Patent Description:
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 footwear, 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. An ankle opening in a heel area generally provides access to the void in the interior of the upper. 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 an article of footwear which may include a knitted component formed of unitary knit construction. The knitted component includes a sock portion and a tongue portion. The sock portion has a hollow structure (a) forming an ankle opening in a heel region of the footwear and (b) extending between the heel region and a forefoot region of the footwear to define a void within the footwear for receiving a foot. The tongue portion has an elongate configuration (a) extending through at least a portion of a length of a throat area of the upper and (b) including two knit layers that lay adjacent to each other.

The objective technical problem to be solved can be considered to overcome or at least to reduce the disadvantages according to the prior art.

The objective technical problem is solved by the subject matter of the independent claims.

According to an aspect an upper is disclosed according to the subject matter of claim <NUM>.

According to another aspect a method is disclosed according to the subject matter of claim <NUM>.

Certain aspects of the present disclosure relate to uppers configured for use in an article of footwear. When referring to articles of footwear, the uppers 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 uppers may also be incorporated into non-athletic shoes, such as dress shoes, loafers, and sandals.

<FIG> is an illustration showing an article of footwear <NUM> formed with an upper <NUM>, where the upper <NUM> is substantially formed as a textile component. The textile component may be any suitable type of textile, and in some embodiments it may be formed as a knitted component <NUM>. As shown, the knitted component <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 additionally include a throat area <NUM> extending from and the 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 shown in <FIG>) may be disposed at least partially in the throat area <NUM>. The tongue may be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included (or in combination with a tongue), the lateral and medial sides of the throat area <NUM> may be joined together.

The article of footwear <NUM> may include a fastening element. Any suitable type of fastening element may be used, such as the depicted lace <NUM>, a cable- tensioning 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 <NUM> for receiving the fastening element, but other suitable element(s) may alternatively be used.

At least a portion of the upper <NUM>, and potentially the entirety of the upper <NUM>, is formed of the knitted component <NUM>. 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 are accomplished by selecting a double jersey knit structure and 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 weight of the knitted component <NUM>, and thus the overall weight of the article of footwear <NUM>, may be reduced with respect to alternative components typically used in footwear. 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). For example, the knitted component <NUM> may include yarns formed of a thermoplastic polymer material (e.g., a polyurethane, polyamide, polyolefin, and/or nylon) 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 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.

<FIG> is an illustration showing a second lateral side view of the article of footwear <NUM> of <FIG>. In <FIG>, the upper <NUM> is depicted without a lace or other fastening element and with certain portions spread out from their typical wearable configurations to showcase certain features of the knitted component <NUM>. As shown, a first portion <NUM> of the knitted component <NUM> may be located between a second portion <NUM> and a third portion <NUM>. The first portion <NUM>, the second portion <NUM>, and/or the third portion <NUM> are formed together on a knitting machine such that they share a common yarn, a common loop, a common course, a common wale, and/or another common knit structure. Thus, the first portion <NUM> is secured to the second portion <NUM> via at least one knit structure of the knitted component <NUM> (such as a common course, a common wale, a common loop, and/or a common yarn), and similarly the first portion <NUM> may be secured to the third portion <NUM> via at least one knit structure of the knitted component <NUM>. Advantageously, no post-knitting step may be necessary for connecting the respective portions of the knitted component, which may save material cost and manufacturing time thereby decreasing the end cost to a consumer.

The second portion <NUM> and/or the third portion <NUM> form an outer surface <NUM> of the upper <NUM> on at least one of the lateral side <NUM> and the medial side <NUM> of the article of footwear <NUM>. In the embodiment of <FIG>, for example, the second portion <NUM> forms at least a portion of the outer surface <NUM> on the lateral side <NUM> and the third portion <NUM> forms at least a portion of the outer surface <NUM> on the medial side <NUM> of the article of footwear. As shown, the second portion <NUM> and/or the third portion <NUM> may overlap the first portion <NUM> (i.e., the second portion <NUM> and the third portion <NUM> may be coextensive with the first portion <NUM> on the medial side <NUM> and lateral side <NUM>, respectively). Thus, an inner surface <NUM> of the second portion <NUM> and/or an inner surface <NUM> of the third portion <NUM> may face, and potentially contact, the first portion <NUM> when the article of footwear <NUM> is in a wearable configuration.

At least one of the first portion <NUM>, the second portion <NUM>, and the third portion <NUM> of the knitted component <NUM> has more than one layer of knitted material. When a portion of the knitted component <NUM> has more than one layer, the multiple layers may be integrally formed (e.g. together during a knitting or other textile manufacturing process), or they may alternatively be separately formed and later attached. The multiple layers are formed on multiple needle beds of a knitting machine but are integral and tightly bound together such that they are inseparable and/or are not readily distinguishable (visually or otherwise), and thus "multiple layers" is not limited to separable layers having a pocket or other space therebetween. However, in some embodiments, the multiple layers are separable and/or otherwise movable with respect to one another and may form a pocket therebetween.

According to the invention, as shown in <FIG>, the first portion <NUM> of the knitted component <NUM> has two separable layers: an upper layer (depicted as the first layer <NUM>) and a lower layer (depicted as the second layer <NUM>). The first layer <NUM> and the second layer <NUM> converge and are secured to one another at a boundary <NUM> of the first portion <NUM>. The boundary may be the point of attachment between the first layer <NUM> and the second layer <NUM>, and the attachment may be provided by a common course, loop, wale, and/or yarn extending between the first layer <NUM> and the second layer <NUM>. Other attachment devices and/or methods are also contemplated (e.g., the first layer <NUM> and the second layer <NUM> may be sewn together, secured via an adhesive, etc.). The boundary <NUM> may be located on at least one of the lateral side <NUM> and the medial side <NUM> and on the outer surface <NUM> (as shown in <FIG>) such that a portion of the second layer <NUM> is exposed on an overfoot portion of the knitted component <NUM>. In other embodiments, the boundary <NUM> may be approximately aligned with the biteline <NUM> and/or may be located on an underfoot portion of the knitted component <NUM>.

When the first portion <NUM> has multiple layers, the first layer <NUM> may primarily be formed on a front needle bed of the knitting machine and the second layer <NUM> may primarily be formed on a back needle bed (or vice versa). The two layers are separable and define a pocket therebetween, the layer formed on the front needle bed and/or the layer formed on the back needle bed may have a single jersey knit structure or another knit structure incorporating needles from only one bed.

Other knitting techniques may be additionally or alternatively used to form a multi-layer structure. For example, it is contemplated that both layers could utilize needles from each bed during the knitting process to enhance the ability to integrate functional and/or visual features within each layer. For example, one or more consecutive courses of the first layer <NUM> may utilize needles from both needle beds to provide the first layer <NUM> with a particular multi-bed knit structure. Then, prior to or during knitting one or more courses of the second layer <NUM>, all loops of the first layer <NUM> may be transferred to a first needle bed to free the needles on the second needle bed to form the second layer <NUM> (and to prevent the first layer <NUM> from binding to the second layer <NUM>). The second layer <NUM> may then be knitted on the second bed alone or may utilize needles on both needle beds (particularly if the first layer <NUM> leaves some needles on the first needle bed unoccupied). If the second layer <NUM> is formed on both beds, once it is time to resume knitting courses of the first layer <NUM>, all loops associated with the second layer <NUM> may be transferred to the second bed to free the first bed for again forming the first layer <NUM> (and to prevent the second layer <NUM> from binding with the first layer <NUM>). This process may be repeated as necessary.

If necessary, when knitting the first layer <NUM> and/or the second layer <NUM>, certain needles on each bed may be skipped by the first layer <NUM> and/or the second layer <NUM> to leave needles unoccupied for knitting the other layer. Thus, the first layer <NUM> and/or the second layer <NUM> may have a reduced gauge and/or stitch density when compared to the knit structure of the second portion <NUM> and the third portion <NUM> of <FIG> (which are formed of a full-gauge or substantially full-gauge in exemplary embodiments). In some embodiments, a gauge of the first layer <NUM> and/or the second layer <NUM> (defined by the ratio of the number of needles used to the total number of needles available) may be at least <NUM>% less than a gauge of the second portion <NUM> and/or a gauge of the third portion <NUM>. In exemplary embodiments, the gauge of the first layer <NUM> (which may be relatively elastic) is about <NUM>% or less than the gauge of the second portion <NUM> and the gauge of the third portion <NUM>.

<FIG> is an illustration showing a sectional view of the article of footwear of <FIG> taken along line <NUM>-<NUM>. As shown, the first layer <NUM> and the second layer <NUM> each have opposite-facing surfaces, and a pocket <NUM> is located between the first layer <NUM> and the second layer <NUM>. That is, the first layer <NUM> includes a first top surface <NUM> and a first bottom surface <NUM> and the second layer <NUM> includes a second top surface <NUM> and a second bottom surface <NUM>. The first bottom surface <NUM> and the second top surface <NUM> face the pocket <NUM>, and the first top surface <NUM> and the second bottom surface <NUM> face away from the pocket <NUM>.

In the depicted embodiment, the second layer <NUM> may form an underfoot portion associated with a plantar aspect of the foot (also known as the sole or bottom of a foot). The first layer <NUM> of the knitted component <NUM> may at least partially form an overfoot portion associated with the remainder of the foot, including the dorsal surface (i.e., the top of the foot), particularly in the throat area <NUM>. As shown, the second top surface <NUM> may contact the plantar aspect of the foot (or sock) of a wearer during typical use, and the first bottom surface <NUM> may contact the dorsal surface of the foot. It is also contemplated that a liner or another component may be located between the knit surfaces and the void, but a liner is optional.

When the first layer <NUM> is configured to form an overfoot portion of the upper <NUM>, it may be advantageous for the first layer <NUM> to have a relatively high elasticity (and thus a relatively low modulus of elasticity (Young's modulus)) such that it provides a secure, snug, and/or comfortable fit around the foot, and such that the first layer <NUM> has the capability of moving and/or flexing dynamically with the foot when the article of footwear experiences typical use. When the second layer <NUM> is configured to form an underfoot portion, the second layer <NUM> may be configured to secure to the sole structure <NUM>. Thus, the second bottom surface <NUM> may be formed with surface characteristics suitable for facilitating attachment to the sole structure through sewing, bonding via adhesive, etc. The second layer <NUM> may have a relatively low elasticity (e.g., a high Young's modulus) and a relatively high strength and durability with respect to the first layer <NUM>. The relative elasticities may be accomplished by selectively utilizing a particular 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, or an elastic material such as spandex) or construction (e.g., multifilament or monofilament), by selecting yarns of a particular size (e.g., denier), or a combination thereof.

The elasticity of at least one area of a knitted portion (e.g., a portion of the knitted component <NUM>) may be determined by subjecting the area to a known amount of force and then measuring the area's elongation. For example, two respective ends of the area may be inserted into grips on measuring arms of an extensometer, the area may be subjected to a known stretching force (i.e., tensile force), and then the deformation may be measured. The modulus of elasticity may then be calculated by determining the force needed to achieve a given amount of deformation. In embodiments where the second layer <NUM> has a low elasticity (and thus high modulus of elasticity) relative to the first layer <NUM>, for example, an area of the second layer <NUM> may deform less relative to an area with the same dimensions of the first layer <NUM> when both areas are subjected to the same amount of stretching force. In one non- limiting method of measuring elasticity, the applied stretching force may be about <NUM> pounds, but other stretching forces are also contemplated (e.g., <NUM> pound or less, <NUM> pounds, <NUM> pounds, <NUM> pounds, etc.).

<FIG> is an illustration showing the knitted component for the article of footwear of <FIG> as it may appear after a knitting process. As shown, the ankle opening <NUM> may be provided in the first layer <NUM>. The ankle opening <NUM> may be formed on the knitting machine when knitting the knitted component <NUM> (e.g., by skipping needles where the ankle opening <NUM> is located), or it may be formed during a post-processing step (e.g., cutting). If the first layer <NUM> can be manipulated to form either an overfoot portion or an underfoot portion (as described in more detail below), it is contemplated that the ankle opening <NUM> may be adjustable in size (e.g., via a drawstring, via the natural elasticity of the knit structure, etc.).

As shown in <FIG>, the second portion <NUM> and the third portion <NUM> may extend from the boundary <NUM> of the first portion <NUM>. Similarly, a heel portion <NUM> of the knitted component <NUM> may extend from the boundary <NUM>. The heel portion <NUM> may include a relatively rigid, strong, and/or another protective characteristic for providing suitable structure and durability in the heel area <NUM> article of footwear. The heel portion <NUM> may overlap (e.g., be coextensive with) the first portion <NUM> when in its wearable configuration, and in some embodiments, the heel portion <NUM> may be secured to at least one of the second portion <NUM> and the third portion <NUM>. The securement between the heel portion <NUM> and the second portion <NUM> and/or the third portion <NUM> may be via a knitted connection structure <NUM> (shown in <FIG>) as is described in more detail below. The heel portion <NUM> and/or the third portion <NUM> may have only one layer of knitted material and/or may have multiple layers that are tightly bound together such that they are inseparable and/or are not readily distinguishable. The second portion <NUM> according to the invention has multiple layers that are tightly bound together such that they are inseparable and/or are not readily distinguishable. The one-layer or bound-layer construction may provide desirable rigidity, elasticity (e.g., relatively low elasticity), durability, and other characteristics that may be deemed desirable for an outer surface of an article of footwear. In <FIG>, the inner surface <NUM> of the second portion <NUM>, and inner surface <NUM> of the third portion <NUM>, and an inner surface <NUM> of the heel portion <NUM> are facing the viewer. When folded or otherwise manipulated into their wearable orientation, those respective inner surfaces of the heel portion <NUM>, the second portion <NUM>, and the third portion <NUM> may face the void <NUM>.

The heel portion <NUM> and/or the third portion <NUM> may be of a single layer (or bound multiple layers) that utilize the full capacity of two needle beds if a knitting machine when formed. As a result, the heel portion <NUM> and/or the third portion <NUM> may have a relatively strong, inelastic, and durable structure that provides the knitted component <NUM> with suitable strength, rigidity, support, protection, and other advantageous characteristics. Thus, the heel portion <NUM> and the third portion <NUM> may each have an elasticity that is less than the elasticity of the first layer <NUM> and/or the second layer <NUM> of the first portion <NUM>. The second portion <NUM> according to the invention has an elasticity that is less than the elasticity of the first layer <NUM> and/or the second layer <NUM> of the first portion <NUM>. Further, the flat nature of the second portion <NUM> and the third portion <NUM> along with the ability to utilize two beds of a flat knitting machine to form the second portion <NUM> and the third portion <NUM> may enhance the ability to include certain knit features, particularly since utilizing the full capacity of two beds (instead of one) significantly increases the ability to selectively include visual designs, varying physical properties, and other features formed by a particular knit structure, particular yarn(s), or a combination thereof. To illustrate, one yarn type (e.g., a yarn with a thermoplastic polymer material composition) may be located on the outer surface <NUM> (see <FIG>) of the second portion <NUM> and a different yarn type may be exposed on an inner surface <NUM> of the second portion <NUM> (and the same may be true of the third portion <NUM>). The flat nature of these portions may additionally enhance the ability for post-knit processing (e.g., applying non-knit graphics, heat pressing, etc.).

Advantageously, the unique structure of the knitted component <NUM> depicted in <FIG> allows the article of footwear to have both (<NUM> ) a comfortable and dynamic fit provided by the relatively high elasticity of the first layer <NUM> of the first portion <NUM> of the knitted component, and also (<NUM>) a sufficiently rigid, protective, durable, and strong outer surface <NUM> (<FIG>) provided by the heel portion <NUM>, the second portion <NUM>, and the third portion <NUM>.

In some embodiments, the second portion <NUM> and/or the third portion <NUM> may have a particular shape configured to enhance functional and/or visual properties of the knitted component <NUM>. As shown in <FIG>, the second portion <NUM> may be corrugated and have one or more spaces <NUM> between corrugations <NUM>. This embodiment may advantageously increase heel-to-toe flexibility of the article of footwear, for example, while maintaining adequate medial-to-lateral support. The third portion <NUM> may include a similar construction, but this is optional. As shown, the third portion <NUM> covers substantially all of the medial side of the article of footwear, which may be advantageous when a high degree of stretch resistance and support is needed in that area. Any other suitable shape for the second portion <NUM> and the third portion <NUM> is contemplated.

<FIG> is an illustration showing another embodiment of an article of footwear <NUM> including a knitted component <NUM> in accordance with the present disclosure. The knitted component <NUM> may be similar to the knitted component <NUM> described with reference to <FIG> above, but the knitted component <NUM> shown in <FIG> may additionally include a forward portion <NUM> extending from a toe area <NUM> of a first portion <NUM> of the knitted component <NUM>. The forward portion <NUM> may include a toebox area <NUM> and a tongue <NUM>. As describe above with respect to other knitted portions, the first portion <NUM> may be have multiple separable layers and may be located between a second portion <NUM> and a third portion <NUM>. The second portion <NUM> and/or the third portion <NUM> may form an outer surface <NUM> of the knitted component <NUM>. The forward portion <NUM> may have one or more layers (separable or bound), and at least one portion of the forward portion <NUM> may primarily include a knit structure (e.g., a double jersey knit structure) utilizing two needle beds of a knitting machine (though this is optional).

The tongue <NUM> may extend from the toebox area <NUM> and over a throat area <NUM> when the knitted component <NUM> is in its wearable configuration. A lateral edge <NUM> of the tongue <NUM> may be overlapped by (i.e., at least partially coextensive with) the second portion <NUM>, and a medial edge (not show) of the tongue <NUM> may be overlapped by the third portion <NUM> (shown in <FIG>) when in its wearable configuration. Advantageously, the tongue <NUM> may be pulled by a user to facilitate entry of a foot into a void of the article of footwear, and the tongue <NUM> may provide additional protection to the dorsal surface of the foot. The toebox area <NUM> may provide additional structural characteristics and protection at the toe area <NUM> of the knitted component <NUM>. The forward portion <NUM> may be formed on a knitting machine with the remainder of the knitted component <NUM> such that no post-knitting attachment step is needed, or, the forward portion <NUM> may be formed separate and then attached after the knitting process.

<FIG> is an illustration showing a second lateral side view of the article of footwear <NUM> of <FIG>, where certain portions the second portion <NUM>, the third portion <NUM>, and the forward portion <NUM> are in a spread or opened configuration to showcase certain features. As shown, the first portion <NUM>, like the first portion <NUM> of <FIG>, may be a multi-layer knitted portion where a first layer <NUM> is located above the foot when the article of footwear <NUM> is in use. The tongue <NUM>, which is pulled forward in the present view, may overlap the first layer <NUM> when the article of footwear is worn. The tongue <NUM> may have edges <NUM> on its medial and lateral sides that are free and unsecured with respect to the second portion <NUM> and the third portion <NUM> of the knitted component <NUM>. In contrast, the toebox area <NUM> of the forward portion <NUM> may be secured to the second portion <NUM> and the third portion <NUM> via a connection structure <NUM>.

As described in more detail below, the connection structure <NUM> may be a knitted connection structure (e.g., formed on a knitting machine), and no post-knitting steps may be necessary for connecting the toebox area <NUM> to the second portion <NUM> and/or the third portion <NUM>. In other embodiments, the connection structure <NUM> may incorporate a sewn seam, an adhesive, a mechanical clamp or other fastening device, or any other suitable device or method for securing the toebox area <NUM> to the second portion <NUM> and/or the third portion <NUM>. Advantageously, and as described in more detail below, securing the toebox area <NUM> of the forward portion <NUM> to at least one of the second portion <NUM> and the third portion <NUM> via the connection structure <NUM> may result in the toebox area <NUM> curving into a cup-like shape with a cavity. The cavity may form a portion of the void of the article of footwear for receiving a foot. However, it is also contemplated that that the toebox area <NUM> may be secured only via the front of the first portion <NUM> such that the toebox area <NUM> is not directly secured to either of the second portion <NUM> or the third portion <NUM>.

<FIG> is an illustration showing a knitting pattern for forming the knitted component <NUM> of <FIG>. While individual courses are not shown, the courses may extend horizontally from the viewpoint of <FIG>. The knitting sequence may be performed in the direction depicted by the arrow <NUM> (such that courses are added to the knitting component in the direction of the arrow <NUM>). The knitted component <NUM>, when being formed, may move against the arrow with respect to the needle beds of a knitting machine. When this direction is used, the heel portion <NUM> of the knitted component <NUM> may be formed first, and a collar <NUM> of the heel portion <NUM> may be at least partially formed by approximately the first formed course of the knitted component <NUM>. The end <NUM> of the tongue <NUM> may be formed by the last course of the knitted component <NUM>.

Since the course-wise direction may be horizontal from the viewpoint of <FIG>, certain courses may extend from an outer lateral edge <NUM> of the second portion <NUM>, through the first portion <NUM>, and to an outer medial edge <NUM> of the third portion <NUM>. When the first portion <NUM> includes multiple layers, the multiple layers may converge and be secured together at the boundary <NUM>. Thus, the second portion <NUM> may extend from the point where the multiple separable layers of the first portion <NUM> converge (i.e., the boundary <NUM>). This may be advantageous since yarns of both the first layer <NUM> and the second layer <NUM> (shown in <FIG>) of the first portion <NUM> can be incorporated into the second portion <NUM> and so the second portion <NUM> may have a rigid, durable, and strong structure formed using the full capacity of two needle beds with all yarns from the relative layers of the first portion <NUM>. The third portion <NUM> has similar advantages due to its position along lateral side of the boundary <NUM>, which also may be a location where the separable layers of the first portion <NUM> converge. It is noted that the first portion <NUM> may not include separable layers in all embodiments.

As describe above, the forward portion <NUM> of the knitted component <NUM> may secure to the second portion <NUM> and/or the third portion <NUM> via a connection structure <NUM> (which is represented by the depicted arrows in <FIG>). The connection structure <NUM> may be formed using a technique where, as the knitting pattern narrows, the knitting machine holds outer loops on needles of a needle bed for a certain number of courses until the pattern again widens. Specifically, referring to the edge <NUM> along the second portion <NUM> of <FIG>, the loops of the courses defining the second portion <NUM> along the edge <NUM> may be formed during formation of the second portion <NUM> and then held for a series of consecutive passes/courses as the knitting machine continues to knit. Similarly the edge <NUM> of the third portion <NUM> may have loops that are held during the formation of additional courses of the first portion <NUM>. As the pattern continues to narrow, more courses may be held.

In the example shown, when the knitting machine reaches the end of the first portion <NUM> and begins knitting the forward portion <NUM>, the held loops may be reincorporated into new courses when forming the forward portion <NUM> and as the knitting pattern widens. In some instances, the held loops may be transferred inward (or outward) such that the placement of the held loops on the needle bed matches their location of incorporated into a new course (which may be determined by a knitting program). For example, the loops of the edge <NUM> may incrementally be transferred between beds and inward/outward until the location of the loops matches the width of the knitting pattern at its respective position of the forward portion <NUM>.

The order of re-incorporation of loops may be inverted with respect to the order that those loops are initially formed. To illustrate, a first loop <NUM> on the edge <NUM> may be initially formed before a second loop <NUM> on the edge <NUM> when knitting the second portion <NUM> of the knitted component <NUM>. However, the second loop <NUM> may be incorporated into a course of the forward portion <NUM> prior to the first loop <NUM> being incorporated into a course of the forward portion <NUM>. As a result, the forward portion <NUM> may curve into a cup-like shape in the toe area of the knitted component <NUM> as it is pulled back towards the throat area of the knitted component due to tension in the courses of the forward portion <NUM>, the second portion <NUM> and/or the third portion <NUM>. In other words, the toebox area <NUM> of the forward portion <NUM> may be curved such that a cavity is formed between the toebox area <NUM> and the underfoot area (defined by at least one layer of the first portion <NUM>), and where the cavity at least partially defines a void for the article of footwear (shown in <FIG>).

The loops that are held for at least one course and then reincorporated into new, later-formed course may form the connection structure <NUM>. The connection structure <NUM> may be fully formed on the knitting machine (without requiring post- knitting securement between the second portion <NUM> and/or the third portion <NUM>). Once the pattern reaches the tongue <NUM> of the forward portion <NUM>, the courses of the forward portion <NUM> may continue to knit the tongue <NUM> having two free edges that may define discrete sides of the tongue <NUM>.

Incorporation of the loops from the edge <NUM> into the forward portion <NUM> may require the forward portion <NUM> and/or the second portion <NUM> to include a knit structure that is less than full gauge (at least adjacent to the connection structure <NUM>) such that enough needles area available to form the connection structure <NUM>. For example, a least a portion of the forward portion <NUM> may have a single jersey knit structure, a half-gauge knit structure (or any other gauge less than full-gauge), or any other suitable knit structure. Alternatively (or additionally), the second portion <NUM> and/or the third portion <NUM> may have a single jersey knit structure, a half-gauge knit structure, or any other suitable knit structure adjacent to the connection structure <NUM>. In one particular example, the depicted edge region <NUM> of the second portion <NUM> may include a single jersey knit structure while the remainders of the second portion <NUM> and the third portion <NUM> include one or more double jersey structures. The third portion <NUM> may include a similar structure.

The heel portion <NUM> may be secured to at least one of the second portion <NUM> and the third portion <NUM>. For example, a medial extension <NUM> of the eel portion <NUM> may include courses with loops that are held on the knitting machine until the pattern reaches the second portion <NUM>, and a lateral extension <NUM> of the heel portion <NUM> may include courses with loops that are held on the knitting machine until the pattern reaches the third portion <NUM> (which may form the connection structures <NUM>, also shown in <FIG>). A base <NUM> of the heel portion <NUM> may extend to the first portion <NUM>.

While the pattern of <FIG> and the related description illustrates and describes the knitting machine as forming the knitted component in the heel-to-toe direction, the knitting direction may be reversed such that the forward portion <NUM> is formed first and the heel portion <NUM> is formed last. Alternatively, it is contemplated that the pattern may be rotated with respect to a needle bed such that the courses are oriented differently than the depicted courses of <FIG> (e.g., the courses may extend in the heel-to-toe direction, diagonally, etc.).

<FIG> is an illustration showing a sectional view of the article of footwear <NUM> taken along line <NUM>-<NUM> of <FIG>. As shown, the toebox area <NUM> of the forward portion <NUM> may be curved to form a cavity <NUM>. The cavity <NUM> may be located in the toe area <NUM> of the article of footwear <NUM> and may correspond with a shape of the void <NUM>. In some embodiments, an inner surface <NUM> of the toebox area <NUM> may face and form an inner surface of the void <NUM>, particularly when the first portion <NUM> of the knitted component <NUM> does not extend above the void <NUM> (as described below with respect to <FIG>). As shown in <FIG>, the tongue <NUM> of the forward portion <NUM> have generally free edges <NUM> that are movable with respect to the second portion <NUM> (shown in <FIG>) and the third portion <NUM>.

<FIG> is an illustration showing a lateral side view of another embodiment of an article of footwear <NUM> including a knitted component <NUM>. Like the embodiments above, the embodiment of the knitted component <NUM> of <FIG> includes a first portion <NUM> located between a second portion <NUM> and a third portion <NUM>. However, the first portion <NUM> of the knitted component <NUM> does not extend to a throat area <NUM> and remains substantially at an underfoot portion of the knitted component <NUM>. Since the first portion <NUM> remains located at the underfoot portion of the knitted component <NUM>, the second portion <NUM> and the third portion <NUM> may form not only the outer surface <NUM> on the lateral side <NUM> and the medial side <NUM>, respectively, but also an inner surface <NUM> and an inner surface <NUM> of the knitted component <NUM> that face and define the void <NUM> of the article of footwear. The inner surface <NUM> and the inner surface <NUM> may be the inner-most surfaces (or at least the inner-most knit surface) with respect to the void <NUM> at their respective locations, and they may be configured to contract a foot (or sock) of a wearer when the article of footwear is in use. It is contemplated that the inner surface <NUM> and/or the inner surface <NUM> may be formed with particular surface characteristics designed for comfort (e.g., a particular softness, anti-abrasiveness, etc.), for example by utilizing a polyester yarn. Since two needle beds may be used to for the second portion <NUM> and the third portion <NUM>, the outer surface <NUM> formed by the second portion <NUM> and/or the outer surface <NUM> formed by the third portion <NUM> may have surface characteristics that are better suited for outward-exposure (e.g., for protection of the foot, for anti-abrasiveness and durability, for waterproofing, etc.).

When a forward portion <NUM> with a tongue <NUM> is included, the tongue <NUM> may also (or alternatively) define the inner surface facing the void <NUM> and may at least partially form the throat area <NUM> of the knitted component <NUM>. However, the tongue <NUM> is optional. In embodiments without a tongue, the second portion <NUM> of the knitted component <NUM> and the third portion <NUM> of the knitted component may approach one another and may potentially overlap during normal use such that substantially all of a user's foot is covered by the knitted component <NUM>. In other embodiments, portions of the user's foot may remain uncovered (e.g., when the article of footwear is a sandal, for example).

In the embodiment of <FIG>, at least some areas of the first portion <NUM> have separable layers that both form the underfoot portion of the knitted component <NUM>.

Referring to <FIG>, which is an illustration showing a sectional view of the article of footwear of <FIG> taken along line <NUM>-<NUM>, the first portion <NUM> of the knitted component <NUM> may include a first layer <NUM> and a second layer <NUM>. The second layer <NUM> of the first portion <NUM> may form an underfoot portion of the knitted component that is secured to a sole structure <NUM> (as described in more detail above). The first layer <NUM> may also form the underfoot portion, and the first layer <NUM> may contact the plantar aspect of the foot (also known as the sole or bottom of a foot) during typical use. In other words, both the first layer <NUM> and the second layer <NUM> may be located beneath the foot of a user when the article of footwear is in typical use. A first top surface <NUM> of the first layer <NUM> may form a bottom surface of a void <NUM> of the article of footwear. A first bottom surface <NUM> of the first layer <NUM> and a second top surface <NUM> of the second layer <NUM> may face and define a pocket <NUM>, and a second bottom surface <NUM> of the second layer <NUM> may face and secure to the sole structure <NUM>.

The pocket <NUM> may be sized and shaped to receive a cushioning element <NUM> (which may be considered a midsole). The cushioning element <NUM> may be a separate element from the knitted component <NUM> and may be inserted into the pocket <NUM> after forming the knitted component <NUM> on a knitting machine. The cushioning element <NUM> may include a foam (e.g., a blown foam), an insertable element formed of plastic, metal, rubber, textile material (such as a knitted material), or another suitable material, or any other suitable object for providing cushioning or protection or otherwise attenuate ground reaction forces when compressed between the foot and the ground during walking, running, or other ambulatory activities. The cushioning element <NUM> may be inserted into the pocket <NUM> in any suitable manner, such as through an opening formed in one of the layers or at another location of the knitted component <NUM>, by substantially non-invasive injection (e.g., when a blown foam is used), etc. It is contemplated that the cushioning element <NUM> may be removable and/or insertable after the manufacturing process such that the user (or other person) may select and interchange particular cushioning elements that have particular characteristics beneficial for a certain foot type or size, a particular activity, a desired level of cushioning, etc. Optionally, the cushioning element <NUM> may be at least partially movable within the pocket relative to at least one of the first bottom surface <NUM> and the second top surface <NUM>. In other embodiments, the cushioning element <NUM> may be secured to one or more of the first layer <NUM> and the second layer <NUM> via an adhesive, sewing, or any other suitable device or method.

In some embodiments, the cushioning element <NUM> may be at least partially formed on a knitting machine with the remainder of knitted component <NUM> such that the cushioning element <NUM> is considered a portion of the knitted component <NUM>. For example, the cushioning element <NUM> may include one or more floating yarns formed of a relatively soft material or other material with characteristics that facilitate cushioning and/or protection. One particular example of a cushioning element may include a plurality cushioning structures defined by one or more floating yarns between the first layer <NUM> and the second layer <NUM> (see, for example, <CIT>).

A knitted component formed in accordance with at least some of the embodiments above may be capable of different configuration to form different types of footwear, and/or different types of fit. For example, the knitted component <NUM> of <FIG> and the knitted component <NUM> of <FIG> may have substantially the same knitting pattern even though the knitted component <NUM> has an additional layer that extends above the foot of a wearer during use (i.e., the first layer <NUM> of <FIG> is primarily located above the void while the first layer <NUM> of <FIG> is primarily located at the underfoot portion). In particular, with reference to <FIG> for illustrative purposes, the first layer <NUM> may be selectively positioned either above or below the void. The positioning of the first layer <NUM> may be performed during the manufacturing of the article of footwear <NUM>, for example, but after knitting.

Advantageously, a single knitting program may be used to form two or more different types of articles of footwear, which may be reduce machine setup time, programming time, training requirements, and the like. After the knitting process, a post-knitting manufacturing step may finalize the position of the first layer <NUM> by, for example, lasting and heat-processing the article of footwear <NUM> (see, e.g., an example of a last and an associated lasting process is described in in <CIT>, and issued as <CIT>), securing the first layer <NUM> to another element (e.g., a cushioning element as described with reference to <FIG>), cutting the ankle opening (if necessary), and/or any other suitable manufacturing step.

Optionally, the knitted component <NUM> of <FIG> and the knitted component <NUM> of <FIG> may have similar or identical knitting patters and programs, but may utilize different yarn materials. For example, the yarns forming the first layer <NUM> of <FIG> maybe relatively elastic such that the first layer <NUM> can be stretch over the void, while the first layer <NUM> of <FIG> may be formed of relatively inelastic yarns to provide the underfoot portion of the article of footwear <NUM> with a suitable degree of strength, rigidity, cushioning, and the like. Thus, during setup, an operator can select particular materials (e.g., yarn types) which may determine the type of footwear formed.

Claim 1:
An upper (<NUM>) for an article of footwear (<NUM>, <NUM>) being formed of a knitted component (<NUM>, <NUM>) comprising:
a first portion (<NUM>, <NUM>), the first portion having a first layer (<NUM>, <NUM>) and a second layer (<NUM>, <NUM>), where the first layer and the second layer each have opposite-facing surfaces, the first layer and the second layer forming a pocket therebetween, and the first layer and the second layer being secured via at least one knit structure of the knitted component at a boundary (<NUM>, <NUM>) of the first portion; and
a second portion (<NUM>, <NUM>) extending from the boundary of the first portion and secured at the boundary via at least one knit structure of the knitted component, wherein the second portion includes a double jersey knit structure having multiple layers that are tightly bound together such that they are inseparable and/or are not readily indistinguishable, wherein the double jersey knit structure of the second portion (<NUM>, <NUM>) forms an outer surface (<NUM>, <NUM>) of the article of footwear (<NUM>, <NUM>) on at least one of a medial and lateral side (<NUM>, <NUM>), wherein yarns of both the first layer (<NUM>, <NUM>) and the second layer (<NUM>, <NUM>) of the first portion (<NUM>, <NUM>) are incorporated into the second portion (<NUM>, <NUM>), wherein the second layer of the first portion at least partially forms an underfoot area of the knitted component,
wherein the second portion (<NUM>, <NUM>) has an elasticity that is less than an elasticity of the first layer (<NUM>, <NUM>) and/or the second layer (<NUM>, <NUM>) of the first portion (<NUM>, <NUM>), and
wherein the first layer of the first portion forms at least one of:
(a) an overfoot portion of the article of footwear such that the pocket forms a void of the article of footwear for receiving a foot and such that the first layer forms a top surface (<NUM>) of the void (<NUM>), and
(b) an underfoot portion of the article of footwear such that the first layer forms a bottom surface (<NUM>) of the void of the article of footwear.