Patent Description:
The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, under the foot, and around the heel area of the foot. In some articles of footwear, such as basketball footwear and boots, the upper may extend upward and around the ankle to provide support or protection for the ankle. Access to the void on the interior of the upper is generally provided by an ankle opening in a heel region of the footwear. A lacing system is often incorporated into the upper to adjust the fit of the upper, thereby permitting entry and removal of the foot from the void within the upper. The lacing system also permits the wearer to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying dimensions. 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 a heel counter to limit movement of the heel.

A variety of material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing the upper. In athletic footwear, for example, the upper may have multiple layers that each include a variety of joined material elements. As examples, the material elements may be selected to impart stretch-resistance, wear-resistance, flexibility, air-permeability, compressibility, comfort, and moisture-wicking to different areas of the upper. In order to impart the different properties to different areas of the upper, material elements are often cut to desired shapes and then joined together, usually with stitching or adhesive bonding. Moreover, the material elements are often joined in a layered configuration to impart multiple properties to the same areas. As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, stocking, cutting, and joining the material elements may also increase. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and type of material elements incorporated into the upper increases. Moreover, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from fewer types and numbers of material elements. By decreasing the number of material elements utilized in the upper, therefore, waste may be decreased while increasing the manufacturing efficiency and recyclability of the upper.

<CIT> discloses an article of footwear having an upper including a knit element. The upper may comprise different zones being formed of different yarns and/or stitch patterns so as to have different properties.

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. An article of footwear is provided according to the subject matter of claim <NUM>.

An article of footwear is provided according to the subject matter of claim <NUM>.

Background knowledge useful for understanding the invention relates to an article of footwear which has an upper and a sole structure secured to the upper, the upper including a knitted component comprising: a knit element including a first yarn, the knit element defining a portion of an exterior surface of the upper and an opposite interior surface of the upper, the interior surface defining a void for receiving a foot, the first yarn being a natural or synthetic twisted fiber yarn; and at least one monofilament area comprised of two knit layers, the two knit layers being overlapping and at least partially coextensive with each other, each knit layer including a monofilament strand; wherein the at least one monofilament area is formed of unitary knit construction with the knit element such that the knitted component is a one-piece element.

Background knowledge useful for understanding the invention relates to an article of footwear which has an upper and a sole structure secured to the upper, the upper including a knitted component comprising: a first portion of the knitted component formed by a first yarn, the first yarn being a natural or synthetic twisted fiber yarn; a second portion of the knitted component formed by a monofilament strand, wherein second portion is formed of unitary knit construction with the first portion such that the knitted component is a one-piece element; and an inlaid tensile element extending through the knitted component, including at least a portion of the first portion and a portion of the second portion.

Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description.

The following discussion and accompanying figures disclose a variety of concepts relating to knitted components and the manufacture of knitted components. Although the knitted components may be used in a variety of products, an article of footwear that incorporates one or more of the knitted components is disclosed below as an example. <FIG> illustrate exemplary embodiments of an article of footwear incorporating a knitted component including one or more monofilament areas formed of unitary knit construction with the remaining portions of the knitted component. The individual features of any of the knitted components described herein may be used in combination or may be provided separately in different configurations for articles of footwear. In addition, any of the features may be optional and may not be included in any one particular embodiment of a knitted component.

<FIG> illustrate an exemplary embodiment of an article of footwear <NUM>, also referred to simply as article <NUM>. Article of footwear <NUM> includes a sole structure <NUM> and an upper <NUM>. Although article <NUM> is illustrated as having a general configuration suitable for running, concepts associated with article <NUM> may also be applied to a variety of other athletic footwear types, including soccer shoes, baseball shoes, basketball shoes, cycling shoes, football shoes, tennis shoes, training shoes, walking shoes, and hiking boots, for example. 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. Accordingly, the concepts disclosed with respect to article <NUM> may be applied to a wide variety of footwear types.

For reference purposes, article <NUM> may be divided into three general regions: a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>, as shown in <FIG>, <FIG>, and <FIG>. Forefoot region <NUM> generally includes portions of article <NUM> corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region <NUM> generally includes portions of article <NUM> corresponding with an arch area of the foot. Heel region <NUM> generally corresponds with rear portions of the foot, including the calcaneus bone. Article <NUM> also includes a lateral side <NUM> and a medial side <NUM>, which extend through each of forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and correspond with opposite sides of article <NUM>. More particularly, lateral side <NUM> corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot), and medial side <NUM> corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and lateral side <NUM>, medial side <NUM> are not intended to demarcate precise areas of article <NUM>. Rather, forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and lateral side <NUM>, medial side <NUM> are intended to represent general areas of article <NUM> to aid in the following discussion. In addition to article <NUM>, forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM> and lateral side <NUM>, medial side <NUM> may also be applied to sole structure <NUM>, upper <NUM>, and individual elements thereof.

Sole structure <NUM> is secured to upper <NUM> and extends between the foot and the ground when article <NUM> is worn. In some embodiments, sole structure <NUM> may include one or more components, including a midsole, an outsole, and/or a sockliner or insole. In an exemplary embodiment, sole structure <NUM> may include an outsole <NUM> that is secured to a lower surface of upper <NUM> and/or a base portion configured for securing sole structure <NUM> to upper <NUM>. In one embodiment, outsole <NUM> may be formed from a wear-resistant rubber material that is textured to impart traction. Although this configuration for sole structure <NUM> provides an example of a sole structure that may be used in connection with upper <NUM>, a variety of other conventional or nonconventional configurations for sole structure <NUM> may also be used. Accordingly, in other embodiments, the features of sole structure <NUM> or any sole structure used with upper <NUM> may vary.

For example, in other embodiments, sole structure <NUM> may include a midsole and/or a sockliner. A midsole may be secured to a lower surface of an upper and in some cases may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In other cases, a midsole may incorporate plates, moderators, fluid-filled chambers, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motions of the foot. In still other cases, the midsole may be primarily formed from a fluid-filled chamber that is located within an upper and is positioned to extend under a lower surface of the foot to enhance the comfort of an article.

Upper <NUM> defines a void within article <NUM> for receiving and securing a foot relative to sole structure <NUM>. The void is shaped to accommodate the foot and extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. Upper <NUM> includes an exterior surface <NUM> and an opposite interior surface <NUM>. Whereas exterior surface <NUM> faces outward and away from article <NUM>, interior surface <NUM> faces inward and defines a majority or a relatively large portion of the void within article <NUM> for receiving the foot. Moreover, interior surface <NUM> may lay against the foot or a sock covering the foot. Upper <NUM> may also include a collar <NUM> that is located in at least heel region <NUM> and forms a throat opening <NUM>. Access to the void is provided by throat opening <NUM>. More particularly, the foot may be inserted into upper <NUM> through throat opening <NUM> formed by collar <NUM>, and the foot may be withdrawn from upper <NUM> through throat opening <NUM> formed by collar <NUM>. In some embodiments, an instep area <NUM> extends forward from collar <NUM> and ankle opening <NUM> in heel region <NUM> over an area corresponding to an instep of the foot in midfoot region <NUM> to an area adjacent to forefoot region <NUM>.

In some embodiments, upper <NUM> may include a tongue portion <NUM>. Tongue portion <NUM> may be disposed between lateral side <NUM> and medial side <NUM> of upper <NUM> through instep area <NUM>. In an exemplary embodiment, tongue portion <NUM> may be integrally attached to and formed of unitary knit construction with portions of upper <NUM> along lateral and medial sides through instep area <NUM>. Accordingly, as shown in the Figures, upper <NUM> may extend substantially continuously across instep area <NUM> between lateral side <NUM> and medial side <NUM>. In other embodiments, tongue portion <NUM> may be disconnected along lateral and medial sides through instep area <NUM> such that tongue portion <NUM> is moveable within an opening between a lateral portion and a medial portion on opposite sides of instep area <NUM>.

A lace <NUM> extends through a plurality of lace apertures <NUM> in upper <NUM> and permits the wearer to modify dimensions of upper <NUM> to accommodate proportions of the foot. In some embodiments, lace <NUM> may extend through lace apertures <NUM> that are disposed along either side of instep area <NUM>. More particularly, lace <NUM> permits the wearer to tighten upper <NUM> around the foot, and lace <NUM> permits the wearer to loosen upper <NUM> to facilitate entry and removal of the foot from the void (i.e., through throat opening <NUM>). In addition, tongue portion <NUM> of upper <NUM> in instep area <NUM> extends under lace <NUM> to enhance the comfort of article <NUM>. Lace <NUM> is illustrated with article <NUM> in <FIG>, while in <FIG>, lace <NUM> may be omitted for purposes of clarity. In further configurations, upper <NUM> may include additional elements, such as (a) a heel counter in heel region <NUM> that enhances stability, (b) a toe guard in forefoot region <NUM> that is formed of a wear-resistant material, and (c) logos, trademarks, and placards with care instructions and material information.

Upper <NUM> includes one or more portions that include monofilament strands, as will be described in more detail below. Monofilament strands may be made from a plastic or polymer material that is extruded to form the monofilament strand. Generally, monofilament strands may be lightweight and have a high tensile strength, i.e., are able to sustain a large degree of stress prior to tensile failure or breaking, so as to provide a large amount or degree of resistance to stretch to upper <NUM>. Portions of upper <NUM> that include monofilament strands may be located in one or more monofilament areas <NUM>.

In some embodiments, monofilament areas <NUM> may be located on various portions of upper <NUM>. In an exemplary embodiment, one or more monofilament areas <NUM> may be located on portions of article <NUM> where upper <NUM> will lay generally flat against a foot of a wearer disposed within upper <NUM>. In this embodiment, monofilament areas <NUM> include a medial monofilament portion <NUM> disposed on medial side <NUM> of upper <NUM> and a lateral monofilament portion <NUM> disposed on lateral side <NUM> of upper <NUM>. Medial monofilament portion <NUM> and lateral monofilament portion <NUM> may be generally located in midfoot region <NUM>. In some embodiments, monofilament areas <NUM> may further include a forefoot monofilament portion <NUM> that is disposed forward of instep area <NUM> in forefoot region <NUM> of upper <NUM>.

Monofilament areas <NUM> are substantially continuous between each monofilament area <NUM> across upper <NUM>. For example, in one embodiment, medial monofilament portion <NUM> may be continuous with forefoot monofilament portion <NUM>, and lateral monofilament portion <NUM> may also be continuous with forefoot monofilament portion <NUM>. With this configuration, monofilament areas <NUM> may form a substantially continuous zone extending across upper <NUM> from lateral side <NUM> across forefoot region <NUM> to medial side <NUM>. In other embodiments, each monofilament area <NUM>, including medial monofilament portion <NUM>, forefoot monofilament portion <NUM>, and/or lateral monofilament portion <NUM>, may be discontinuous with other monofilament areas <NUM> disposed on upper <NUM>. In embodiments where monofilament areas <NUM> are discontinuous, each monofilament area <NUM>, for example, medial monofilament portion <NUM>, forefoot monofilament portion <NUM>, and/or lateral monofilament portion <NUM>, may be surrounded or circumscribed by the remaining portions of upper <NUM>.

Many conventional footwear uppers are formed from multiple material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) that are joined through stitching or bonding, for example. In contrast, in some embodiments, a majority of upper <NUM> is formed from a knitted component <NUM>, which will be discussed in more detail below. Knitted component <NUM> may, for example, be manufactured through a flat knitting process and extends through each of each of forefoot region <NUM>, midfoot region <NUM>, and heel region <NUM>, along both lateral side <NUM> and medial side <NUM>, over forefoot region <NUM>, and around heel region <NUM>. In an exemplary embodiment, knitted component <NUM> forms substantially all of upper <NUM>, including exterior surface <NUM> and a majority or a relatively large portion of interior surface <NUM>, thereby defining a portion of the void within upper <NUM>. In some embodiments, knitted component <NUM> may also extend under the foot. In other embodiments, however, a strobel sock or thin sole-shaped piece of material is secured to knitted component <NUM> to form a base portion of upper <NUM> that extends under the foot for attachment with sole structure <NUM>. In addition, a seam <NUM> extends vertically through heel region <NUM>, as depicted in <FIG>, to join edges of knitted component <NUM>.

Although seams may be present in knitted component <NUM>, a majority of knitted component <NUM> has a substantially seamless configuration. Moreover, knitted component <NUM> is formed of unitary knit construction. As utilized herein, a knitted component (e.g., knitted component <NUM>) is defined as being formed of "unitary knit construction" when formed as a one-piece element through a knitting process. That is, the knitting process substantially forms the various features and structures of knitted component <NUM> without the need for significant additional manufacturing steps or processes. A unitary knit construction may be used to form a knitted component having structures or elements that include one or more courses of yarn, strands, or other knit material that are joined such that the structures or elements include at least one course in common (i.e., sharing a common yarn) and/or include courses that are substantially continuous between each of the structures or elements. With this arrangement, a one-piece element of unitary knit construction is provided.

Although portions of knitted component <NUM> may be joined to each other (e.g., edges of knitted component <NUM> being joined together) following the knitting process, knitted component <NUM> remains formed of unitary knit construction because it is formed as a one-piece knit element. Moreover, knitted component <NUM> remains formed of unitary knit construction when other elements (e.g., a lace, logos, trademarks, placards with care instructions and material information, structural elements) are added following the knitting process.

Knitted component <NUM> incorporates various types of yarn that impart different properties to separate areas of upper <NUM>. That is, one area of knitted component <NUM> may be formed from a first type of yarn that imparts a first set of properties, and another area of knitted component <NUM> may be formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout upper <NUM> by selecting specific yarns for different areas of knitted component <NUM>. The properties that a particular type of yarn will impart to an area of knitted component <NUM> partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the yarns selected for knitted component <NUM> may affect the properties of upper <NUM>. For example, a yarn forming knitted component <NUM> may be a monofilament yarn or a multifilament yarn. The yarn may also include separate filaments that are each formed of different materials. In addition, the yarn may include filaments that are each formed of two or more different materials, such as a bicomponent yarn with filaments having a sheath-core configuration or two halves formed of different materials. Different degrees of twist and crimping, as well as different deniers, may also affect the properties of upper <NUM>. Accordingly, both the materials forming the yarn and other aspects of the yarn may be selected to impart a variety of properties to separate areas of upper <NUM>.

In some configurations of knitted component <NUM>, materials forming yarns may be non-fusible or fusible. For example, a non-fusible yarn may be substantially formed from a thermoset polyester material and fusible yarn may be at least partially formed from a thermoplastic polyester material. When a fusible yarn is heated and fused to non-fusible yarns, this process may have the effect of stiffening or rigidifying the structure of knitted component <NUM>. Moreover, joining portions of non-fusible yarn using fusible yarns may have the effect of securing or locking the relative positions non-fusible yarns within knitted component <NUM>, thereby imparting stretch-resistance and stiffness. That is, portions of non-fusible yarn may not slide relative to each other when fused with the fusible yarn, thereby preventing warping or permanent stretching of knitted component <NUM> due to relative movement of the knit structure. Another feature of using fusible yarns in portions of knitted component <NUM> relates to limiting unraveling if a portion of knitted component <NUM> becomes damaged or one of the non-fusible yarns is severed. Accordingly, areas of knitted component <NUM> may be configured with both fusible and non-fusible yarns within the knit structure.

Upper <NUM> includes a first type of yarn that is knitted to form portions of knitted component <NUM> other than monofilament areas <NUM>. Monofilament areas <NUM> on upper <NUM> are formed by knitting with a monofilament strand to form knitted component <NUM> of unitary knit construction with the portions knitted with the first type of yarn. That is, monofilament areas <NUM> are formed of unitary knit construction with the remaining portions of knitted component <NUM> so as to be a one-piece element.

In some embodiments, knitted component <NUM> may include one or more boundary zones. Boundary zones define the portion of knitted component <NUM> where the yarn used to knit knitted component <NUM> transitions from one yarn type to another yarn type. For example, knitted component <NUM> may transition from a first type of yarn to a monofilament strand forming monofilament areas <NUM> at one or more boundary zones on upper <NUM>. In an exemplary embodiment, the first type of yarn transitions from a natural or synthetic twisted fiber yarn to the monofilament strand at one or more boundary zones associated with each of monofilament areas <NUM>. In this embodiment, medial monofilament portion <NUM> includes a rear medial boundary <NUM> disposed towards heel region <NUM> of upper <NUM> where a monofilament strand forming medial monofilament portion <NUM> transitions to the first type of yarn used to form the remaining portions of knitted component <NUM>. Medial monofilament portion <NUM> may further include a top medial boundary <NUM> and a bottom medial boundary <NUM>. In one embodiment, top medial boundary <NUM> is located along medial side <NUM> of upper <NUM> and may be spaced apart from collar <NUM> and throat opening <NUM> by a first distance D1. In one embodiment, bottom medial boundary <NUM> is also located along medial side <NUM> of upper <NUM> and may be spaced apart from sole structure <NUM> by a second distance D2.

In some embodiments, forward medial boundary <NUM> may define a forward location of medial monofilament portion <NUM> on upper <NUM>. In embodiments where monofilament areas <NUM> are substantially continuous, forward medial boundary <NUM> may simply transition into forefoot monofilament portion <NUM>. In embodiments where each monofilament area <NUM> is discontinuous, however, forward medial boundary <NUM> may define the transition from the monofilament strand back to the first yarn type. It should be understood that in such discontinuous embodiments, forefoot monofilament portion <NUM> will be defined by another boundary zone where the yarn again transitions back to the monofilament strand.

Continuing along upper <NUM>, forefoot monofilament portion <NUM> may include a rear forefoot boundary <NUM> and a forward forefoot boundary <NUM>. In one embodiment, rear forefoot boundary <NUM> may be located forward of instep area <NUM> and spaced apart by a third distance D3. Similarly, forward forefoot boundary <NUM> may be located near a toe end of article <NUM> and spaced apart by a fourth distance D4. In this embodiment, lateral monofilament portion <NUM> includes a rear lateral boundary <NUM> disposed towards heel region <NUM> of upper <NUM> where a monofilament strand forming lateral monofilament portion <NUM> transitions to the first type of yarn used to form the remaining portions of knitted component <NUM>. Lateral monofilament portion <NUM> may further include a top lateral boundary <NUM> and a bottom lateral boundary <NUM>. In one embodiment, top lateral boundary <NUM> is located along lateral side <NUM> of upper <NUM> and may be spaced apart from collar <NUM> and throat opening <NUM> by a fifth distance D5. In one embodiment, bottom lateral boundary <NUM> is also located along lateral side <NUM> of upper <NUM> and may be spaced apart from sole structure <NUM> by a sixth distance D6.

In different embodiments, the distances associated with first distance D1, second distance D2, third distance D3, fourth distance D4, fifth distance D5, and/or sixth distance D6 may vary. For example, in some cases, first distance D1 and fifth distance D5 may vary from <NUM> to <NUM>. In an exemplary embodiment, first distance D1 and fifth distance D5 may be approximately <NUM> to <NUM>. In some cases, second distance D2 and sixth distance D6 may vary from <NUM> to <NUM>. In an exemplary embodiment, second distance D2 and sixth distance D6 may be approximately <NUM> to <NUM>. In some cases, third distance D3 may vary from <NUM> to <NUM>. In one embodiment, third distance D3 may be approximately <NUM> to <NUM>. In some cases, fourth distance D4 may vary from <NUM> to <NUM>. In one embodiment, fourth distance D4 may be approximately <NUM> to <NUM>. In other cases, the distances associated with first distance D1, second distance D2, third distance D3, fourth distance D4, fifth distance D5, and/or sixth distance D6 may be larger or smaller to provide monofilament areas <NUM> of varying shapes and/or sizes.

In some embodiments, a forward lateral boundary <NUM> may define a forward location of lateral monofilament portion <NUM> on upper <NUM>. Similar to forward medial boundary <NUM>, in embodiments where monofilament areas <NUM> are substantially continuous, forward lateral boundary <NUM> may simply transition into forefoot monofilament portion <NUM>. In embodiments where each monofilament area <NUM> is discontinuous, however, forward lateral boundary <NUM> may define the transition from the monofilament strand back to the first yarn type. It should be understood that in such discontinuous embodiments, forefoot monofilament portion <NUM> will be defined by another boundary zone where the yarn again transitions back to the monofilament strand.

In some embodiments, medial monofilament portion <NUM> and lateral monofilament portion <NUM> may have similar arrangements on each of medial side <NUM> and lateral side <NUM> so as to be approximately symmetric. In these embodiments, first distance D1 and fifth distance D5 may be approximately equal. Similarly, in second distance D2 and sixth distance D6 may also be approximately equal. In other embodiments, however, each of medial side <NUM> and lateral side <NUM> may have monofilament areas <NUM> that are different between each side. Accordingly, in such other embodiments, each of first distance D1 and fifth distance D5 may be different and/or second distance D2 and sixth distance D6 may be different to locate medial monofilament portion <NUM> and lateral monofilament portion <NUM> farther or closer to collar <NUM> and/or sole structure <NUM>. In still other embodiments, only one of medial side <NUM> or lateral side <NUM> may include monofilament areas <NUM>. It should be understood that other configurations of monofilament areas <NUM> of varying size, shape, and/or location may be arranged according to the processes described herein.

In some embodiments, monofilament areas <NUM> on upper <NUM> may be transparent, translucent, or opaque depending on the characteristics or properties of the material used to make the monofilament strand forming the respective monofilament area <NUM>. In one embodiment, a single monofilament strand having a diameter of approximately <NUM> may be used for forming monofilament areas <NUM>, including each of medial monofilament portion <NUM>, forefoot monofilament portion <NUM>, and lateral monofilament portion <NUM>. A monofilament strand having a larger or smaller diameter may be used in other embodiments. Additionally, in other embodiments, different monofilament strands may be used for each separate monofilament area <NUM> on upper <NUM> so as to provide different properties or characteristics to the respective monofilament area <NUM>.

By incorporating knitted component <NUM> with monofilament areas <NUM> into upper <NUM> for article <NUM>, monofilament areas <NUM> may provide strength, stretch resistance, reduced weight, and/or assist with airflow through upper <NUM> to provide ventilation to the interior of article <NUM>. For example, as shown in <FIG>, medial monofilament portion <NUM> and lateral monofilament portion <NUM> are disposed along each of medial side <NUM> and lateral side <NUM> of upper <NUM> in midfoot region <NUM>. With this configuration, medial side <NUM> and lateral side <NUM> of upper <NUM> may have increased strength and resistance to stretch in these areas. Additionally, the structure of medial monofilament portion <NUM> and lateral monofilament portion <NUM> allows air to easily pass through upper <NUM> into the interior of article <NUM>. For example, when a foot of a wearer is disposed along a base portion <NUM> of upper <NUM> within the interior of article <NUM>, air may circulate into and out of upper <NUM> to assist with providing ventilation to article <NUM>.

Moreover, by forming upper <NUM> with one or more monofilament areas <NUM>, the overall weight of upper <NUM> may be significantly reduced compared with an upper formed wholly of a natural or synthetic twisted fiber yarn. For example, in one embodiment, an upper for an adult men's size <NUM> may weigh approximately <NUM> grams when knitted with a natural or synthetic twisted fiber yarn. In contrast, upper <NUM> with monofilament areas <NUM> may weigh only <NUM> grams for a similar size. Therefore, the weight savings associated with using the monofilament strand for monofilament areas <NUM> in upper <NUM> may be lighter by at least <NUM>%. In addition, by varying the number, shape, and/or size of monofilament areas <NUM> on upper <NUM>, additional weight savings to increase the reduction in weight to more than <NUM>% may be achieved.

Referring now to <FIG> and <FIG>, an exemplary embodiment of knitted component <NUM> is shown in a planar or flat configuration. In this embodiment, knitted component <NUM> has a generally Y-shaped configuration that is outlined by an outer perimeter edge <NUM>. In this embodiment, outer perimeter edge <NUM> extends around knitted component <NUM> from lateral side <NUM> to medial side <NUM>. The outer perimeter of knitted component <NUM> also includes a pair of heel edges <NUM> disposed on each of lateral side <NUM> and medial side <NUM>. In an exemplary embodiment, knitted component <NUM> may further include an inner perimeter edge along collar <NUM> that will be associated with and define throat opening <NUM>, described above. When incorporated into an article of footwear, including article <NUM>, outer perimeter edge <NUM> and at least a portion of heel edges <NUM> may lay against an upper surface of sole structure <NUM> as base portion <NUM>, shown in <FIG>. In other embodiments, knitted component <NUM> may be joined to a strobel sock or sockliner for attachment to sole structure <NUM>. In addition, heel edges <NUM> are joined to each other and extend vertically in heel region <NUM> of article <NUM> to form seam <NUM>. In some embodiments of an article of footwear, a material element may cover seam <NUM> between heel edges <NUM> to reinforce seam <NUM> and enhance the aesthetic appeal of the article.

Knitted component <NUM> may include instep area <NUM> that is formed of unitary knit construction with the remaining portion of upper <NUM>, as described above. In some embodiments, instep area <NUM> includes plurality of lace apertures <NUM> disposed in knitted component <NUM>. Lace apertures <NUM> may extend through knitted component <NUM> from exterior surface <NUM> to interior surface <NUM> and are configured to receive a lace, including lace <NUM>. In an exemplary embodiment, lace apertures <NUM> may be formed directly into knitted component <NUM> by knitting. In other embodiments, however, lace apertures <NUM> may include additional reinforcing elements added to knitted component <NUM>.

Knitted component <NUM> incorporates various types of yarn that impart different properties to separate areas of upper <NUM>. For example, one area of knitted component <NUM> is formed from a first type of yarn that imparts a first set of properties, and another area of first knitted component <NUM> is formed from a second type of yarn that imparts a second set of properties. In this configuration, properties may vary throughout upper <NUM> by selecting specific yarns for different areas of knitted component <NUM>. Knitted component <NUM> includes monofilament areas <NUM>, as described above. In one embodiment, monofilament areas <NUM> may include medial monofilament portion <NUM>, forefoot monofilament portion <NUM>, and/or lateral monofilament portion <NUM>. As described above, knitted component <NUM> is formed of unitary knit construction such that each of the areas of knitted component <NUM>, including monofilament areas <NUM>, are knitted as a one-piece element.

Referring now to <FIG>, enlarged views of portions of monofilament areas <NUM> along various boundary zones are illustrated to show the unitary knit construction of knitted component <NUM>. As described above, boundary zones on knitted component <NUM> define the portion of knitted component <NUM> where the yarn used to knit knitted component <NUM> transitions from one yarn type to another yarn type. For example, knitted component <NUM> may transition from a first type of yarn <NUM> to a monofilament strand <NUM> forming monofilament areas <NUM> at one or more boundary zones on upper <NUM>. In an exemplary embodiment, first type of yarn <NUM> transitions from a natural or synthetic twisted fiber yarn to monofilament strand <NUM> at one or more boundary zones associated with each of monofilament areas <NUM>.

As shown in <FIG>, at forward forefoot boundary <NUM> in forefoot region <NUM> of knitted component <NUM>, knitted component <NUM> transitions from forefoot monofilament portion <NUM> formed by monofilament strand <NUM> to the remaining portion of knitted component <NUM> formed by first type of yarn <NUM>. In this embodiment, a course of monofilament strand <NUM> is joined (e.g., by interlooping) to an adjacent course of first type of yarn <NUM>. That is, a course formed by knitting monofilament strand <NUM> is substantially continuous with a course formed by knitting first type of yarn <NUM>. With this configuration, monofilament areas <NUM> may be formed of unitary knit construction with knitted component <NUM>.

Similarly, adjacent wales of knitted component <NUM> may also transition from one type of yarn to a different type of yarn at boundary zones. As shown in <FIG>, at top medial boundary <NUM>, knitted component <NUM> transitions from a portion formed by first type of yarn <NUM> to medial monofilament portion <NUM> formed by monofilament strand <NUM>. In this embodiment, wales of first type of yarn <NUM> are joined to an adjacent wale of monofilament strand <NUM>. In one embodiment, monofilament areas <NUM> may be knit using an intarsia knitting technique to transition between yarn types along boundary zones. For example, wales of first type of yarn <NUM> may joined to adjacent wales of monofilament strand <NUM> by using intarsia knit construction techniques. With this configuration, monofilament areas <NUM> may be formed of unitary knit construction with knitted component <NUM>.

By forming knitted component <NUM> with monofilament areas <NUM> of unitary knit construction, monofilament areas <NUM> are surrounded by the remaining portions of knitted component <NUM> so as to place monofilament areas <NUM> under tension. That is, first type of yarn <NUM> may be configured to surround monofilament areas <NUM> formed by monofilament strand <NUM>. Because first type of yarn <NUM> may have a smaller stretch resistance than monofilament strand <NUM>, which is non-elastic and resists stretch, knitted component <NUM> may stretch in the portions surrounding monofilament areas <NUM> so as to apply a slight tensioning force on monofilament areas <NUM>. With this configuration, the tensioning force applied on monofilament areas <NUM> by the surrounding portion of knitted component <NUM> may assist with preventing or reducing kinks or sharp bends in monofilament strand <NUM> in monofilament areas <NUM> that may produce an uncomfortable feeling to a foot of a wearer.

In different embodiments, an article of footwear incorporating a knitted component having different features may be provided. In some embodiments, an article of footwear may be configured with a knitted component having different types of monofilament areas on an upper. Depending on the desired type and location, monofilament areas may be varied to provide different properties to an upper. For example, in some embodiments, a monofilament area with a natural or synthetic twisted fiber yarn interior layer may be configured to provide comfort to a foot of a wearer. <FIG> illustrate another exemplary embodiment of an article of footwear <NUM>, also referred to simply as article <NUM>, with multiple types of monofilament areas <NUM>. In some embodiments, article of footwear <NUM> may include an upper <NUM> that is attached to sole structure <NUM>, described above. In an exemplary embodiment, upper <NUM> may include multiple types of monofilament areas <NUM>.

In some embodiments, upper <NUM> may include multiple components that are substantially similar to components of upper <NUM>, described above. For example, upper <NUM> includes an exterior surface <NUM> and an opposite interior surface <NUM> that are substantially similar to exterior surface <NUM> and interior surface <NUM>, described above. Upper <NUM> may also include a collar <NUM> that is substantially similar to collar <NUM> and that is located in at least heel region <NUM> and forms a throat opening <NUM>, which provides access to the interior of upper <NUM>. Additionally, upper <NUM> may also include an instep area <NUM> that is substantially similar to instep area <NUM>, described above.

In some embodiments, instep area <NUM> may further include a tongue portion <NUM> that is disposed between lateral side <NUM> and medial side <NUM> of upper <NUM> through instep area <NUM>. In an exemplary embodiment, tongue portion <NUM> may be substantially similar to tongue portion <NUM>, described above, and may be integrally attached to and formed of unitary knit construction with portions of upper <NUM> along lateral and medial sides through instep area <NUM>. As with tongue portion <NUM>, in other embodiments, tongue portion <NUM> may be similarly disconnected along lateral and medial sides through instep area <NUM> such that tongue portion <NUM> is moveable within an opening between a lateral portion and a medial portion on opposite sides of instep area <NUM>.

Article <NUM> may further be used with lace <NUM>, described above, that extends through a plurality of lace apertures <NUM> in upper <NUM> and permits the wearer to modify dimensions of upper <NUM> to accommodate proportions of the foot. In some embodiments, lace <NUM> may extend through lace apertures <NUM> that are disposed along either side of instep area <NUM>. In some embodiments, lace apertures <NUM> may be lace-receiving members formed by a looped portion of an inlaid tensile element <NUM>, as will be further described below. More particularly, lace <NUM> permits the wearer to tighten upper <NUM> around the foot, and lace <NUM> permits the wearer to loosen upper <NUM> to facilitate entry and removal of the foot from the void (i.e., through throat opening <NUM>). In addition, tongue portion <NUM> of upper <NUM> in instep area <NUM> extends under lace <NUM> to enhance the comfort of article <NUM>. Lace <NUM> is illustrated with article <NUM> in <FIG>, while in <FIG>, lace <NUM> may be omitted for purposes of clarity. In further configurations, upper <NUM> may include additional elements, such as (a) a heel counter in heel region <NUM> that enhances stability, (b) a toe guard in forefoot region <NUM> that is formed of a wear-resistant material, and (c) logos, trademarks, and placards with care instructions and material information.

In some embodiments, upper <NUM> includes one or more portions that include monofilament strands, as described above. In an exemplary embodiment, portions of upper <NUM> that include monofilament strands may be located in one or more monofilament areas <NUM>. In this embodiment, monofilament areas <NUM> may include two or more different types of monofilament areas. For example, in one embodiment, different monofilament areas may have different knit structures. In another embodiment, different monofilament areas may be formed using a combination of monofilament strands and natural or synthetic twisted fiber yarns.

As with monofilament areas <NUM>, described above, monofilament areas <NUM> may be located on various portions of upper <NUM>. In an exemplary embodiment, one or more monofilament areas <NUM> may be located on portions of article <NUM> where upper <NUM> will lay generally flat against a foot of a wearer disposed within upper <NUM>. In this embodiment, monofilament areas <NUM> include a medial monofilament portion <NUM> disposed on medial side <NUM> of upper <NUM> and a lateral monofilament portion <NUM> disposed on lateral side <NUM> of upper <NUM>. Medial monofilament portion <NUM> and lateral monofilament portion <NUM> may be generally located in midfoot region <NUM>. In some embodiments, monofilament areas <NUM> may further include a forefoot monofilament portion <NUM> and a heel monofilament portion <NUM>. Forefoot monofilament portion <NUM> is disposed forward of instep area <NUM> in forefoot region <NUM> of upper <NUM> and heel monofilament portion <NUM> is disposed in heel region <NUM>. In an exemplary embodiment, heel monofilament portion <NUM> may extend substantially continuously around heel region <NUM> of upper <NUM> between lateral side <NUM> and medial side <NUM>.

In some embodiments, monofilament areas <NUM> may be substantially continuous between each monofilament area <NUM> across upper <NUM>. For example, in one embodiment, medial monofilament portion <NUM> may be continuous with forefoot monofilament portion <NUM>, and lateral monofilament portion <NUM> may also be continuous with forefoot monofilament portion <NUM>. Similarly, lateral monofilament portion <NUM> may be continuous with heel monofilament portion <NUM> and medial monofilament portion <NUM> may also be continuous with at least a portion of heel monofilament portion <NUM>. With this configuration, monofilament areas <NUM> may form a substantially continuous zone extending across upper <NUM> from lateral side <NUM> across forefoot region <NUM> to medial side <NUM> in the front portion of article <NUM> and may also form a substantially continuous zone extending across upper <NUM> from lateral side across heel region <NUM> to medial side in the rear portion of article <NUM>.

In other embodiments, each monofilament area <NUM>, including medial monofilament portion <NUM>, forefoot monofilament portion <NUM>, lateral monofilament portion <NUM>, and/or heel monofilament portion <NUM> may be discontinuous with other monofilament areas <NUM> disposed on upper <NUM>. In embodiments where monofilament areas <NUM> are discontinuous, each monofilament area <NUM> may be entirely surrounded or circumscribed by the remaining portions of upper <NUM>.

Knitted component <NUM> shown in <FIG> may include additional structures or elements as compared with knitted component <NUM>, described above. In an exemplary embodiment, the primary elements of knitted component <NUM> are a knit element <NUM> and an inlaid tensile element <NUM>. Knit element <NUM> may be formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops that define a variety of courses and wales. That is, knit element <NUM> has the structure of a knit textile. Inlaid tensile element <NUM> extends through knit element <NUM> and passes between the various loops within knit element <NUM>. Although inlaid tensile element <NUM> generally extends along courses within knit element <NUM>, inlaid tensile element <NUM> may also extend along wales within knit element <NUM>. Inlaid tensile element <NUM> may impart stretch-resistance and, when incorporated into article <NUM>, operates in connection with lace <NUM> to enhance the fit of article <NUM>. In an exemplary embodiment, inlaid tensile element <NUM> may pass through one or more portions of knit element <NUM>, including portions of one or more monofilament areas <NUM>.

In some embodiments, inlaid tensile element <NUM> may extend upwards through knit element <NUM> in a vertical direction from sole structure <NUM> towards instep area <NUM>. In an exemplary embodiment, portions of inlaid tensile element <NUM> may form a loop that serves as lace aperture <NUM> and then may extend downwards back in the vertical direction from instep area <NUM> towards sole structure <NUM>. In addition, when article <NUM> is provided with lace <NUM>, inlaid tensile element <NUM> may be tensioned when lace <NUM> is tightened, and inlaid tensile element <NUM> resists stretch in upper <NUM>. Moreover, inlaid tensile element <NUM> assists with securing upper <NUM> around the foot and operates in connection with lace <NUM> to enhance the fit of article <NUM>. In some embodiments, inlaid tensile element <NUM> may exit knit element <NUM> at one or more portions, including along medial and lateral sides of instep area <NUM> so as to be exposed on exterior surface <NUM> of upper <NUM>.

As described above with reference to knitted component <NUM>, knitted component <NUM> may similarly include yarns formed of different materials, including any of the suitable materials for forming a yarn described above. In some embodiments, knitted component <NUM> may further include non-fusible yarns and fusible yarns, as described above. When a fusible yarn is heated and fused to non-fusible yarns, this process may have the effect of stiffening or rigidifying the structure of knitted component <NUM>. Moreover, by joining (a) one portion of a non-fusible yarn to another portion of a non-fusible yarn, and/or (b) non-fusible yarn and inlaid tensile element <NUM> to each other has the effect of securing or locking the relative positions of non-fusible yarns and inlaid tensile element <NUM>, thereby imparting stretch-resistance and stiffness. That is, portions of non-fusible yarns may not slide relative to each other when fused with fusible yarns, thereby preventing warping or permanent stretching of knit element <NUM> due to relative movement of the knit structure. Additionally, inlaid tensile element <NUM> may not slide relative to knit element <NUM>, thereby preventing portions of inlaid tensile element <NUM> from pulling outward from knit element <NUM>. Accordingly, areas of knitted component <NUM> may be configured with both fusible and non-fusible yarns within knit element <NUM>.

Knitted component <NUM> includes knit element <NUM> with multiple knit layers. Knit layers associated with knitted component <NUM> may be partially co-extensive and overlapping portions of knit element <NUM> that include at least one common yarn or monofilament strand that passes back and forth between the knit layers so as to join and interlock the layers to each other. With this configuration, the knit layers together form a single knit textile formed of unitary knit construction.

In an exemplary embodiment, knit element <NUM> may include at least two knit layers interlocked with each other at one or more portions to form knitted component <NUM>. In one embodiment, a first knit layer may form a majority of a first side of knitted component <NUM> and a second knit layer may form a majority of a second side of knitted component <NUM>. In some embodiments, the first knit layer may be associated with a majority of exterior surface <NUM> and the second knit layer may be associated with a majority of interior surface <NUM>. In an exemplary embodiment, inlaid tensile element <NUM> may extend through portions of the first knit layer, the second knit layer, and/or through portions of knit element <NUM> between the first knit layer and the second knit layer.

In some embodiments, knitted component <NUM> may include one or more boundary zones, as described above with reference to knitted component <NUM>. Boundary zones define the portion of knitted component <NUM> where the yarn used to knit a portion of knitted component <NUM> transitions from one yarn type to another yarn type. For example, knitted component <NUM> may transition from a first type of yarn to a monofilament strand forming monofilament areas <NUM> at one or more boundary zones on upper <NUM>. Additionally, in embodiments where knitted component <NUM> may further have the configuration of multiple knit layers, boundary zones may transition yarn types at only one of the first knit layer and the second knit layer, or may transition yarn types at both the first knit layer and the second knit layer. That is, the boundary zone may apply at the level of individual knit layers of knit element <NUM>.

In an exemplary embodiment, the first type of yarn transitions from a natural or synthetic twisted fiber yarn to the monofilament strand at one or more boundary zones associated with each of monofilament areas <NUM>. In this embodiment, medial monofilament portion <NUM> includes a rear medial boundary <NUM> disposed along a portion of upper <NUM> on medial side <NUM> towards heel region <NUM> where at least one monofilament strand forming one knit layer of medial monofilament portion <NUM> transitions to the first type of yarn in at least one knit layer of knit element <NUM> used to form the remaining portions of knitted component <NUM>. Medial monofilament portion <NUM> may further include a top medial boundary <NUM> and a bottom medial boundary <NUM>. In one embodiment, top medial boundary <NUM> is located along medial side <NUM> of upper <NUM> and may be spaced apart from collar <NUM> and throat opening <NUM> by first distance D1 and bottom medial boundary <NUM> is also located along medial side <NUM> of upper <NUM> and may be spaced apart from sole structure <NUM> by second distance D2, described above.

In some embodiments, forward medial boundary <NUM> may define a forward location of medial monofilament portion <NUM> on upper <NUM>. In embodiments where monofilament areas <NUM> are substantially continuous, forward medial boundary <NUM> may simply transition into forefoot monofilament portion <NUM>. In embodiments where each monofilament area <NUM> is discontinuous, however, forward medial boundary <NUM> may define the transition from the monofilament strand back to the first yarn type for both knit layers forming knit element <NUM>. It should be understood that in such discontinuous embodiments, forefoot monofilament portion <NUM> will be defined by another boundary zone where the yarn again transitions back to the monofilament strand for forming at least one knit layer.

Continuing along upper <NUM>, forefoot monofilament portion <NUM> may include a rear forefoot boundary <NUM> and a forward forefoot boundary <NUM>. In one embodiment, rear forefoot boundary <NUM> may be located forward of instep area <NUM> and spaced apart by third distance D3 and forward forefoot boundary <NUM> may be located near a toe end of article <NUM> and be spaced apart by fourth distance D4, described above. In this embodiment, lateral monofilament portion <NUM> includes a rear lateral boundary <NUM> disposed on lateral side <NUM> of upper <NUM> towards heel region <NUM> at least one monofilament strand forming one knit layer of lateral monofilament portion <NUM> transitions to the first type of yarn in at least one knit layer of knit element <NUM> used to form the remaining portions of knitted component <NUM>. Lateral monofilament portion <NUM> may further include a top lateral boundary <NUM> and a bottom lateral boundary <NUM>. In one embodiment, top lateral boundary <NUM> is located along lateral side <NUM> of upper <NUM> and may be spaced apart from collar <NUM> and throat opening <NUM> by fifth distance D5 and bottom lateral boundary <NUM> may also be located along lateral side <NUM> of upper <NUM> and may be spaced apart from sole structure <NUM> by sixth distance D6, described above.

In some embodiments, a forward lateral boundary <NUM> may define a forward location of lateral monofilament portion <NUM> on upper <NUM>. Similar to forward medial boundary <NUM>, in embodiments where monofilament areas <NUM> are substantially continuous, forward lateral boundary <NUM> may simply transition into forefoot monofilament portion <NUM>. In embodiments where each monofilament area <NUM> is discontinuous, however, forward lateral boundary <NUM> may define the transition from the monofilament strand back to the first yarn type for both knit layers forming knit element <NUM>. It should be understood that in such discontinuous embodiments, forefoot monofilament portion <NUM> will be defined by another boundary zone where the yarn again transitions back to the monofilament strand for forming at least one knit layer.

In some embodiments, medial monofilament portion <NUM> and lateral monofilament portion <NUM> may have similar arrangements on each of medial side <NUM> and lateral side <NUM> so as to be approximately symmetric, as described in reference to knitted component <NUM> above. In these embodiments, first distance D1 and fifth distance D5 may be approximately equal. Similarly, in second distance D2 and sixth distance D6 may also be approximately equal. In other embodiments, however, each of medial side <NUM> and lateral side <NUM> may have monofilament areas <NUM> that are different between each side. Accordingly, in such other embodiments, each of first distance D1 and fifth distance D5 may be different and/or second distance D2 and sixth distance D6 may be different to locate medial monofilament portion <NUM> and lateral monofilament portion <NUM> farther or closer to collar <NUM> and/or sole structure <NUM>. In still other embodiments, only one of medial side <NUM> or lateral side <NUM> may include monofilament areas <NUM>. It should be understood that other configurations of monofilament areas <NUM> of varying size, shape, and/or location may be arranged according to the processes described herein.

Additionally, in an exemplary embodiment, knitted component <NUM> may further include boundary zones associated with heel monofilament portion <NUM>. In this embodiment, heel monofilament portion <NUM> may include a top heel boundary <NUM> and a bottom heel boundary <NUM>. Top heel boundary <NUM> may be spaced apart from collar <NUM> and throat opening <NUM> in heel region <NUM> of upper <NUM> and bottom heel boundary <NUM> may be spaced apart from sole structure <NUM>. In some embodiments, top heel boundary <NUM> may be spaced apart from collar <NUM> by a substantially similar distance as top medial boundary <NUM> and/or top lateral boundary <NUM> and bottom heel boundary <NUM> may be spaced apart from sole structure <NUM> by a substantially similar distance as bottom medial boundary <NUM> and/or bottom lateral boundary <NUM>. In other embodiments, the spacing of top heel boundary <NUM> and/or bottom heel boundary <NUM> may vary.

As described above, in some embodiments, knitted component <NUM> may include multiple types of monofilament areas <NUM> having different structures. For example, in an exemplary embodiment, monofilament areas <NUM> may include a first type of monofilament area formed from two knit layers knit with monofilament strands and a second type of monofilament area formed from two knit layers knit with a monofilament strand and natural or synthetic twisted fiber yarns. In an exemplary embodiment, monofilament areas <NUM> of the first type, i.e., two knit layers of monofilament strands, may be disposed along each of lateral side <NUM> and medial side <NUM>. In this embodiment, medial monofilament portion <NUM> and/or lateral monofilament portion <NUM> may be monofilament areas of the first type. That is, medial monofilament portion <NUM> and/or lateral monofilament portion <NUM> may include a first knit layer formed of a first monofilament strand and a second knit layer formed of a second monofilament strand.

In an exemplary embodiment, portions of knitted component <NUM> that are configured to rest against the toes and heel of a foot of a wearer when disposed within upper <NUM> may be configured with monofilament areas <NUM> of the second type, i.e., two knit layers having one knit layer formed of a monofilament strand and one knit layer formed of natural or synthetic twisted fiber yarns. In this embodiment, forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> may be monofilament areas of the second type. That is, forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> may include a first knit layer formed of a monofilament strand and a second knit layer formed of natural or synthetic twisted fiber yarns.

In an exemplary embodiment, the first knit layer formed of the monofilament strand in forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> may be associated with exterior surface <NUM> of upper <NUM> and the second knit layer formed of natural or synthetic twisted fiber yarns in forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> may be associated with interior surface <NUM> of upper <NUM>. For example, in one embodiment, the second knit layer associated with interior surface <NUM> may be made from a polyester yarn in forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM>. With this configuration, the second knit layer of polyester yarn may provide a smooth and soft interior surface <NUM> for a foot of a wearer disposed within upper <NUM>. Additionally, the second knit layer may provide protection to the foot from sharp edges or bent portions of the first knit layer formed of the monofilament strand in forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM>.

In another embodiment, the second knit layer associated with interior surface <NUM> may be made from a combination of polyester yarn and fusible yarn in forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM>. With this configuration, the fusible yarn portion associated with the second knit layer may be configured to assist with setting forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> in place within knitted component <NUM> when heated, as described above.

By incorporating knitted component <NUM> with different types of monofilament areas <NUM> into upper <NUM> for article <NUM>, monofilament areas <NUM> may provide strength, stretch resistance, reduced weight, and/or assist with airflow through upper <NUM> to provide ventilation to the interior of article <NUM>, as described above. Additionally, by varying the two knit layer configuration of monofilament areas <NUM>, upper <NUM> may provide these features while also remaining comfortable to a foot of a wearer. Referring now to <FIG>, cross-sectional views of article <NUM> having upper <NUM> incorporating knitted component <NUM> with different types of monofilament areas <NUM> are illustrated.

<FIG> shows a cross-section view of forefoot region <NUM> taken across upper <NUM>. In this embodiment, forefoot monofilament portion <NUM> is disposed along a top portion of upper <NUM>. In an exemplary embodiment, forefoot monofilament portion <NUM> may be a monofilament area <NUM> of the second type, described above. In this embodiment, forefoot monofilament portion <NUM> includes two knit layers, including a first knit layer formed by a monofilament strand that is associated with exterior surface <NUM> of knitted component <NUM> and a second knit layer formed by a natural or synthetic twisted fiber yarn that is associated with interior surface <NUM>. In some embodiments, the second knit layer of forefoot monofilament portion <NUM> may be made from the same yarn as the remaining portion of knit element <NUM> forming knitted component <NUM>.

With this configuration, when a foot of a wearer is disposed along a base portion <NUM> of upper <NUM> within the interior of article <NUM>, air may circulate into and out of upper <NUM> to assist with providing ventilation to article <NUM> and forefoot monofilament portion <NUM> may include a softer knit layer along interior surface <NUM> to provide a comfortable feel to the foot.

<FIG> shows a cross-section view of midfoot region <NUM> taken across upper <NUM>. In this embodiment, medial monofilament portion <NUM> and lateral monofilament portion <NUM> are disposed along each of medial side <NUM> and lateral side <NUM> of upper <NUM> in midfoot region <NUM>. In an exemplary embodiment, medial monofilament portion <NUM> and/or lateral monofilament portion <NUM> may be a monofilament area <NUM> of the first type, described above. Medial monofilament portion <NUM> and/or lateral monofilament portion <NUM> includes two knit layers, including a first knit layer formed by a first monofilament strand that is associated with exterior surface <NUM> of knitted component <NUM> and a second knit layer formed by a second monofilament strand that is associated with interior surface <NUM>. With this configuration, medial side <NUM> and lateral side <NUM> of upper <NUM> may have increased strength and resistance to stretch in these areas.

<FIG> shows a cross-section view of heel region <NUM> taken across upper <NUM>. In this embodiment, heel monofilament portion <NUM> is disposed along lateral side <NUM> and medial side <NUM> of upper <NUM>. In an exemplary embodiment, heel monofilament portion <NUM> may be a monofilament area <NUM> of the second type, described above. In this embodiment, heel monofilament portion <NUM> may have a substantially similar structure as forefoot monofilament portion <NUM>, including a first knit layer formed by a monofilament strand that is associated with exterior surface <NUM> of knitted component <NUM> and a second knit layer formed by a natural or synthetic twisted fiber yarn that is associated with interior surface <NUM>. In some embodiments, the second knit layer of heel monofilament portion <NUM> may be made from the same yarn as the remaining portion of knit element <NUM> forming knitted component <NUM>.

Additionally, in this embodiment, portions of inlaid tensile element <NUM> are shown extending through portions of knitted component <NUM>, including knit element <NUM>, as well as through monofilament areas <NUM>, for example, heel monofilament portion <NUM>.

Referring now to <FIG> and <FIG>, an exemplary embodiment of knitted component <NUM> is shown in a planar or flat configuration. As described above, knitted component <NUM> includes knit element <NUM> and inlaid tensile element <NUM>. In this embodiment, knitted component <NUM> may have an oblong offset configuration that is outlined by a top forefoot perimeter edge <NUM>, a top side perimeter edge <NUM>, a pair of heel edges, including a medial heel edge <NUM> and a lateral heel edge <NUM>, a bottom side perimeter edge <NUM>, and a bottom forefoot perimeter edge <NUM>. In addition, knit element <NUM> has a first side forming a portion of exterior surface <NUM> of upper <NUM> and an opposite second side that may form a portion of interior surface <NUM> of upper <NUM>, thereby defining at least a portion of the void within upper <NUM>. In many configurations, inlaid tensile element <NUM> may extend through portions of knit element <NUM>, including portions of monofilament areas <NUM>, between the first side and the second side of knit element <NUM>.

As shown in <FIG> and <FIG>, inlaid tensile element <NUM> repeatedly extends from top side perimeter edge <NUM> toward instep area <NUM>, where a portion of inlaid tensile element <NUM> forms a loop to serve as lace aperture <NUM>, and back to top side perimeter edge <NUM>. Inlaid tensile element <NUM> may follow a similar path on the opposite side of knitted component <NUM>. In this embodiment, inlaid tensile element <NUM> repeatedly extends from bottom side perimeter edge <NUM> toward instep area <NUM>, where a portion of inlaid tensile element <NUM> forms a loop to serve as lace aperture <NUM>, and back to bottom side perimeter edge <NUM>. In some embodiments, portions of inlaid tensile element <NUM> may angle rearwards and extend to medial heel edge <NUM> and/or lateral heel edge <NUM>. Additionally, inlaid tensile element <NUM> may pass through one or more monofilament areas <NUM> of knitted component <NUM>, including portions of medial monofilament portion <NUM> and/or lateral monofilament portion <NUM>, as inlaid tensile element <NUM> extends towards or away from top side perimeter edge <NUM> and/or bottom side perimeter edge <NUM>. Similarly, inlaid tensile element <NUM> may also pass through portions of forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> as inlaid tensile element <NUM> extends towards or away from medial heel edge <NUM> and/or lateral heel edge <NUM>.

In comparison with knit element <NUM>, inlaid tensile element <NUM> exhibits greater stretch-resistance. That is, inlaid tensile element <NUM> stretches less than knit element <NUM>. Given that numerous sections of inlaid tensile element <NUM> extend through knit element <NUM>, inlaid tensile element <NUM> may impart stretch-resistance to portions of upper <NUM> between instep area <NUM> and a lower area adjacent to sole structure <NUM>. Moreover, placing tension upon lace <NUM> may impart tension to inlaid tensile element <NUM>, thereby inducing the portions of upper <NUM> between instep area <NUM> and the lower area to lay against the foot. Additionally, given that numerous sections of inlaid tensile element <NUM> extend toward medial heel edge <NUM> and/or lateral heel edge <NUM>, inlaid tensile element <NUM> may impart stretch-resistance to portions of upper <NUM> in heel region <NUM>. Moreover, placing tension upon lace <NUM> may induce the portions of upper <NUM> in heel region <NUM> to lay against the foot. For example, inlaid tensile element <NUM> may assist with locating monofilament areas <NUM> along lateral side <NUM> and medial side <NUM> of upper <NUM> to lay flat against a foot of a wearer. As such, inlaid tensile element <NUM> operates in connection with lace <NUM> to enhance the fit of article <NUM>.

Knit element <NUM> may incorporate any of the various types of yarn discussed above for knitted component <NUM>. In some embodiments, the configuration of inlaid tensile element <NUM> may vary significantly. In addition to yarn, inlaid tensile element <NUM> may have the configurations of a filament (e.g., a monofilament), thread, rope, webbing, cable, or chain, for example. In comparison with the yarns forming knit element <NUM>, the thickness of inlaid tensile element <NUM> may be greater. In some configurations, inlaid tensile element <NUM> may have a significantly greater thickness than the yarns of knit element <NUM>. Although the cross-sectional shape of inlaid tensile element <NUM> may be round, triangular, square, rectangular, elliptical, or irregular shapes may also be utilized. Moreover, the materials forming inlaid tensile element <NUM> may include any of the materials for the yarn within knit element <NUM>, such as cotton, elastane, polyester, rayon, wool, and nylon. As noted above, inlaid tensile element <NUM> may exhibit greater stretch-resistance than knit element <NUM>. As such, suitable materials for inlaid tensile element <NUM> may include a variety of engineering filaments that are utilized for high tensile strength applications, including glass, aramids (e.g., para-aramid and meta-aramid), ultra-high molecular weight polyethylene, and liquid crystal polymer. As another example, a braided polyester thread may also be utilized as inlaid tensile element <NUM>.

<CIT>, provides a discussion of the manner in which a knitted component (e.g., knitted component <NUM>, <NUM>) may be formed, including the process of inlaying or otherwise locating inlaid tensile element within a knit element.

In an exemplary embodiment, one or more of the perimeter edges of knitted component <NUM> may be joined to form upper <NUM>. In this embodiment, knitted component <NUM> may be folded at a folding point <NUM> between top forefoot perimeter edge <NUM> and bottom forefoot perimeter edge <NUM> to place top forefoot perimeter edge <NUM> and bottom forefoot perimeter edge <NUM> in contact with each other. Similarly, top side perimeter edge <NUM> may be placed in contact with bottom side perimeter edge <NUM> and pair of heel edges, medial heel edge <NUM> and lateral heel edge <NUM>, may be placed in contact with each other. In an exemplary embodiment, medial heel edge <NUM> and lateral heel edge <NUM> may be joined along seam <NUM> disposed along medial side <NUM> of upper <NUM> in heel region <NUM>. In addition, seam <NUM> may further extend along and connect each of top forefoot perimeter edge <NUM> and bottom forefoot perimeter edge <NUM> and top side perimeter edge <NUM> and bottom side perimeter edge <NUM> to form upper <NUM>.

Referring now to <FIG>, enlarged views of portions of knitted component, including knit element <NUM> and different types of monofilament areas <NUM>, are illustrated to show the unitary knit construction of knitted component <NUM>. As described above, monofilament areas <NUM> of knitted component <NUM> may include multiple types of monofilament areas <NUM> having different structures. For example, in an exemplary embodiment, monofilament areas <NUM> may include a first type of monofilament area formed from two knit layers knit with monofilament strands and a second type of monofilament area formed from two knit layers knit with a monofilament strand and natural or synthetic twisted fiber yarns. In this embodiment, medial monofilament portion <NUM> and/or lateral monofilament portion <NUM> may be monofilament areas of the first type. That is, medial monofilament portion <NUM> and/or lateral monofilament portion <NUM> may include a first knit layer formed of a first monofilament strand <NUM> and a second knit layer formed of a second monofilament strand <NUM>. Thus, as may be seen in <FIG>, monofilament areas <NUM> of this first type include knit layers formed of monofilament strands on both exterior surface <NUM> and interior surface <NUM> of upper <NUM>.

In this embodiment, forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> may be monofilament areas of the second type. That is, forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM> may include a first knit layer formed of monofilament strand <NUM> and a second knit layer formed of a natural or synthetic twisted fiber yarn <NUM>. In an exemplary embodiment, as may be seen in <FIG>, the first knit layer formed of monofilament strand <NUM> may be associated with exterior surface <NUM> of knitted component <NUM> and the second knit layer formed of natural or synthetic twisted fiber yarn <NUM> may be associated with interior surface <NUM>.

Additionally, in embodiments where inlaid tensile element <NUM> extends through portions of knitted component <NUM> that include monofilament areas <NUM>, inlaid tensile element <NUM> may be located between exterior surface <NUM> and interior surface <NUM> of upper <NUM>. As shown in <FIG>, inlaid tensile element <NUM> extends through heel monofilament portion <NUM> between the first knit layer formed of monofilament strand associated with exterior surface <NUM> and the second knit layer formed of natural or synthetic twisted fiber yarn associated with interior surface <NUM>. In some configurations, portions of inlaid tensile element <NUM> may be visible through one or both of surfaces. In other embodiment, portions of inlaid tensile element <NUM> may lay against one of exterior surface <NUM> and/or interior surface <NUM>, or knit element <NUM> may form indentations or apertures through which inlaid tensile element <NUM> passes.

In the remaining portions of knitted component <NUM> not including monofilament areas <NUM>, knit element <NUM> may have a similar two knit layer structure. For example, as shown in <FIG>, a portion of knit element <NUM> may include a first knit layer formed of a first natural or synthetic twisted fiber yarn <NUM> and a second knit layer formed of a second natural or synthetic twisted fiber yarn <NUM>. In an exemplary embodiment, the first knit layer formed of first natural or synthetic twisted fiber yarn <NUM> may be associated with exterior surface <NUM> of knitted component <NUM> and the second knit layer formed of second natural or synthetic twisted fiber yarn <NUM> may be associated with interior surface <NUM>. In an exemplary embodiment, the same second natural or synthetic twisted fiber yarn <NUM> may be used to knit monofilament areas <NUM> of the second type and the remaining portions of knitted component <NUM> that also include second natural or synthetic twisted fiber yarn <NUM>.

By forming knitted component <NUM> with monofilament areas <NUM> of unitary knit construction, monofilament areas <NUM> are surrounded by the remaining portions of knitted component <NUM> so as to place monofilament areas <NUM> under tension, as described above with reference to knitted component <NUM>. With this configuration, the tensioning force applied on monofilament areas <NUM> by the surrounding portion of knitted component <NUM> may assist with preventing or reducing kinks or sharp bends in monofilament strands in monofilament areas <NUM> that may produce an uncomfortable feeling to a foot of a wearer.

Referring now to <FIG>, a portion of knitted component <NUM> that includes medial monofilament portion <NUM> is illustrated. In this embodiment, inlaid tensile element <NUM> extends through knit element <NUM> and medial monofilament portion <NUM>. In an exemplary embodiment, the portion of knitted component <NUM> at bottom medial boundary <NUM> may transition from monofilament strand <NUM> forming medial monofilament portion <NUM> to natural or synthetic twisted fiber yarn <NUM> forming the remaining portion of knit element <NUM>, as described above. As shown in the enlarged view of <FIG>, a first course <NUM> of knitted component <NUM> and a fourth course <NUM> of knitted component <NUM> transition from monofilament strand <NUM> forming medial monofilament portion <NUM> to natural or synthetic twisted fiber yarn <NUM> at bottom medial boundary <NUM>. In one embodiment, a second course <NUM> and a third course <NUM> of knitted component <NUM> also include inlaid tensile element <NUM>. In this embodiment, second course <NUM> and third course <NUM> also transition from monofilament strand <NUM> to natural or synthetic twisted fiber yarn <NUM>, or another different type of yarn, at bottom medial boundary <NUM>, as with first course <NUM> and fourth course <NUM>.

In an exemplary embodiment, second course <NUM> and third course <NUM> may correspond with inlaid tensile element <NUM> as inlaid tensile element <NUM> extends through knit element <NUM>. With this configuration, inlaid tensile element <NUM> may extend through monofilament strand <NUM> in medial monofilament portion <NUM>, and continue extending through natural or synthetic twisted fiber yarn <NUM> in the remaining portion of knit element <NUM>. Accordingly, natural or synthetic twisted fiber yarn <NUM> may substantially surround portions of inlaid tensile element <NUM> as it extends through the remaining portions of knit element <NUM> outside of medial monofilament portion <NUM>. With this configuration, inlaid tensile element <NUM> may be hidden from view on exterior surface <NUM> of knitted component <NUM> outside of monofilament areas <NUM>.

In other embodiments, one or more courses of knitted component <NUM> that include a monofilament strand may extend along through the remaining portions of knit element <NUM> beyond monofilament areas <NUM>. Referring now to <FIG>, an optional configuration for a portion of knitted component <NUM> that includes medial monofilament portion <NUM> is illustrated. As with <FIG>, inlaid tensile element <NUM> extends through knit element <NUM> and medial monofilament portion <NUM>. In this embodiment, however, one or more courses formed by a monofilament strand, for example monofilament strand <NUM>, described above, may further extend through knit element <NUM> outside of medial monofilament portion <NUM> together with inlaid tensile element <NUM>.

In an exemplary embodiment, the portion of knitted component <NUM> at bottom medial boundary <NUM> may transition from monofilament strand <NUM> forming medial monofilament portion <NUM> to natural or synthetic twisted fiber yarn <NUM> forming the remaining portion of knit element <NUM>, as described above. As shown in the enlarged view of <FIG>, a first course <NUM> of knitted component <NUM> and a fourth course <NUM> of knitted component <NUM> transition from monofilament strand <NUM> forming medial monofilament portion <NUM> to natural or synthetic twisted fiber yarn <NUM> at bottom medial boundary <NUM>. In one embodiment, a second course <NUM> and a third course <NUM> of knitted component <NUM> do not transition from monofilament strand <NUM> to natural or synthetic twisted fiber yarn <NUM> , or another different type of yarn, at bottom medial boundary <NUM>. Instead, second course <NUM> and third course <NUM> continue in a substantially continuous manner to be formed with the same monofilament strand <NUM> forming medial monofilament portion <NUM>.

In this embodiment, second course <NUM> and third course <NUM> knit with monofilament strand <NUM> may correspond with inlaid tensile element <NUM> as inlaid tensile element <NUM> extends through knit element <NUM>. With this configuration, inlaid tensile element <NUM> may extend through monofilament strand <NUM> in medial monofilament portion <NUM>, as well as through the remaining portion of knit element <NUM>. Accordingly, monofilament strand <NUM> may substantially surround portions of inlaid tensile element <NUM> as it extends through the remaining portions of knit element <NUM> outside of medial monofilament portion <NUM>. In other embodiments, one or more courses of monofilament strands may extend outside of each monofilament areas <NUM>, including medial monofilament portion <NUM>, forefoot monofilament portion <NUM>, lateral monofilament portion <NUM>, and/or heel monofilament portion <NUM>, to follow and correspond with the path of inlaid tensile element <NUM> throughout knitted component <NUM>. By enclosing or surrounding inlaid tensile element <NUM> with monofilament strand <NUM>, additional strength and support may be provided to inlaid tensile element <NUM>.

In some embodiments, monofilament areas <NUM> of the second type, i.e., two knit layers having one knit layer formed of a monofilament strand and one knit layer formed of natural or synthetic twisted fiber yarns, may be knit with a knit structure that forms plurality of indentations during the knitting process in the knit layer formed of natural or synthetic twisted fiber yarns. Such a configuration may further provide ventilation to the interior of upper <NUM> while still providing a comfortable feel to a foot of a wearer along interior surface <NUM>.

A suitable knit structure for forming monofilament areas <NUM> of the second type includes a 1x1 inverted mock mesh knit structure or 2x2 inverted mock mesh structure. In contrast with a mesh knit structure, which may be used to form apertures that extend fully through a knit element, including both a first knit layer and a second knit layer, an inverted mock mesh knit structure forms indentations in second knit layer, i.e., the layer associated with interior surface <NUM> of upper <NUM>. An exemplary embodiment of a looping diagram <NUM> for knitting an inverted 2x2 mock mesh structure is illustrated. In this embodiment, looping diagram <NUM> illustrates the sequence of stitches and movements performed by a knitting machine, for example, a flat-knitting machine, to form an inverted 2x2 mock mesh structure making up a portion of monofilament areas <NUM> of the second type. As shown in <FIG>, the spaced apart dots represent the needles of a knitting machine and the illustrated steps represent the direction of movement of a yarn or strand between the needles of each of a front bed and a back bed of a knitting machine.

As shown in <FIG>, monofilament strand <NUM> may be used to knit the first knit layer of monofilament area <NUM> that is associated with exterior surface <NUM> of upper <NUM>, while natural or synthetic twisted fiber yarn <NUM> may be used to knit the second knit layer of monofilament area <NUM> that is associated with interior surface <NUM> of upper <NUM>. In contrast to the first knit layer, the second knit layer includes a number of tuck stitches performed with or natural or synthetic twisted fiber yarn <NUM>. In this embodiment, the width or gap in second knit layer is associated with <NUM> needles to form the inverted 2x2 mock mesh structure. For example, such an inverted 2x2 mock mesh structure may be used to form one or more of forefoot monofilament portion <NUM> and/or heel monofilament portion <NUM>, described above. In other embodiments, however, a larger or smaller knit structure may be provided by making the gap associated with a larger or smaller number of needles. For example, an inverted 3x3 mock mesh structure may be formed by increasing the gap to <NUM> needles and an inverted 1x1 mock mesh structure may be formed by decreasing the gap to a single needle.

Claim 1:
An article of footwear (<NUM>) having an upper (<NUM>) and a sole structure (<NUM>) secured to the upper, the upper including a knitted component (<NUM>) comprising:
a knit element (<NUM>) including a first yarn (<NUM>), the knit element defining a portion of an exterior surface (<NUM>) of the upper and an opposite interior surface (<NUM>) of the upper, the interior surface defining a void for receiving a foot, the first yarn (<NUM>) being a natural or synthetic twisted fiber yarn; and
at least one monofilament area (<NUM>) comprised of two knit layers, the two knit layers being overlapping and at least partially coextensive with each other, each knit layer including a monofilament strand (<NUM>);
wherein the at least one monofilament area (<NUM>) is formed of unitary knit construction with the knit element such that the knitted component is a one-piece element, wherein at least one course formed of the monofilament strand (<NUM>) is substantially continuous with at least one course formed of the first yarn (<NUM>),
wherein the article of footwear (<NUM>) is characterized in that the first yarn (<NUM>) has a smaller stretch-resistance than the monofilament strand (<NUM>), and
wherein the at least one monofilament area (<NUM>) is surrounded by remaining portions of the knitted component (<NUM>) so as to place the at least one monofilament area (<NUM>) under tension.