Articles of footwear with knitted components and methods of manufacturing the same

Abstract

Footwear with integrally knit uppers having features for increasing strength and durability of the footwear while removing weight associated with traditional components are provided. The upper includes a knitted component with a plurality of courses knit with a first yarn and a tensile element having a greater tenacity compared to the first yarn, where such courses form midfoot regions on the lateral side and medial side of the upper. Within the plurality of courses, the tensile element is knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence. The sequence is repeated multiple times along each course within the plurality of courses.

What is claimed is: 
     
         1 . An article of footwear having an upper comprising:
 a knitted component comprising:
 one or more first zones with a plurality of courses knit with a first yarn and a tensile element having a greater tenacity compared to the first yarn, wherein within the one or more first zones, the tensile element is knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence, wherein the sequence is repeated multiple times along each course within the plurality of courses; and 
 one or more second zones lacking tensile elements knit with the sequence. 
   
     
     
         2 . The article of footwear of  claim 1 , wherein the tensile element has a greater diameter than the first yarn. 
     
     
         3 . The article of footwear of  claim 1 , wherein the one or more first zones form midfoot regions on a lateral side and/or a medial side of the upper. 
     
     
         4 . The article of footwear of  claim 3 , wherein the one or more first zones form a heel region of the upper. 
     
     
         5 . The article of footwear of  claim 1 , wherein each course within the one or more first zones includes the tensile element knit with the sequence. 
     
     
         6 . The article of footwear of  claim 1 , wherein the one or more first zones are integrally knit with the one or more second zones so as to have a seamless transition between at least a first zone and a second zone. 
     
     
         7 . The article of footwear of any of  claim 1 , wherein the one or more second zones form a central portion of a forefoot region of the upper. 
     
     
         8 . The article of footwear of  claim 7 , wherein the one or more first zones form lateral and medial portions of the forefoot region. 
     
     
         9 . The article of footwear of  claim 1 , wherein the plurality of courses each extend from an outer perimeter of the knitted component to a throat area of the upper. 
     
     
         10 . The article of footwear of  claim 1 , wherein courses within the plurality of courses are adjacent courses. 
     
     
         11 . An article of footwear having an upper comprising:
 a knitted component having a plurality of courses knit with a first yarn and a tensile element having a greater tenacity than the first yarn,   wherein, within the plurality of courses, the tensile element is knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence, the quantity of wales being at least 3 wales and no greater than 8 wales; and   wherein the sequence is repeated multiple times along each course within the plurality of courses.   
     
     
         12 . The article of footwear of  claim 11 , wherein the quantity of wales is 5 and the quantity of knitted loop stitches is 1. 
     
     
         13 . The article of footwear of  claim 11 , wherein the quantity of wales is 4 and the quantity of knitted loop stitches is 1. 
     
     
         14 . The article of footwear of  claim 11 , wherein the tensile element is knit with the sequence in courses in a heel region of the upper and a midfoot region of the upper on a lateral side and a medial side. 
     
     
         15 . The article of footwear of  claim 14 , wherein the tensile element is knit with the sequence in each course within the heel region and the midfoot region. 
     
     
         16 . The article of footwear of  claim 11 , wherein the sequence is repeated at least 5 times within at least one course within the plurality of courses. 
     
     
         17 . The article of footwear of  claim 11 , wherein the tensile element is knit without floats in an area adjacent an outer perimeter of the knitted component and in an area adjacent an inner perimeter of the knitted component. 
     
     
         18 . A method of manufacturing an article of footwear comprising:
 knitting a plurality of courses with a first yarn and a tensile element having at least one of a greater diameter and greater tenacity compared to the first yarn, the plurality of courses forming midfoot regions on a lateral side and/or a medial side of the upper; and   wherein knitting the plurality of courses includes knitting the tensile element with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence and repeating the sequence multiple times along each course within the plurality of courses.   
     
     
         19 . The method of manufacturing an article of footwear of  claim 18 , wherein the plurality of courses also form a heel region of the upper. 
     
     
         20 . The method of manufacturing an article of footwear of  claim 18 , where the quantity of wales is at least 3 wales and no greater than 8 wales. 
     
     
         21 . An article of footwear having an upper comprising:
 a knitted component comprising radially-extending courses extending from an outer perimeter towards a throat area; the radially-extending courses forming:
 one or more first zones with radially-extending courses knit with a first yarn and a tensile element having a greater tenacity compared to the first yarn, wherein within the one or more first zones, the tensile element is knit with a sequence of one or more knitted loop stitches and a float stitch extending a quantity of wales that is greater than a quantity of knitted loop stitches within the sequence, wherein the sequence is repeated multiple times along each course within the plurality of courses; and 
 one or more second zones with radially-extending courses and lacking tensile elements knit with the sequence. 
   
     
     
         22 . The article of footwear of  claim 21 , wherein the tensile element has a greater diameter than the first yarn. 
     
     
         23 . The article of footwear of  claim 21 , wherein the one or more first zones form midfoot regions on a lateral side and/or a medial side of the upper. 
     
     
         24 . The article of footwear of  claim 23 , wherein the one or more first zones form a heel region of the upper. 
     
     
         25 . The article of footwear of  claim 21 , wherein each course within the one or more first zones includes the tensile element knit with the sequence. 
     
     
         26 . The article of footwear of  claim 21 , wherein the one or more first zones are integrally knit with the one or more second zones so as to have a seamless transition between at least a first zone and a second zone. 
     
     
         27 . The article of footwear of any of  claim 21 , wherein the one or more second zones form a central portion of a forefoot region of the upper. 
     
     
         28 . The article of footwear of  claim 27 , wherein the one or more first zones form lateral and medial portions of the forefoot region. 
     
     
         29 . The article of footwear of  claim 27 , wherein the one or more first zones extend along entire lengths of a heel region and a midfoot region. 
     
     
         30 . The article of footwear of  claim 21 , wherein radially-extending courses form a plurality of wedge-shaped portions in at least a forefoot region and a midfoot region. 
     
     
         31 . The article of footwear of  claim 21 , wherein radially-extending courses of the one or more first zones knit with at least the tensile element in the sequence are consecutive with one another.