Knitted components reinforced with high tenacity yarn

Abstract

Knitted components may include a first knit layer including a first yarn, a second knit layer, and a plurality of inlaid courses of a high tenacity yarn having a tenacity of at least six grams-force per denier. The plurality of inlaid courses of the high tenacity yarn may include at least three courses of high tenacity yarn, each of which may be separated from an adjacent course of the first plurality of courses of the high tenacity yarn by no more than five courses of the first yarn.

We claim: 
     
         1 . An article of footwear, comprising:
 an upper, comprising:   a knitted component, comprising:
 a first knit layer; 
 a second knit layer; 
 a plurality of inlaid courses of a high tenacity yarn inlaid between the first knit layer and the second knit layer; 
 a plurality of openings formed in the first knit layer, through which exposed portions of the plurality of inlaid courses of the high tenacity yarn are visible, wherein the plurality of openings form a pattern, wherein at least a portion of the pattern has an orientation different than a course-wise direction or a wale-wise direction, such that adjacent openings of the plurality of openings expose different inlaid courses of the high tenacity yarn; and 
 a sole structure secured to the upper. 
   
     
     
         2 . The article of footwear of  claim 1 , wherein the pattern extends diagonally relative to a first edge and a second edge of the knitted component. 
     
     
         3 . The article of footwear of  claim 1 , wherein the exposed portions of the plurality of inlaid courses protrude through one or more of the plurality of openings. 
     
     
         4 . The article of footwear of  claim 1 , wherein the high tenacity yarn comprises at least one different visual property compared to the first knit layer. 
     
     
         5 . The article of footwear of  claim 4 , wherein the at least one different visual property comprises color. 
     
     
         6 . The article of footwear of  claim 4 , wherein the at least one different visual property comprises reflectivity. 
     
     
         7 . The article of footwear of  claim 4 , wherein the at least one different visual property comprises texture. 
     
     
         8 . The article of footwear of  claim 1 , wherein the plurality of openings are located in at least a forefoot region of the upper. 
     
     
         9 . A knitted component, comprising:
 an exterior knit layer;   a interior knit layer;   a plurality of inlaid courses of a high tenacity yarn positioned between the exterior knit layer and the interior knit layer; and   a plurality of openings formed in the exterior knit layer, through which exposed portions of the plurality of inlaid courses of the high tenacity yarn are visible, wherein the plurality of openings form a pattern of openings, wherein at least a portion of the pattern of openings has an orientation different than a course-wise direction or a wale-wise direction, such that adjacent openings of the plurality of openings expose different inlaid courses of the high tenacity yarn.   
     
     
         10 . The knitted component of  claim 9 , wherein the pattern of openings extends diagonally relative to a first edge and a second edge of the knitted component. 
     
     
         11 . The knitted component of  claim 9 , wherein each course of the plurality of inlaid courses of the high tenacity yarn has a linear density of at least 1,000 denier. 
     
     
         12 . The knitted component of  claim 9 , wherein each course of the plurality of inlaid courses of the high tenacity yarn has a maximum tensile strength of at least 7,000 grams-force. 
     
     
         13 . The knitted component of  claim 9 , wherein the knitted component further comprises a plurality of raised knit structures forming a diagonal pattern. 
     
     
         14 . The knitted component of  claim 9 , wherein the pattern of openings comprises a first diagonal line and a second diagonal line, wherein the second diagonal line is an opposite diagonal line relative to the first diagonal line. 
     
     
         15 . An article of footwear, comprising:
 an upper, comprising:   a knitted component, comprising:
 a first knit layer; 
 a second knit layer; 
 a plurality of inlaid courses of a high tenacity yarn inlaid between the first knit layer and the second knit layer; 
 a plurality of openings formed in the first knit layer, through which exposed portions of the plurality of inlaid courses of the high tenacity yarn are visible, wherein the plurality of openings form a pattern, wherein at least a portion of the pattern has an orientation different than a course-wise direction or a wale-wise direction, wherein the pattern provides a visual impression that the high tenacity yarn extends in a direction of the pattern when the high tenacity yarn extends in the course-wise direction; and 
 a sole structure secured to the upper. 
   
     
     
         16 . The article of footwear of  claim 15 , wherein the pattern extends diagonally relative to a first edge and a second edge of the knitted component. 
     
     
         17 . The article of footwear of  claim 15 , wherein the high tenacity yarn comprises at least one different visual property than the first knit layer. 
     
     
         18 . The article of footwear of  claim 17 , wherein the at least one different visual property comprises color. 
     
     
         19 . The article of footwear of  claim 15 , wherein the plurality of openings are at least partially located in a forefoot region of the article of footwear. 
     
     
         20 . The article of footwear of  claim 15 , wherein each opening of the plurality of openings has its longest dimension oriented in the course-wise direction.