HK1261605B - Upper for an article of footwear having a knitted component with a fused area - Google Patents

Description

Upper for an article of footwear having a knitted component with fused areas

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Serial No. 62/301,436, filed February 29, 2016, which is incorporated herein by reference in its entirety.

background

Conventional footwear typically includes two main components: an upper and a sole structure. The upper is typically secured to the sole structure and may form a cavity within the footwear for comfortably and securely receiving the foot. The sole structure is typically secured to the lower surface of the upper so as to be positioned between the upper and the ground. For example, in some athletic 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 reduce stress on the foot and leg during walking, running, and other ambulatory movements. The outsole may be secured to the lower surface of the midsole and may form the ground-engaging portion of the sole structure, which is formed from a durable and wear-resistant material.

The upper of an article of footwear typically extends over the instep and toe area of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. Typically, access to the interior cavity of the upper is provided through an ankle opening in the heel area of the footwear. A lacing system is typically incorporated into the upper to adjust the fit of the upper, thereby facilitating entry and removal of the foot from the cavity within the upper. In addition, the upper may include a tongue that extends below the lacing system to enhance the adjustability of the footwear, and the upper may include a heel counter to limit the movement of the heel.

describe

In one aspect, the present disclosure provides an upper for an article of footwear. The upper may include a knitted component having a first yarn and a second yarn, wherein the first yarn has a core with a sheath formed of a thermoplastic material having a melting temperature, wherein the second yarn is substantially free of the thermoplastic material, wherein the knitted component further includes a first layer having a first surface and a second layer having a second surface, wherein the first layer and the second layer are secured by a knit structure of the knitted component, and wherein the knitted component further includes a first region and a second region.

The first zone may include a first surface substantially formed by the first yarn and a second surface substantially formed by the second yarn. The first yarn of the first surface may merge into the second surface at at least one location within the first zone. The first zone may extend along an edge of the upper adjacent to a bite line.

The second zone may include a first surface formed substantially from the second yarn and a second surface formed substantially from the first yarn.The second zone may extend along a throat area of the upper.

The first yarn may be thermoformed to form the fused region.

The thermoplastic polymer material of the sheath may consist essentially of at least one thermoplastic polyurethane.The core of the first yarn may comprise at least one polyester.

The first layer may be knitted integrally with the second layer.

The upper may include a throat region formed from a thermoplastic polymer material extending from an edge of the upper toward the throat region, wherein the fused region terminates adjacent the throat region.

The auxiliary component may be formed from a material different from the knitted material and secured to the fused region by a thermoplastic polymer material.

In another aspect, the present disclosure provides an upper that may include a knitted component having a first yarn and a second yarn, wherein the first yarn has a core with a sheath formed of a thermoplastic material having a melting temperature, wherein the second yarn is substantially free of thermoplastic material, wherein the knitted component further includes a first layer having a first surface and a second layer having a second surface, wherein the first layer and the second layer are secured by a knit structure of the knitted component, and wherein a molten area is formed on the first layer in a first zone from a thermoplastic polymer material.

The upper may further comprise a second region, wherein the second yarn forms at least a portion of the first layer in the second region.The first yarn may form at least a portion of the second layer in the second region.

The melted area may extend along an edge of the upper adjacent the bite line.

The fused region may terminate adjacent a throat area of the upper.

In another aspect, the present disclosure provides a method of manufacturing an upper for an article of footwear. The method may include knitting a knitted component having a first layer and a second layer, wherein the first layer comprises a first yarn having a core and a sheath, the sheath being formed of a thermoplastic polymer material having a melting point, and wherein the second layer comprises a second yarn substantially free of the thermoplastic polymer material; heating at least a portion of the thermoplastic polymer material of the first yarn to form a molten region on the first layer; and cooling the knitted component to solidify the molten region.

The method may further include placing the auxiliary structure in contact with the knitted component and providing an amount of energy to at least one of the auxiliary structure and the knitted component to adhere the auxiliary structure to the knitted component.

The first layer may be at least partially formed on a first bed of the flat knitting machine, and the second layer may be at least partially formed on a second bed of the knitting machine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example of an article of footwear according to certain aspects of the present disclosure.

2 illustrates an upper including a knitted component and fused areas, according to certain aspects of the present disclosure.

3 illustrates an example of a sequential knitting pattern for knitting a knitted component, according to certain aspects of the present disclosure.

4 illustrates an example of an article of footwear including an upper having a knitted component with a fused area and a transition zone, according to certain aspects of the present disclosure.

5A-D illustrate an example of a heat press and related components used in one process of forming a shoe upper having fused regions, according to certain aspects of the present disclosure.

6 illustrates an article of footwear having different types of auxiliary components, according to certain aspects of the present disclosure.

6A illustrates a cross-sectional view of the article of footwear of FIG. 6 with an internal auxiliary component, according to certain aspects of the present disclosure.

Detailed description

The various aspects are described below with reference to the accompanying drawings, in which similar elements are generally represented by similar reference numerals. The relationship and function of the various elements can be better understood with reference to the following description. However, the aspects are not limited to those shown in the accompanying drawings or explicitly described below. It should also be understood that the drawings are not necessarily drawn to scale, and in some cases, details that are not necessary for understanding the aspects disclosed herein may have been omitted.

Certain aspects of the present disclosure relate to uppers configured for use in articles of footwear. The uppers can be used with any type of footwear. Illustrative, non-limiting examples of articles of footwear include basketball shoes, cycling shoes, cross-training shoes, international football (soccer) shoes, American football shoes, bowling shoes, golf shoes, hiking boots, ski or snowboard boots, tennis shoes, running shoes, and walking shoes. The uppers can also be incorporated into non-athletic footwear and shoes, for example, dress shoes, loafers, and sandals.

1 , an example of an article of footwear 100 is generally depicted as including a sole 110 and an upper 120. Upper 120 may include a lateral side 104, a medial side 105, a heel region 122, a midfoot region 102, and a toe region 101. The area of the shoe where sole 110 joins the outer edges of upper 120 may be referred to as a bite line 116. Upper 120 may be fixedly joined to sole 110 using any suitable technique (e.g., by using adhesives, gluing, stitching, etc.).

In some embodiments, sole 110 may include a midsole 111 and an outsole 112. The article of footwear may further include a throat 136 and an ankle opening 121, which is surrounded by a collar 129. Upper 120 may define a cavity 128 of the article of footwear that is configured to receive and accommodate the foot of a user or wearer. Throat 136 may generally be disposed in midfoot region 102 of upper 120. Midfoot region 102 is generally depicted as the section of upper 120 located between heel region 122 and toe region 101.

In FIG1 , tongue 124 is disposed within throat 136 of the shoe, but like lace 103, tongue 124 is an optional component. Although tongue 124 is depicted in FIG1 as a conventional tongue, tongue 124, if included, can be any type of tongue, such as a gusseted tongue or a burrito tongue. If a tongue is not included, for example, the lateral and medial sides of throat 136 can be joined together.

The throat area 148 may include one or more loops 152 extending from the depicted tensile strands 154. The tensile strands 154 are optional components and may form eyelets (e.g., holes passing through the loops 152) to receive shoelaces and/or may loop around eyelets formed in the layers of the knitted element 140. The tensile strands may be yarn, cable, rope, or any other type of thread. The tensile strands may be flexible, but they may also have a substantially fixed length measured from the first end to the second end. Thus, the tensile strands may be substantially inelastic. One or more tensile strands may extend in any direction on the upper 120. The tensile strands may be at least partially embedded in the knitted element 140. The tensile strands may limit the stretching of the knitted element. Additionally, in some aspects, portions of the tensile strands may be exposed from the knitted element. For example, portions of the tensile strands may extend out of the knitted element in the throat area to form loops 152. See, for example, U.S. Patent Application Publication No. 2015/0359290, U.S. Patent Application Publication No. 2014/0237861, and U.S. Patent No. 9,145,629, which are incorporated herein in their entireties. Tensile strands 154 can be positioned between layers of knit element 140 and/or can be incorporated primarily into any of the layers at any location within knit element 140. In some embodiments, tensile strands 154 can be secured within fused region 126, although this is not required.

As described in further detail below, upper 120 can have a fused area 126 formed at least in part by a thermoplastic polymer material. In this description, the term "fused area" generally refers to an area of upper 120 where different parts of the material forming the upper (e.g., different individual threads or yarns of a knitted component) are partially or substantially combined together." fused area" does not need to be formed by any specific process. In a non-limiting example, two or more separated yarns (comprising monofilament yarn and/or multifilament yarn) can form a fused area when at least a portion of the separated yarn is combined so that at least a portion of the separated yarn is continuous with each other. In addition, after being combined to form the fused area, the material of the once separated yarn may become visually or physically indistinguishable, or both visually and physically indistinguishable.

Melted areas 126 may have any suitable size and shape, and upper 120 may have multiple melted areas 126. Melted areas 126 may define a portion of first surface 130 of upper 120, which may be an exterior surface. As depicted, second surface 132 of upper 120 may be an interior surface that at least partially defines cavity 128 of the article of footwear, and second surface 132 may be at least partially located between melted areas 126 and cavity 128 of the article of footwear (e.g., such that melted areas 126 are separated from the cavity at least in one location). Melted areas 126 may extend from bite line 116 toward throat 136 and/or collar 129. In some embodiments, melted areas 126 may extend along substantially the entire bite line 116 (e.g., extending substantially around the entire perimeter of the article of footwear). As described in more detail below, melted areas 126 may be water-repellent, water-resistant, and/or substantially waterproof.

Referring to Figure 2, upper 120 (shown as being separated from the other elements of the article of footwear of Figure 1) can be at least partially formed by knitted component 140 (and at least a portion of the knitted component can be referred to as "knitted element"). As depicted in Figure 2, upper 120 can be formed substantially or entirely by knitted component 140. Although upper 120 is described herein as including knitted component 140, upper 120 can alternatively or additionally include textile components formed by processes other than knitting (knitting) (e.g., weaving (weaving)) and can also include other materials, including but not limited to leather, plastic, rubber and any other materials suitable for incorporation into the upper of an article of footwear. Knitted component 140 can be a single-layer knitted component, or it can be a multi-layer knitted component. In some embodiments, knitted component 140 can be a two-layer knitted component, wherein the first layer forms a first surface 130 (e.g., an outer surface), and the second layer forms a second surface 132 (e.g., an inner surface), as described in further detail below. Although not required in all embodiments, both the first layer and the second layer may be knit layers, and they will be referred to herein as the "first layer" and the "second layer."

The first surface 130, which may be formed by the first layer, may include at least one fused area 126, and the fused area 126 may extend partially or continuously along the peripheral edge 142 from the heel area 122 on the lateral side 104, around the toe area 101, and back to the heel area 122 on the medial side 105. The heel area 122 may be an area in the area near the ankle bone of the wearer's foot and does not necessarily extend to the back of the wearer's heel. The fused area 126 may extend continuously along substantially the entire peripheral edge 142 so that when the upper 120 is incorporated into the article of footwear, the fused area 126 provides the article of footwear with water-repellent, water-resistant, and/or substantially waterproof properties above (and optionally below) the bite line 116. The fused area 126 may extend any distance from the peripheral edge 142 toward the throat 136 and/or collar 129. In one exemplary embodiment, melted region 126 extends a distance from edge 142 such that melted region 126 covers at least approximately 10 mm above bite line 116 (see FIG. 1 ) of the article of footwear. In other embodiments, melted region 126 may provide more or less coverage, and it is contemplated that melted region 126 may cover at least approximately 50 mm, 1 cm, 5 cm, or even more above bite line 116. It is also contemplated that melted region 126 may terminate slightly inward from the end of peripheral edge 142 of upper 120, which may be advantageous when a non-melted portion of upper 120 is more suitable for attachment to other elements of the article of footwear (e.g., to a midsole). In other words, a boundary of a non-melted region may exist around at least a portion of peripheral edge 142.

As shown in exemplary Figure 2, first yarn 144 can form at least a portion of the first (outer) surface 130 of knitted component 140. In this description, first yarn 144 can include such yarn (or multiple yarns): this yarn includes or contains the thermoplastic polymer material that is constructed to form molten zone 126. Illustrative non-limiting examples of thermoplastic polymers include polyurethane, polyamide, polyolefin and nylon. Compared with thermosetting polymer materials (described below), thermoplastic polymers melt when heated and return to solid state when cooled. More particularly, when subjected to a temperature at or above its melting point, thermoplastic polymers transition to a softened state or liquid state from the solid state, and then when fully cooled below its melting point, thermoplastic polymers transition to a solid state from the softened state or liquid state.

Any portion of the first yarn 144 may have one or more thermoplastic polymers (collectively referred to as "thermoplastic polymer materials"), and in some embodiments, substantially the entire first yarn 144 may be formed of a thermoplastic polymer material. In one non-limiting example, the first yarn 144 may be a yarn having a polyester core and a thermoplastic polymer sheath. The thermoplastic polymer material of the sheath may have a melting temperature that is less than the melting temperature or decomposition temperature of the polyester core. For example, in some embodiments, the melting temperature of the thermoplastic polymer material may have a melting temperature that is about 100°C less than the melting temperature of the polyester core, but any other suitable melting temperature difference is conceivable. The melting temperature of the polyester core may be about 260°C, and the decomposition temperature may be about 350°C or higher. The melting temperature of the thermoplastic polymer may be, for example, between about 80°C and about 1°C based on sea level atmospheric pressure, for example, from about 100°C to about 125°C. In an exemplary embodiment, the first yarn 144 may include a sheath formed of thermoplastic polyurethane. The first yarn 144 may specifically be a yarn sold as thermoplastic polyurethane covered yarn manufactured by Sambu Fine Chemical Co., LTD.

Knitted component 140 can also include one or more yarns formed by materials other than the above-mentioned specific thermoplastic polymer material. In one example, the second yarn 146 depicted can be basically formed by a material having a melting point (if it is a thermoplastic polymer material) or a decomposition point (if it is a thermosetting material) higher than the melting point of the first yarn 144. Exemplary non-limiting examples of various types of yarns that can form the second yarn 146 include yarns comprising thermosetting polymer materials and natural fibers, such as cotton, silk and wool or materials with a relatively high melting point. When subjected to moderate levels of heat, thermosetting polymer materials tend to remain stable. In addition, when subjected to high levels of heat, thermosetting polymer materials and natural fibers may burn or otherwise degrade or decompose. In this way, thermosetting polymer materials generally maintain a permanent solid state. In some embodiments, based on sea level atmospheric pressure, the melting point or decomposition temperature of the second yarn 146 is greater than about 140°C. Second yarn 146 may also be formed from a material having a higher melting point than first yarn 144, and reference herein to a first yarn being formed from a thermoplastic polymer material does not limit the second yarn to being, for example, a separate thermoplastic polymer having a higher melting point. A specific example is polyester yarn, which has a melting point of approximately 250°C and a boiling point or decomposition point of approximately 350°C. It should be noted that second yarn 146 may include one or more yarns having one or more properties, such as yarns having different elasticity, breathability, and/or durability properties, or different visual properties, or a combination thereof.

As described above, the knitted component 140 can have more than one layer. In one embodiment, at least a portion of the knitted component 140 has two layers: a first layer defining the first surface 130 and a second layer defining the second surface 132. Although more than two layers can be included, for simplicity of description, this specification generally describes the knitted component 140 as having two layers. Furthermore, it is contemplated that different portions of the knitted component 140 can have different numbers of layers (e.g., a portion corresponding to the molten region 126 can have multiple layers, while a portion corresponding to an area without the molten region 126 can have only one layer).

The first layer and the second layer of the knitted component 140 can be formed separately or integrally, and one or both layers can be formed during knitting or other textile manufacturing processes. In one example, the first layer defining the first (outer) surface 130 and the second layer forming the second (inner) surface 132 can be formed during a single knitting process (e.g., formed simultaneously on a knitting machine). For example, the first layer and the second layer can be formed on a flat knitting machine having two needle beds. The first layer can be formed primarily on the front needle bed and the second layer can be formed primarily on the back needle bed, or vice versa. In some embodiments, the first layer and the second layer can be integral and tightly combined so that they are inseparable and/or not easily distinguishable. In another example (or in another position of the knitted component 140), the knitted component 140 can have at least one position at which the first layer and the second layer are separable and/or a pocket is formed between the first layer and the second layer, which pocket can be filled with a filling material (e.g., a cushioning material). It is conceivable that the first layer and the second layer can be attached only at the edge of the knitted component 140, or the first layer and the second layer can be attached at another point by knotting stitches at any one or more points on the upper. In addition, it is conceivable that the knitted component 140 can have some areas where the layers are substantially combined or attached together (in an indistinguishable manner, or not in an indistinguishable manner) and other areas where the layers are substantially separable. The separable first and second layers can be formed by a circular knitting process, wherein the yarn forming the first layer is knitted only on one bed of the knitting machine, and the yarn of the second layer is knitted only on the second bed of the knitting machine. Alternatively, the knitted component 140 can be formed by two or more layers, which are knitted or otherwise formed separately and then joined together by, for example, a stitching or sewing process, by using an adhesive, or by other suitable bonding/attachment techniques.

The first layer defining the first surface 130 of the knitted component 140 may include a first yarn 144 so that the first layer includes a thermoplastic polymer material at least at the position of the first layer that is constructed to form the above-mentioned melting zone 126. It is also conceivable that the thermoplastic polymer material can be added to the first layer in addition or alternatively separately from the yarn (for example, the thermoplastic polymer material can be sprayed or otherwise applied after the knitting process). In some embodiments, the first layer of the knitted component 140 can be substantially formed by the first yarn 144 at least in the area corresponding to the melting zone 126. However, other yarns (such as the second yarn 146) can be incorporated into the first layer in addition or alternatively at certain positions. The amount of the first yarn 144 incorporated into the first layer and/or the amount of the thermoplastic polymer material included in the first yarn 144 can be optimized so that the desired amount of thermoplastic polymer material is included in specific and desired areas, including the area corresponding to the melting zone 126. For example, if a region of the first layer includes both first yarn 144 and second yarn 146 (or some other combination such that both thermoplastic polymer material and a different material are included), the ratio of thermoplastic polymer material to non-thermoplastic polymer material in that region can be about 5:95, about 10:90, about 20:80, about 30:70, about 40:60, about 50:50, about 60:40, about 70:30, about 80:20, about 90:10, about 95:10, or about 100:0. The first layer may also include regions that substantially exclude first yarn 144 (e.g., in throat region 148, as shown in FIG. 1 ).

As shown in Figure 2, in the area corresponding to melting zone 126, the second layer forming the second surface 132 of knitted component 140 can be formed substantially by second yarn 146, and second yarn 146 can be substantially free of thermoplastic polymer material or can be formed by thermoplastic polymer material with relatively high melting point. In an exemplary embodiment, second layer 146 is polyester yarn. Can comprise several different types of yarns with different properties (for example, different stretchability, durability and/or breathability, denier and/or color or its combination). There are several advantages related to the second layer formed by second yarn 146. In a non-limiting example, the second surface 132 that can be configured to face the cavity 128 of footwear can be formed by the yarn comprising the following material: this material realizes the comfortable inner surface for contacting the wearer's foot. The second layer can further be formed to have a high elasticity so that the selected portion of footwear is relatively elastic, particularly relatively elastic in the area not corresponding to melting zone 126.

When the first and second layers are formed together on a knitting machine, it is contemplated that the two layers have opposite compositions of thermoplastic polymer material and second material configured to form molten regions. For example, in molten region 126 (where thermoplastic polymer material is desired on outer surface 130), approximately 90% or more of the thermoplastic polymer material at that location may be in the first layer forming outer surface 130, and approximately 10% or less of the thermoplastic polymer material may be in the second layer forming inner surface 132. In another area, such as throat region 148, the majority of the thermoplastic polymer material may instead be in the second layer forming inner surface 132. Advantageously, the thermoplastic polymer material may form molten regions 126 at certain locations during heat treatment (as described in more detail below), but the thermoplastic polymer material may be shielded from heat application to other areas of outer surface 130 (e.g., throat region 148), thereby preventing melting where it may be undesirable.

The second layer of the knitted component 140 can be at least partially located between the first layer having the molten region 126 and the cavity 128 (shown in Figure 1). This can provide a knitted component 140 of the upper 120 that has the above-mentioned molten region 126 on one side (e.g., the first surface 130) but does not have a molten region on the opposite side (e.g., the second surface 132). Advantageously, the knitted component 140 can provide a footwear article that has the desired characteristics (e.g., water repellency, water resistance, and waterproofness) of the above-mentioned molten region 126 while also providing the advantages associated with the second yarn 146 (including but not limited to comfort and elasticity). In addition, all of the advantages described in connection with the second layer can also be applied to the first layer in areas where the molten region 126 is not present. It is also conceivable that the thermoplastic polymer material can exhibit the advantageous properties associated with the second yarn 146 when not heat-treated.

When the second layer forms the inner surface 132, the second layer of the knitted component 140 does not need to be completely free of thermoplastic polymer material, even in the molten area 126. In some embodiments, the first yarn 144 can be integrated into the second layer of the knitted component 140. For example, during the knitting process, wherein the first and second layers are formed substantially on different needle beds of a knitting machine, the first yarn 144 can be knitted on a needle bed associated with the second layer at a selected position. This can physically attach and/or combine the first and second layers together at one or more points. Additionally or alternatively, by tucking the first yarn 144 at a series of positions during the knitting process, a series of floats of the first yarn 144 can be formed, which extend behind (e.g., inwardly) the first layer. Advantageously, the floats described can enhance some of the desired properties of the molten area 126 (e.g., water resistance). For example, the floats can reduce and/or eliminate the pores in the molten area 126 by, for example, extending backward and filling certain areas that might otherwise be porous. It is also contemplated that in some cases a fused region may be desired on the second layer.

Similarly, a second yarn 146, which is typically associated with the second layer of the knitted component 140, can be knitted or otherwise moved at selected locations onto a bed associated with the first layer of the knitted component 140. This can be advantageous, for example, in areas where the second yarn 146 has properties that provide specific characteristics (e.g., elasticity, desired aesthetics, durability, breathability, and/or combinations thereof) to the first layer of the knitted component 140, and/or in areas where the second yarn 146 is used to join the first and second layers of the knitted component 140 together at one or more selected points throughout the upper 120.

When forming the first and second layers of the knitted component 140 on the knitting machine, any suitable knitting sequence may be used. FIG3 illustrates a knitting sequence that has been found to be suitable. Referring to FIG3 , the first pass in a series of knitting passes may include knitting a second yarn 146 on every other needle of the back bed 302, as shown in step A. Next, in the second pass shown in step B, another second yarn 146 (this second yarn 146 may be the same yarn used in the first pass or may be a separate yarn) may be knitted on the back bed 302 on the needles not used in step A. Providing two passes of the second yarn 146 on the back bed, rather than a single pass, may provide several advantages, such as a dense, non-porous structure, the ability to vary the color configuration on the second surface 132 ( FIG2 ), the ability to control the elasticity of the knitted component 140, and/or the ability to control the softness and other surface properties of the second surface 132. The next described step, step C, may include knitting the first yarn 144 (e.g., a yarn comprising a thermoplastic polymer material) on all needles of the front bed 304 of the knitting machine. Each pass depicted in steps A-C can be performed along the needle bed in the first direction 306. In step D, now moving in the second direction 308, the first yarn 144 can be transferred to the back bed 302 on every other needle. Finally, in step E, again moving in the first direction 306, the first yarn 144 can be transferred to the back bed on every other needle (on the needle opposite from step D). This knitting sequence can then be reversed and repeated as needed. Again, the knitting sequence depicted in FIG3 is provided only as a non-limiting example, and any other suitable sequence may be used.

With reference to Fig. 4, upper 120 is shown as having fused zone 126, and fused zone 126 can extend from the bite line 116 (and/or edge 142 of Figure 2) on the outer periphery of knitted component 140 toward throat area 148. Melted zone 126 can terminate near or adjacent to throat area 148, and throat area 148 can be substantially free of thermoplastic polymer material at least on the outer layer. The first layer at throat area 148 can be substantially formed by second yarn 146, as mentioned above, and second yarn 146 can be polyester yarn. This can advantageously provide desired elasticity for throat area 148, which can allow the knitted component 140 of upper 120 to stretch in throat area 148, thereby facilitating the user's foot to enter and remove from the cavity 128 of footwear and providing a close fit around the foot. The visual contrast between throat area 148 and fused zone 126 is also aesthetically advantageous. In other embodiments, fused region 126 may extend to and/or within throat area 148 .

In some embodiments, the amount and/or density of the molten and/or non-molten thermoplastic polymer material present in one or more layers of the knitted component 140 can vary. Hereinafter, the term "density" when referring to a molten area refers to the amount (i.e., mass) of molten material (e.g., molten thermoplastic polymer material) per a determined surface area. For example, in the embodiment depicted in FIG4 , the amount and/or density of the thermoplastic polymer material included in the outer (first) layer of the knitted component 140 may decrease as one moves from the bite line 116 toward the throat area 148 of the article of footwear 100.

To illustrate, the first layer of knitted component 140 can be at least partially, and more preferably, entirely or substantially, formed of a thermoplastic polymer material in an area adjacent to bite line 116 (this area may be referred to as a first area), as shown in FIG4 . In a second area of knitted component 140, depicted in FIG4 as transition area 150 between fused region 126 and throat region 148, the first layer can include a relatively reduced amount of thermoplastic polymer material (this may be due to some yarns formed of thermoplastic polymer material moving to a second or inner layer in this area). Transition area 150 can still include the properties of fused region 126 (e.g., water repellency, water resistance, waterproofing), but the extent of some of these properties may be relatively reduced as one moves toward throat region 148 and/or toward collar 129. A third area, such as throat region 148 and/or an area adjacent to collar 129 of knitted component 140, can have relatively less thermoplastic polymer material in the first layer than transition area 150, and may even include substantially no thermoplastic polymer material. In one non-limiting example, the ratio of thermoplastic polymer material to the other material in the first layer can be approximately 70:30 in the depicted melt region 126 adjacent to the bite line 116, can be approximately 50:50 in the transition region 150, and can be approximately 5:95 or 0:100 in the throat area 148. It is also contemplated that the melt region (e.g., transition region 150) can gradually decrease in its thermoplastic polymer material density and/or in the ratio of melted and non-melted thermoplastic polymer material to the other material as one moves from one location to another (e.g., from the bite line 116 to the throat area 148).

It is also contemplated that, instead of (or in addition to) varying the amount of thermoplastic polymer at different areas of the knitted component 140, different areas of the knitted component 140 having the thermoplastic polymer may be treated differently (e.g., during a heat press, more heat and/or pressure may be applied in one or more areas near the bite line 116 than near the shoe throat 136). In some embodiments, some selected areas of the knitted component 140 having the thermoplastic polymer may not form a molten region at all. For example, while the knitted component 140 may include the first yarn 144 in the outer layer in certain areas where a molten region is not desired, no additional treatment (e.g., heat treatment or the like) that would result in the formation of a molten region may be performed in these areas.

Melted region 126 can be water-resistant or substantially waterproof. According to this specification, in a test performed by the inventors to evaluate an embodiment of an article of footwear having melted region 126, the article of footwear was placed in a container of water filled to a level up to 10 mm above bite line 116 of the article of footwear. Melted region 126 extended above the water level. The article of footwear remained in the container for two hours. After the two-hour period, the article of footwear was removed from the container. No water was detected passing through melted region 126.

5A-D , in one non-limiting example, a thermoforming process, such as a heat press process, can be performed to form the molten region 126 from a thermoplastic polymer material. More specifically, the thermoplastic polymer material can be incorporated into the knitted component 140 by knitting with the aforementioned first yarn 144 having the thermoplastic polymer material.

Figures 5A-5D generally depict heat press 560 and related components. Heat press 560 may include a top plate 562 and a bottom plate 564. Each of these plates may or may not provide heat and may or may not contact the side of the shoe upper. The materials used to form the plates are not limited. In some aspects, the plates may include metal and/or silicone, or a combination thereof. In some embodiments, bottom plate 564 may be formed from silicone, and top plate 562 may be formed from metal.

In some embodiments, the upper 520 can be arranged on the base plate 564, and the top plate 562 can be lowered until its surface contacts the upper 520. A certain amount of pressure can be applied by the top plate, and because the base plate is fixed, the upper 520 is at least partially compressed in one or more selected areas. In some aspects, after the top plate is lowered to contact the upper 520, the top plate and the base plate remain separated and do not contact each other. The hot press may include a stopper (not shown) to prevent the top plate 562 and the base plate 564 from contacting each other.

As shown in FIG5B , a fixture 566 can be used to hold and/or position the shoe upper 520 during the heat pressing process. The fixture 566 can be a separate component from the heat press 560 or can be located on the base plate 564 of the heat press 560. The fixture 566 can have a top section 563 and a bottom section 565, each of which can be formed from any material, such as rubber or metal. If the material used to form the fixture 566 has a melting point, the melting point should be higher than the typical temperature reached during the heat pressing process to ensure that the heat pressing process does not destroy, alter, damage, or otherwise negatively impact the fixture 566. The shape and configuration of the fixture 566 are also not limited. In FIG5B , the fixture 566 is generally rectangular in shape. The fixture 566 can include a positioning device, in this case, a plurality of spring-loaded pins 568 configured to position the shoe upper 520. Here, the plurality of spring-loaded pins 568 are shaped substantially the same as the shape of the upper 520, such that the shape of the plurality of spring-loaded pins 568 corresponds to the outer perimeter of the upper 520. The upper 520 may include a plurality of holes configured to receive the spring-loaded pins 568, and/or the spring-loaded pins may pass through the upper 520 to hold the upper 520 in position on and within the jig 566.

The fixture 566 may also include a pad 569 configured to prevent the upper 520 from adhering to the heat press 560. The pad can be thermally insulating and/or provide cooling, particularly when the desired melting area (e.g., melting area 126 in FIG. 1 ) is located only on one side or one surface of the upper 520. The pad 569 can generally be the shape of the desired melting area of the upper 520. The thickness of the pad 569 can reduce the amount of heat applied and even reduce or substantially prevent areas of the upper 520 that do not correspond to the melting area (e.g., the throat area) from being squeezed, directly heated, and/or burned. In one embodiment, the pad 569 is formed of Teflon and is approximately 5 mm thick, although any suitable thickness may be used. The spring-loaded pins 568 are configured to compress if necessary during the heat press process so that they do not inhibit the pressure applied to the upper 520 (e.g., if the spring-loaded pins 568 are longer than the thickness of the upper 520). In some embodiments, the fixture 566 can be configured so that two or more uppers 520 can be processed simultaneously. As shown, release paper 570 may also be placed over the areas corresponding to the melted areas of upper 520. The release paper is preferably constructed of a material that reduces or prevents the melted areas of the upper from adhering thereto, and thus, release paper 570 may also prevent the melted areas of upper 520 from adhering to jig 566. Release paper 570 may be configured to allow heat to be conducted directly through release paper 570 to upper 520 without interfering with the heating process.

Next, referring to Figure 5C, the clamp 566 can be closed and placed in the hot press 560. The hot press 560 can be preheated to a temperature between about 100°C and about 150°C (or any other suitable temperature range). The press can then be started. In one embodiment, the hot press can apply a pressure of about 8 kg/ ^cm2 for 30 seconds at a temperature between about 120°C and about 150°C. When subjected to this heat and pressure, the thermoplastic polymer material of the upper 520, such as the thermoplastic polymer material contained in the yarn (i.e., the first yarn 144 described above), can at least partially melt. As a result, the materials of the separate yarns that originally formed the upper 520 can become combined and/or continuous to form a molten region. Therefore, any one or more regions where the upper 520 contains a thermoplastic polymer material and the material is subjected to a suitable process (such as the hot press process described herein) can be expected to form a molten region 126. A thermocouple (not shown) can measure the temperature of the upper 520 during this process. Once upper 520 reaches a predetermined temperature (eg, between about 120° C. and about 132° C.), heat press 560 can be opened and upper 520 can be removed. Although a heat press process is described, any other suitable process can be used to form the fused region.

Next, the heated upper 520 can undergo a cooling process, such as a cold pressing process. The cooling process can solidify the molten areas of the upper 520, or otherwise cause the molten areas to enter a state other than a molten state. Referring to Figure 5D, the upper 520 can be placed in a cold press 580. Silicone pads 582 (which can be any other suitable material) can be placed on one or both sides of the upper 520, and particularly over the heated and/or partially melted areas to ensure uniform pressure. The cold press 580 can include a refrigeration system, but in some embodiments, the cold press 580 is at or approximately at room temperature. In a non-limiting example, when activated, the cold press 580 can apply a pressure of approximately 15-18 kg/ ^cm2 for approximately 12 seconds. During the cold pressing process, the release paper 570 can remain attached to the upper 520 to prevent the upper 520 from adhering to the cold press 580, although this is not required. Furthermore, although the cold press 580 is shown without a clamp, the cold press 580 may be used in conjunction with a clamp similar to the clamp 566 described with respect to the hot pressing process.

In some embodiments, a heat press process can be used to attach an auxiliary component to the upper 520. Although not shown, an auxiliary component that may include a thermoplastic polymer material can be placed in contact with the upper 520 so that the auxiliary component is at least partially melted during the heat press process and thereby adhered to the upper 520. Alternatively, or in addition, the auxiliary component can be substantially free of thermoplastic polymer and can be bonded to the upper 520 by placing the auxiliary component in contact with the heated thermoplastic polymer of the upper 520. This can be done in conjunction with the process of forming the melted area 126 (see FIG. 2 ) or can be done at a different time. In an exemplary embodiment of an article of footwear, the auxiliary component 680 shown in FIG. 6A can be bonded to the upper 620 during the heat press step. For example, the auxiliary component can provide additional support in the toe area 601 of the article of footwear.

The auxiliary components may additionally or alternatively be connected to the upper 620 via another suitable process. For example, the auxiliary components may be attached using adhesives, stitching, heat treatment, or the like. In one example, a high-frequency welding process ("HF welding process") may be used. Referring to the article of footwear 600 shown in FIG6 , a plurality of second auxiliary components 682 may be attached to the upper using HF welding. Like the molten region 626, the second auxiliary components 682 may be at least partially formed from a thermoplastic polymer material that at least partially melts when heated to a certain temperature. During the HF welding process, energy in the form of electromagnetic energy may be provided (e.g., via electrodes, not shown) to the second auxiliary components 682 and/or the molten region 626, thereby causing the molecules within the material of the second auxiliary components 682 and/or the molten region 626 to move at a high frequency to generate heat. In one non-limiting example, the electromagnetic energy is supplied at approximately 27.17 MHz. Any suitable amount of electromagnetic energy may be provided. For example, approximately 0.35 amperes to approximately 0.45 amperes may be provided for approximately 10 seconds, although any suitable combination of current and duration may be used. The heat generated can be sufficient to at least partially melt the second auxiliary component 682 and/or the molten region 626. Although not required, additional thermal energy (i.e., heat) can be provided in another form during the HF welding process. Once cooled, the second auxiliary component 682 can be secured to the molten region 626. It is contemplated that the second auxiliary component 682 does not necessarily need to be HF welded to the molten region 626, but can be HF welded or otherwise secured to another area of the upper 620 by mechanical or chemical means.

After the HF welding process (or other process), the upper 620 may undergo a cooling process, such as the cold pressing process described above. Other cooling processes may be used. Furthermore, when the HF welding process is used, the HF welding process may be performed before, during, or after the hot pressing process.

The auxiliary component can have several advantageous properties. For example, the auxiliary component 680 can provide additional support in the toe area 601 of the footwear article. In one example, the second auxiliary component 682 can provide a texture that is conducive to gripping another object. The auxiliary component can be any suitable shape, size and material, can be fixed to the footwear article using any suitable fixing process, and can be configured to be used for any function. In some embodiments, the auxiliary component can be mainly used for aesthetic purposes, including but not limited to design components, labels, signs (tags) and/or trademarks.

In view of the present disclosure, all structures and methods disclosed and claimed herein can be made and realized without excessive experimentation. Although the present disclosure can be implemented in many different forms, the specific aspects of the present disclosure are described in detail herein. The present disclosure is an illustration of the principles of the disclosure and is not intended to limit the present disclosure to the specific aspects shown. In addition, unless clearly stated to the contrary, the use of the term "a" is intended to include "at least one" or "one or more". For example, "a yarn" is intended to include "at least one yarn" or "one or more yarns".

Any range given in absolute terms or in approximate terms is intended to encompass both, and any definition used herein is intended to illustrate and is not intended to limit. Although the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximate, the numerical values set forth in the specific examples are recorded as accurately as possible. However, any numerical value inherently contains certain errors that are inevitably caused by the standard deviation found in its respective test measurements. In addition, all ranges disclosed herein are understood to include any and all subranges (including all fractional values and integer values) included therein.

In addition, the present disclosure includes any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. These changes and modifications may be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. Therefore, these changes and modifications are intended to be covered by the appended claims.

Claims (16)

1. An upper for footwear articles, the upper comprising: A knitted component having a first yarn and a second yarn. The first yarn includes a core with a sheath, the sheath being formed of a thermoplastic material having a melting temperature. The second yarn does not contain the thermoplastic material. The knitted component further includes a first layer having a first surface and a second layer having a second surface. The first layer and the second layer are formed simultaneously on the knitting machine and fixed by the knitting structure of the knitting component. The knitted component further includes a first region and a second region, wherein in the first region, 90% or more of the thermoplastic material is located in the first layer and 10% or less of the thermoplastic material is located in the second layer, and in the second region, most of the thermoplastic material is located in the second layer. 2. The upper according to claim 1, wherein the first yarn of the first surface is incorporated into the second surface at least at one location within the first region. 3. The upper according to claim 1, wherein the first region extends along the edge of the upper adjacent to the interlocking line. 4. The upper according to claim 1, wherein the second region extends along the throat region of the upper. 5. The upper according to claim 1, wherein the first yarn is thermoformed to form a molten region. 6. The upper according to claim 1, wherein the thermoplastic material of the sheath is essentially composed of at least one thermoplastic polyurethane. 7. The upper according to claim 6, wherein the core of the first yarn comprises at least one polyester. 8. The upper according to claim 1, wherein the first layer and the second layer are knitted integrally. 9. The upper of claim 1, further comprising a throat region, wherein a molten region formed of the thermoplastic material extends from the edge of the upper toward the throat region, and wherein the molten region terminates adjacent to the throat region. 10. The upper of claim 5 further includes an auxiliary component formed of a material different from the knitted material and fixed to the molten region via the thermoplastic material. 11. An upper for footwear articles, the upper comprising: A knitted component having a first yarn and a second yarn. The first yarn includes a core with a sheath, the sheath being formed of a thermoplastic material having a melting temperature. The second yarn does not contain the thermoplastic material. The knitted component further includes a first layer having a first surface and a second layer having a second surface. The first layer and the second layer are formed simultaneously on the knitting machine and fixed by the knitting structure of the knitting component, and The shoe upper includes a first region and a second region, wherein a molten region in the first region is formed on the first layer by the thermoplastic material, and wherein the first yarn forms at least a portion of the second layer in the second region. 12. The upper of claim 11, wherein the second yarn forms at least a portion of the first layer in the second region. 13. The upper of claim 11, wherein the molten region extends along the edge of the upper adjacent to the interlocking line. 14. The upper according to claim 13, wherein the molten region terminates adjacent to the throat region of the upper. 15. A method for manufacturing an upper for footwear articles, the method comprising: A knitted component having a first layer and a second layer, wherein the first layer comprises a first yarn having a core and a sheath formed of a thermoplastic polymer material having a melting point, wherein the second layer comprises a second yarn not containing the thermoplastic polymer material, wherein the first layer and the second layer are formed simultaneously on a knitting machine and fixed by the knitting structure of the knitted component such that the first layer and the second layer have opposite compositions of the first yarn and the second yarn; Heating at least a portion of the thermoplastic polymer material of the first yarn to form a molten region on the first layer; and The knitted part is cooled to solidify the molten area. 16. The method of claim 15, further comprising: The auxiliary structure is placed in contact with the knitted component; and A certain amount of energy is provided to at least one of the auxiliary structure and the knitted part to attach the auxiliary structure to the knitted part.