Sole system for an article of footwear incorporating a knitted component

Abstract

An article of footwear includes an upper comprising a knitted component forming a one-piece integrally knit element that forms a lower portion of the upper and extends from the lower portion toward a collar. The lower portion of the upper is configured to extend under a wearer's foot. The article of footwear includes an insert member having a bottom side with a plurality of protuberances that extend away, and the lower portion of the upper is vacuum molded around at least some portions of the protuberances of the insert member. The article of footwear may also include a sole assembly secured to the bottom side of the lower portion of the upper.

We claim: 
     
         1 . A sole system for an article of footwear, the sole system comprising:
 a knitted component including an underfoot portion having a plurality of knitted cleat members; and   an outsole cover assembly having a plurality of recesses corresponding to the plurality of knitted cleat members of the knitted component,   wherein the outsole cover assembly substantially covers the underfoot portion of the knitted component.   
     
     
         2 . The sole system of  claim 1 , wherein the knitted component further includes a portion forming at least one of a lateral side and a medial side of an upper for the article of footwear. 
     
     
         3 . The sole system of  claim 1 , wherein a lip of the outsole cover assembly extends around an outer periphery of the outsole cover assembly. 
     
     
         4 . The sole system of  claim 1 , wherein a top side of the outsole cover assembly is bonded to at least one cleat face using a thermoplastic polymer material. 
     
     
         5 . The sole system of  claim 4 , wherein the thermoplastic polymer material is included in a yarn at least partially forming at least one cleat face. 
     
     
         6 . The sole system of  claim 1 , wherein the outsole cover assembly includes a plurality of cleat cover elements that extend from a bottom surface of the outsole cover assembly. 
     
     
         7 . The sole system of  claim 1 , the underfoot portion of the knitted component is located between the outsole cover assembly and an insert member located in a cavity of the article of footwear. 
     
     
         8 . An article of footwear, comprising:
 an upper that is at least partially formed with a knitted component, the knitted component including an underfoot portion having a plurality of knitted cleat members; and   an outsole cover assembly having a plurality of recesses corresponding to the plurality of knitted cleat members of the knitted component,   wherein the outsole cover assembly substantially covers the underfoot portion of the knitted component.   
     
     
         9 . The article of footwear of  claim 8 , wherein the knitted component further includes a portion forming at least one of a lateral side and a medial side of an upper. 
     
     
         10 . The article of footwear of  claim 8 , wherein a lip of the outsole cover assembly extends around an outer periphery of the outsole cover assembly. 
     
     
         11 . The article of footwear of  claim 8 , wherein a top side of the outsole cover assembly is bonded to at least one cleat face using a thermoplastic polymer material. 
     
     
         12 . The article of footwear of  claim 11 , wherein the thermoplastic polymer material is included in a yarn at least partially forming at least one cleat face. 
     
     
         13 . The article of footwear of  claim 8 , wherein the outsole cover assembly includes a plurality of cleat cover elements that extend from a bottom surface of the outsole cover assembly. 
     
     
         14 . The article of footwear of  claim 8 , the underfoot portion of the knitted component is located between the outsole cover assembly and an insert member located in a cavity of the article of footwear. 
     
     
         15 . A method, comprising:
 forming a knitted component including an underfoot portion having a plurality of knitted cleat members; and   securing the knitted component to an outsole cover assembly having a plurality of recesses corresponding to the plurality of knitted cleat members of the knitted component,   wherein the outsole cover assembly substantially covers the underfoot portion of the knitted component.   
     
     
         16 . The method of  claim 15 , wherein the knitted component further includes a portion forming at least one of a lateral side and a medial side of an upper for an article of footwear. 
     
     
         17 . The method of  claim 15 , wherein a lip of the outsole cover assembly extends around an outer periphery of the outsole cover assembly. 
     
     
         18 . The method of  claim 15 , wherein a top side of the outsole cover assembly is bonded to at least one cleat face using a thermoplastic polymer material. 
     
     
         19 . The method of  claim 18 , wherein the thermoplastic polymer material is included in a yarn at least partially forming at least one cleat face. 
     
     
         20 . The method of  claim 15 , wherein the outsole cover assembly includes a plurality of cleat cover elements that extend from a bottom surface of the outsole cover assembly.