Article of footwear with enhanced durability features

Abstract

Aspects herein are directed to, among other things, a knitted upper for an article of footwear. The knitted upper includes different knit zones including a first knit zone which may be located in a toe and forefoot region of the article of footwear. The first knit zone includes a first knit layer forming an outer-facing surface of the knitted upper, a second knit layer forming an inner-facing surface of the knitted upper, and a third thermoformed layer substantially contained between the first knit layer and the second knit layer. The third thermoformed layer acts as a barrier, reducing the likelihood of abrasion forces that may occur from contact between the knitted upper and a ground or other surface from contacting yarns that form the second knit layer, thereby increasing the structural integrity of the knitted upper.

What is claimed is: 
     
         1 . An article of footwear, comprising:
 a sole structure; and   a knitted upper secured to the sole structure, the knitted upper comprising:
 a first knit zone comprising:
 a first knit layer located on an outer-facing surface of the knitted upper, 
 a second knit layer located on an inner-facing surface of the knitted upper, and 
 a third thermoformed layer substantially contained between the first knit layer and the second knit layer, and 
 
 a second knit zone comprising:
 the first knit layer, 
 the second knit layer, and 
 a first plurality of inlaid yarns at least partially positioned between the first knit layer and the second knit layer. 
 
   
     
     
         2 . The article of footwear of  claim 1 , wherein the first plurality of inlaid yarns comprises a thermoplastic material. 
     
     
         3 . The article of footwear of  claim 1 , further comprising a third knit zone comprising:
 the first knit layer;   the second knit layer; and   a second plurality of inlaid yarns at least partially positioned between the first knit layer and the second knit layer.   
     
     
         4 . The article of footwear of  claim 3 , wherein in the second knit zone, the first knit layer comprises a first plurality of openings having a first size, and wherein in the third knit zone, the first knit layer comprises a second plurality of openings having a second size smaller than the first size. 
     
     
         5 . The article of footwear of  claim 4 , wherein at least a portion of the first plurality of inlaid yarns is visible by way of the first plurality of openings in the first knit layer. 
     
     
         6 . The article of footwear of  claim 4 , wherein at least a portion of the second plurality of inlaid yarns is visible by way of the second plurality of openings in the first knit layer. 
     
     
         7 . The article of footwear of  claim 3 , wherein the first plurality of inlaid yarns comprises either one or two yarn ends inlaid along each of a plurality of knit courses in the second knit zone. 
     
     
         8 . The article of footwear of  claim 3 , wherein the second plurality of inlaid yarns comprises either one or two yarn ends inlaid along each of a plurality of knit courses in the third knit zone. 
     
     
         9 . The article of footwear of  claim 3 , wherein the first knit zone is located at a toe area of the knitted upper. 
     
     
         10 . The article of footwear of  claim 3 , wherein the second knit zone is located at one or more of a medial side and a lateral side of a midfoot region of the knitted upper. 
     
     
         11 . The article of footwear of  claim 3 , wherein the third knit zone is located at a heel area of the knitted upper. 
     
     
         12 . The article of footwear of  claim 1 , wherein the third thermoformed layer forms a substantially water-resistant or water-proof barrier. 
     
     
         13 . An article of footwear, comprising:
 a sole structure; and   a knitted upper secured to the sole structure, the knitted upper comprising:
 a first knit zone comprising:
 a first knit layer located on an outer-facing surface of the knitted upper, 
 a second knit layer located on an inner-facing surface of the knitted upper, and 
 a third layer of thermoplastic material substantially contained between the first knit layer and the second knit layer; and 
 
 a second knit zone comprising:
 the first knit layer, the first knit layer comprising a first plurality of openings, 
 the second knit layer, and 
 a first plurality of inlaid yarns at least partially positioned between the first knit layer and the second knit layer, at least a portion of the first plurality of inlaid yarns being visible by way of the first plurality of openings in the first knit layer. 
 
   
     
     
         14 . The article of footwear of  claim 13 , wherein the third layer in the first knit zone comprises a thermoformed layer. 
     
     
         15 . The article of footwear of  claim 14 , wherein the third layer is not visible in the first knit zone. 
     
     
         16 . The article of footwear of  claim 13 , wherein each opening of the first plurality of openings has a length dimension and a width dimension, the length dimension being greater than the width dimension. 
     
     
         17 . The article of footwear of  claim 13 , wherein the first plurality of inlaid yarns comprises a thermoplastic material. 
     
     
         18 . The article of footwear of  claim 13 , wherein the first plurality of inlaid yarns comprises either one or two yarn ends inlaid along each of a plurality of knit courses in the second knit zone. 
     
     
         19 . The article of footwear of  claim 13 , wherein the first knit zone is located at a toe area of the knitted upper and along a portion of a medial side and a lateral side of a forefoot region of the knitted upper. 
     
     
         20 . The article of footwear of  claim 19 , wherein the first knit zone extends a greater distance toward a heel area of the knitted upper on the lateral side of the forefoot region compared to the medial side of the forefoot region. 
     
     
         21 . The article of footwear of  claim 20 , wherein the second knit zone is located at one or more of the medial side and the lateral side of a midfoot region of the knitted upper. 
     
     
         22 . The article of footwear of  claim 13 , wherein the second knit zone is integrally knit with the first knit zone such that the second knit zone seamlessly extends from the first knit zone. 
     
     
         23 . The article of footwear of  claim 13 , further comprising a third knit zone comprising:
 the first knit layer having a second plurality of openings;   the second knit layer; and   a second plurality of inlaid yarns at least partially positioned between the first knit layer and the second knit layer, at least a portion of the second plurality of inlaid yarns being visible by way of the second plurality of openings in the first knit layer.   
     
     
         24 . The article of footwear of  claim 23 , wherein the first plurality of openings in the second knit zone comprises a first size, and wherein the second plurality of openings in the third knit zone comprises a second size smaller than the first size. 
     
     
         25 . The article of footwear of  claim 24 , wherein the third knit zone is located at a heel area of the knitted upper. 
     
     
         26 . The article of footwear of  claim 25 , wherein the third knit zone is integrally knit with the second knit zone such that the third knit zone seamlessly extends from the second knit zone. 
     
     
         27 . A method of manufacturing a knitted upper, the method comprising:
 forming at least a first knit zone and a second knit zone by knitting a first knit layer and a second knit layer on a knitting machine and inlaying one or more inlaid yarns within the first knit zone and the second knit zone, the one or more inlaid yarns inlaid between the first knit layer and the second knit layer, the one or more inlaid yarns comprising a thermoplastic material having a melting point;   at the first knit zone of the knitted upper, applying one or more of heat and pressure such that the thermoplastic material of the one or more inlaid yarns rises to a temperature at or above the melting point of the thermoplastic material, wherein the one or more of heat and pressure are not applied to the second knit zone of the knitted upper; and   cooling the knitted upper such that a third thermoformed layer is formed in the first knit zone, the third thermoformed layer substantially contained between the first knit layer and the second knit layer.   
     
     
         28 . The method of manufacturing the knitted upper of  claim 27 , wherein in the first knit zone, at least three yarn ends are inlaid along each of a plurality of knit courses in the first knit zone. 
     
     
         29 . The method of manufacturing the knitted upper of  claim 28 , wherein in the second knit zone, either one or two yarn ends are inlaid along each of a plurality of knit courses in the second knit zone. 
     
     
         30 . The method of manufacturing the knitted upper of  claim 27 , wherein yarns used to knit the first knit layer and the second knit layer have a melting point greater than the melting point of the thermoplastic material of the one or more inlaid yarns. 
     
     
         31 . The method of manufacturing the knitted upper of  claim 27 , further comprising forming at least a third knit zone by knitting the first knit layer and the second knit layer and inlaying the one or more inlaid yarns between the first knit layer and the second knit layer, wherein the one or more of heat and pressure are not applied to the third knit zone of the knitted upper. 
     
     
         32 . The method of manufacturing the knitted upper of  claim 31 , further comprising forming a first plurality of openings in the first knit layer in the second knit zone. 
     
     
         33 . The method of manufacturing the knitted upper of  claim 32 , wherein forming the first plurality of openings in the first knit layer in the second knit zone comprises executing a two-needle transfer. 
     
     
         34 . The method of manufacturing the knitted upper of  claim 33 , further comprising forming a second plurality of openings in the first knit layer in the third knit zone. 
     
     
         35 . The method of manufacturing the knitted upper of  claim 34 , wherein forming the second plurality of openings in the first knit layer in the third knit zone comprises executing a one-needle transfer. 
     
     
         36 . The method of manufacturing the knitted upper of  claim 31 , wherein in the third knit zone, either one or two yarn ends are inlaid along each of a plurality of knit courses in the third knit zone.