Knitted component with inlaid cushioning

Abstract

A knitted component may include a knit element with a first surface and an opposite second surface. An inlaid yarn may extend through the knit element and between the first surface and the second surface. A secured area where the first surface and the second surface are secured together may be included, where the inlaid yarn is secured by loops forming the first surface and the second surface. A cushioning area may be included, where the cushioning area has a tubular construction such that the first surface and the second surface are separable, forming a cavity therebetween, and where the inlaid yarn extends through the cavity formed between the first surface and the second surface.

We claim: 
     
         1 . An article of footwear, comprising:
 an upper that includes a knitted component, the knitted component comprising:
 a knit element, comprising:
 a plurality of yarns; 
 a first layer forming a first surface of the knit element and a second layer forming an opposite second surface of the knit element; 
 a secured area where at least a first knit loop of the knit element forms a portion of both the first layer and the second layer; and 
 an unsecured area where at least a second knit loop of the knit element forms a portion of the first layer and not the second layer, and where at least a third knit loop of the knit element forms a portion of the second layer and not the first layer; 
 an inlaid yarn extending through the first knit loop of the knit element in the secured area and between the first layer and the second layer of the knit element in the unsecured area, wherein the inlaid yarn is lofted and has a first diameter in the unsecured area, and wherein the inlaid yarn is compressed and has a second diameter in the secured area; and 
 
   a sole secured to the upper.   
     
     
         2 . The article of footwear of  claim 1 , wherein the first diameter is at least 50% larger than the second diameter. 
     
     
         3 . The article of footwear of  claim 1 , wherein the inlaid yarn is a cushioning yarn texturized to loft or is a multifilament polyester yarn texturized to loft. 
     
     
         4 . The article of footwear of  claim 1 , wherein the knit element further comprises one or more additional inlaid yarns texturized to loft, wherein the one or more additional inlaid yarns are also extend through the first knit loop of the knit element in the secured area and between the first layer and the second layer of the knit element in the unsecured area. 
     
     
         5 . The article of footwear of  claim 1 , wherein the unsecured area comprises a cushioning area. 
     
     
         6 . The article of footwear of  claim 5 , wherein the knit element comprises a plurality of cushioning areas. 
     
     
         7 . The article of footwear of  claim 6 , wherein at least a portion of the plurality of cushioning areas comprise different dimensions and/or different shapes at different locations on the knit element. 
     
     
         8 . The article of footwear of  claim 6 , wherein the plurality of cushioning areas are placed in at least one of an ankle area, a midfoot area, a collar area, a throat area, and an underfoot area of the upper for the article of footwear. 
     
     
         9 . The article of footwear of  claim 1 , wherein the secured area is adjacent to the unsecured area, and wherein the secured area comprises a double jersey knit structure. 
     
     
         10 . The article of footwear of  claim 1 , wherein first diameter is at least twice as large as the second diameter. 
     
     
         11 . A knitted component, comprising:
 a first layer forming a first surface comprising a first course and a second layer forming an opposite second surface comprising a second course;   a secured area where the first layer and the second layer are secured together, wherein a first loop of the first course of the knitted component is intermeshed with a second loop of the second course of the knitted component; and   an unsecured area forming a cushioning area, the unsecured area comprising a tubular construction where the first layer and the second layer are separated, forming a cavity therebetween; and   one or more inlaid yarns,
 wherein, in the secured area, a first portion of the one or more inlaid yarns extends through the first course and the second course, 
 wherein, in the unsecured area, a second portion of the one or more inlaid yarns extends between the first course and the second course. 
   
     
     
         12 . The knitted component of  claim 11 , wherein the secured area is adjacent to the unsecured area, and wherein the secured area comprises a double jersey knit structure. 
     
     
         13 . The knitted component of  claim 11 , wherein the one or more inlaid yarns comprise cushioning yarns texturized to loft. 
     
     
         14 . The knitted component of  claim 11 , wherein, in the secured area, each of the one or more inlaid yarns comprises a first diameter, and wherein, in the unsecured area, each of the one or more inlaid yarns comprises a second diameter. 
     
     
         15 . The knitted component of  claim 14 , wherein the first diameter is at least 50% larger than the second diameter. 
     
     
         16 . The knitted component of  claim 15 , wherein in the first diameter is a maximum diameter of the one or more inlaid yarns. 
     
     
         17 . The knitted component of  claim 11 , wherein the cushioning area is located in at least one of an ankle area, a midfoot area, a collar area, a throat area, and an underfoot area of an upper for an article of footwear comprising the knitted component. 
     
     
         18 . The knitted component of  claim 11 , wherein the knitted component comprises a plurality of cushioning areas having different dimensions and/or different shapes, wherein the plurality of cushioning areas are positioned at different locations on the knitted component. 
     
     
         19 . A method of manufacturing an article of footwear comprising a knitted upper, the method comprising:
 knitting the knitted upper, the knitted upper comprising a knit element comprising a plurality of yarns, the knit element comprising an unsecured area and a secured area, wherein the knit element has a first layer forming a first surface and a second layer forming an opposite second surface, the first layer and second layer being separated in the unsecured area and joined to each other in the secured area, wherein at least a first knit loop of the knit element forms a portion of both the first layer and the second layer in the secured area, wherein at least a second knit loop of the knit element forms a portion of the first layer and not the second layer in the unsecured area, and wherein at least a third knit loop of the knit element forms a portion of the second layer and not the first layer in the unsecured area; and   inlaying an inlaid yarn in the knit element such that the inlaid yarn extends between the first layer and the second layer in the secured area and in the unsecured area, wherein the inlaid yarn is lofted and has a first diameter in the unsecured area, and wherein the inlaid yarn is compressed and has a second diameter in the secured area; and   attaching a sole to the knitted upper.   
     
     
         20 . The method of  claim 19 , wherein the unsecured area forms a cushioning area of the knitted component.