Footwear upper incorporating a knitted component with sock and tongue portions

Abstract

An article of footwear including a knitted component is provided. The knitted component may include at least one layer and a thermoplastic material that is fused. In accordance with other aspects, the knitted component may include a polymer sheet that is bonded to the knitted component.

We claim: 
     
         1 . An upper for footwear, comprising:
 a knitted component that integrally extends from a collar portion, across an overfoot portion, across medial and lateral side portions, across an underfoot portion, and to a toe portion,   the knitted component comprising at least one knit layer formed from at least one yarn, and   a thermoplastic material that is fused.   
     
     
         2 . The upper of  claim 1 , wherein the at least one knit layer comprises a single knit layer. 
     
     
         3 . The upper of  claim 1 , wherein the at least one knit layer comprises multiple knit layers. 
     
     
         4 . The upper of  claim 1 , wherein the at least one yarn includes a yarn comprising the thermoplastic material. 
     
     
         5 . The upper of  claim 4 , wherein the yarn is a bi-component yarn. 
     
     
         6 . The upper of  claim 4 , wherein the yarn is a sheath-core yarn. 
     
     
         7 . The upper of  claim 1 , wherein a polymer sheet is bonded to a surface of the knitted component. 
     
     
         8 . The upper of  claim 1 , wherein the knitted component comprises a first knit layer and a second knit layer that transition into each other at an edge of the collar portion. 
     
     
         9 . The upper of  claim 1 , wherein a portion of the knitted component comprises a yarn that can stretch. 
     
     
         10 . An article of footwear, comprising:
 an upper, comprising:
 a knitted component, comprising:
 a yarn comprising a thermoplastic material that is fused, 
 wherein the knitted component forms a sock portion comprising a collar portion, an overfoot portion, an underfoot portion, and a toe portion, which are knitted together; and 
 
 a sole structure secured to the upper. 
   
     
     
         11 . The article of footwear of  claim 10 , wherein the yarn comprises a bi-component yarn. 
     
     
         12 . The article of footwear of  claim 10 , wherein the yarn is a sheath-core yarn. 
     
     
         13 . The article of footwear of  claim 10 , wherein the knitted component comprises a single knit layer. 
     
     
         14 . The article of footwear of  claim 10 , wherein the knitted component comprises multiple knit layers. 
     
     
         15 . The article of footwear of  claim 10 , wherein the knitted component includes different knit structures. 
     
     
         16 . The article of footwear of  claim 10 , wherein the knitted component comprises a unitary knit construction from the collar portion to the toe portion. 
     
     
         17 . The article of footwear of  claim 10 , further comprising a cover component secured to the knitted component. 
     
     
         18 . The article of footwear of  claim 17 , wherein the cover component comprises a textile. 
     
     
         19 . The article of footwear of  claim 17 , wherein the cover component comprises a polymer sheet. 
     
     
         20 . The article of footwear of  claim 19 , wherein the polymer sheet is bonded to the knitted component. 
     
     
         21 . The article of footwear of  claim 17 , wherein the cover component comprises a layered structure formed of multiple materials. 
     
     
         22 . An article of footwear, comprising:
 an upper, comprising:
 a sock portion formed by a knitted component that includes a collar portion, an overfoot portion, an underfoot portion, and a toe portion, which are knitted together, wherein the knitted component comprises at least one knit layer formed from at least one yarn, and 
 a polymer sheet that is bonded to a surface of the knitted component; and 
   a sole structure secured to the upper.   
     
     
         23 . The article of footwear of  claim 22 , wherein the at least one yarn includes a yarn comprising a thermoplastic material that is fused. 
     
     
         24 . The article of footwear of  claim 22 , wherein the at least one knit layer comprises a single knit layer. 
     
     
         25 . The article of footwear of  claim 22 , wherein the at least one knit layer comprises multiple knit layers. 
     
     
         26 . The article of footwear of  claim 22 , wherein a tongue portion is secured to the knitted component.