Knitted component with at least one expandable yarn

Abstract

An upper may include a knitted component that at least partially forms a throat area of the upper. A first expandable yarn may be at least partially inlaid within a first course of the knitted component, the first expandable yarn having an inlaid portion that is between a first surface and a second surface of the knitted component, the first surface and the second surface including knitted loops of at least one course including a second yarn. The first expandable yarn may include an exposed portion that is exposed on the first surface of the knitted component. The inlaid portion of the first expandable yarn may have a first diameter, where the exposed portion of the first expandable yarn has a second diameter, and where the second diameter is larger than the first diameter.

We claim: 
     
         1 . An upper for an article of footwear, comprising:
 a knitted component that at least partially forms a throat area of the upper and has a first surface and a second surface with at least one course of knitted loops;   a first expandable yarn being at least partially inlaid within a first course of the at least one course of knitted loops, the first expandable yarn having an inlaid portion that is between the first surface and the second surface; and   a second yarn forming the knitted loops of the at least one course,   wherein the first expandable yarn includes an exposed portion that is exposed on the first surface of the knitted component, and   wherein the inlaid portion of the first expandable yarn has a first diameter, and wherein the exposed portion of the first expandable yarn has a second diameter that is larger than the first diameter.   
     
     
         2 . The upper of  claim 1 , wherein the first expandable yarn extends through the throat area of the upper, and wherein the exposed portion of the first expandable yarn is exposed in the throat area. 
     
     
         3 . The upper of  claim 1 , wherein the first expandable yarn comprises a plurality of inlaid portions and a plurality of exposed portions extending lengthwise on the first expandable yarn, each inlaid portion within the plurality of inlaid portions extending between two exposed portions within the plurality of exposed portions. 
     
     
         4 . The upper of  claim 1 , wherein the first surface is an exterior surface of the upper. 
     
     
         5 . The upper of  claim 4 , wherein the exposed portion of the first expandable yarn is located on the exterior surface in the throat area such that is configured to provide cushioning between a fastening element of the article of footwear and a user's foot. 
     
     
         6 . The upper of  claim 1 , wherein the first surface is an interior surface of the upper, and wherein the exposed portion of the first expandable yarn is located on the interior surface such that it extends into a void of the article of footwear. 
     
     
         7 . The upper of  claim 1 , wherein the second diameter is at least 50% larger than the first diameter. 
     
     
         8 . The upper of  claim 1 , wherein the second diameter is at least 100% larger than the first diameter. 
     
     
         9 . The upper of  claim 1 , further comprising:
 a second expandable yarn being at least partially inlaid within a second course of the at least one course of the knitted component, the second course being parallel to the first course,   wherein the second expandable yarn has an inlaid portion that is between the first surface and the second surface of the knitted component, and   wherein the second expandable yarn includes an exposed portion that is exposed on the first surface of the knitted component.   
     
     
         10 . The upper of  claim 9 , wherein the inlaid portion of the second expandable yarn has a first diameter, wherein the exposed portion of the second expandable yarn has a second diameter, and wherein the second diameter is larger than the first diameter. 
     
     
         11 . The upper of  claim 9 , wherein the first expandable yarn has a plurality of first exposed portions that are exposed on the first surface, wherein the second expandable yarn has a plurality of second exposed portions that are exposed on the first surface, and wherein first exposed portions within the plurality of first exposed portions are offset relative to second exposed portions within the plurality of second exposed portions in a direction perpendicular to a coursewise direction. 
     
     
         12 . A knitted component, comprising:
 a first surface and a second surface, the first surface and the second surface including a set of knitted loops within a first course;   a first expandable yarn being at least partially inlaid within a first course of the knitted component; and   a second yarn forming the set of knitted loops of the first course,   wherein the first expandable yarn includes an inlaid portion that is positioned between the first surface and the second surface of the knitted component,   wherein the first expandable yarn includes an exposed portion that is exposed on the first surface of the knitted component, and   wherein the inlaid portion of the first expandable yarn has a first diameter, and wherein the exposed portion of the first expandable yarn has a second diameter that is larger than the first diameter.   
     
     
         13 . The knitted component of  claim 12 , wherein the first expandable yarn includes a plurality of inlaid portions and a plurality of exposed portions extending lengthwise on the first expandable yarn, each inlaid portion within the plurality of inlaid portions extending between two exposed portions within the plurality of exposed portions. 
     
     
         14 . The knitted component of  claim 12 , further comprising:
 a second expandable yarn being at least partially inlaid within a second course of the knitted component, the second course being parallel to the first course,   wherein the second expandable yarn has an inlaid portion that is positioned between the first surface and the second surface of the knitted component, and   wherein the second expandable yarn includes an exposed portion that is exposed on the first surface of the knitted component.   
     
     
         15 . The knitted component of  claim 14 , wherein the inlaid portion of the second expandable yarn has a first diameter, and wherein the exposed portion of the second expandable yarn has a second diameter that is larger than the first diameter. 
     
     
         16 . The knitted component of  claim 12 , wherein the second diameter is at least 50% larger than the first diameter. 
     
     
         17 . The knitted component of  claim 12 , wherein the first expandable yarn includes a second exposed portion that is exposed on the second surface of the knitted component. 
     
     
         18 . The knitted component of  claim 12 , wherein the knitted component at least partially forms an article of apparel. 
     
     
         19 . A method of forming a knitted component, comprising:
 knitting the knitted component having a first surface and a second surface that include knitted loops in at least a first course, the knitted component comprising:   a first expandable yarn being at least partially inlaid within the first course of the knitted component; and   a second yarn forming the knitted loops in at least the first course,   wherein the first expandable yarn includes an inlaid portion that is positioned between the first surface and the second surface,   wherein the first expandable yarn includes an exposed portion that is exposed on the first surface, and   wherein the inlaid portion of the first expandable yarn has a first diameter, and wherein the exposed portion of the first expandable yarn has a second diameter that is larger than the first diameter.   
     
     
         20 . The method of  claim 19 , further comprising inlaying a plurality of inlaid portions and a plurality of exposed portions on a knitting machine, the plurality of inlaid portions and the plurality of exposed portions extending lengthwise on the first expandable yarn, each inlaid portion within the plurality of inlaid portions extending between two exposed portions within the plurality of exposed portions.