> on a knitting machine, or it may be separately formed and then later attached to the knitted component <NUM> after the knitting process (e.g., via sewing). The article of footwear <NUM> may also include a fastening element. Any suitable type of fastening element may be used, such as the depicted lace <NUM>, a cabletensioning system, and/or any other suitable device. The upper <NUM> may be configured to secure to and communicate with the fastening element such that the fastening element may adjust and/or tighten the upper <NUM> around a foot of a wearer. For example, the upper <NUM> may include a set of apertures for receiving the fastening element, but other suitable element(s) may alternatively be used.

Like certain embodiments described above, the knitted component <NUM> may include one or more pods <NUM>. The pods <NUM> may incorporate any of the characteristics, constructions, or other features described with respect to the embodiments above. As shown, the pods <NUM> may be located on the knitted component <NUM> on an outer surface <NUM> of the upper <NUM> in a location other than in the throat area <NUM>. Additionally or alternatively, the pods <NUM> may be located on the tongue <NUM>. Advantageously, the pods <NUM> on the tongue <NUM> may provide protection, rigidity, cushioning, durability, and/or other related characteristics in the throat area <NUM> without sacrificing the ability of the upper <NUM> to be tightened around the foot.

<FIG> is an illustration showing a top view of an embodiment of an article <NUM>. The article <NUM> may be a swatch for an article of apparel. Non-limiting examples of articles of apparel include shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats, and the like. Like the examples above, the article <NUM> may include a plurality of pods <NUM> surrounded by edge regions <NUM>. The article <NUM> is substantially formed by a knitted component <NUM>. The knitted component <NUM> includes a construction similar to the construction described with respect to the embodiments above. As shown, the pods <NUM> may include a variety of shapes and sizes. Certain pods <NUM> may be substantially formed as triangles, rectangles, pentagons, hexagons, etc. Optionally, at least some of the pods <NUM> may be demarcated by edge regions <NUM> that are curved, as shown (see, e.g., pod <NUM>).

In some embodiments, dimensions of the edge regions <NUM> may vary. For example, a first edge region <NUM> may have a first thickness, a second edge region <NUM> may have a second thickness, and the first thickness may be greater than the second thickness. Advantageously, thicker edge regions may be placed in locations where more flexibility, stretchability, and/or other characteristics are desired. Similarly, larger pods <NUM> may be placed in locations where stiffness, rigidity and/or structure and other related characteristics are desired.

Referring to <FIG>, in some embodiments, the pods <NUM> of the article <NUM> may have an irregular shape (and in some embodiments, only one irregular pod may be included). For example, the edge regions <NUM> may extend in an irregular path (e.g., a curved, swerved, jagged, or otherwise nonlinear path) through the knitted component <NUM> of the article <NUM>.

All of the structures and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While this disclosure may be embodied in many different forms, there are described in detail herein specific aspects of the disclosure. The present disclosure is an exemplification of the principles of the disclosure and is not intended to limit the disclosure to the particular aspects illustrated. In addition, unless expressly stated to the contrary, use of the term "a" is intended to include "at least one" or "one or more. " For example, "a yarn" is intended to include "at least one yarn" or "one or more yarns.

Claim 1:
An article (<NUM>, <NUM>, <NUM>) formed of a knitted component (<NUM>, <NUM>, <NUM>), the article (<NUM>, <NUM>, <NUM>) comprising:
a first surface (<NUM>) and a second surface (<NUM>), the first surface (<NUM>) facing opposite the second surface (<NUM>);
a pod (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) having the first surface (<NUM>) formed by a first layer (<NUM>) and the second surface (<NUM>) formed by a second layer (<NUM>), wherein the pod (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) includes a pocket (<NUM>) formed between the first layer (<NUM>) and the second layer (<NUM>); and
an edge region (<NUM>, <NUM>, <NUM>, <NUM>) having the first surface (<NUM>) and the second surface (<NUM>), the edge region (<NUM>, <NUM>, <NUM>, <NUM>) at least partially demarcating the pod (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>);
a first yarn (<NUM>) comprising a first material that is fusible, wherein the first material is a thermoplastic polymer material, wherein the first surface (<NUM>) within the pod (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is formed from a fused area;
a second yarn (<NUM>) substantially forming the second surface (<NUM>) of the pod (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>);
wherein a third yarn (<NUM>) is laid in within the pocket (<NUM>) between the first layer (<NUM>) and the second layer (<NUM>), characterised in that the fused area is of the first material that is heat-processed during manufacturing such that it is fused, and in that the second yarn (<NUM>) substantially forms the first surface (<NUM>) of the edge region (<NUM>, <NUM>, <NUM>, <NUM>).