Knitted component with an inner layer having a thermoplastic material and related method

Abstract

A method may include one or more of the following steps: knitting a first knit layer and a second knit layer on a knitting machine, where the first knit layer and the second knit layer each include a plurality of intermeshed loops, and where at least one loop of the first knit layer is intermeshed with at least one loop of the second knit layer; inlaying an inlaid strand between the first knit layer and the second knit layer during the knitting of the first knit layer and the second knit layer, where the inlaid strand includes a thermoplastic material having a melting point; and applying heat to at least a portion of the thermoplastic material of the inlaid strand such that the portion of the thermoplastic material rises to a temperature at or above the melting point.

What is claimed is: 
     
         1 . An article of footwear, comprising:
 an upper, comprising:   a knitted component, comprising:
 a first knit layer, 
 a second knit layer, and 
 a thermoplastic material positioned at least partially between the first knit layer and the second knit layer, 
 wherein the thermoplastic material has been melted and re-solidified such that the thermoplastic material penetrates the first knit layer and is exposed on a surface of the first knit layer which forms part of an outer-facing surface of the upper. 
   
     
     
         2 . The article of footwear of  claim 1 , wherein the thermoplastic material completely penetrates the first knit layer such that the thermoplastic material surrounds a plurality of loops of the first knit layer. 
     
     
         3 . The article of footwear of  claim 1 , wherein the knitted component comprises at least one inlaid strand that is inlaid between the first knit layer and the second knit layer, wherein the at least one inlaid strand comprises the thermoplastic material. 
     
     
         4 . The article of footwear of  claim 1 , wherein the knitted component comprises at least one yarn comprising the thermoplastic material. 
     
     
         5 . The article of footwear of  claim 1 , wherein the thermoplastic material is a thermoplastic polyurethane (TPU). 
     
     
         6 . The article of footwear of  claim 1 , wherein the knitted component comprises a first region having a first stiffness and a second region having a second stiffness, the first stiffness being greater than the second stiffness. 
     
     
         7 . The article of footwear of  claim 1 , wherein the knitted component comprises a third layer between the first knit layer and the second knit layer, wherein the third layer comprises the thermoplastic material. 
     
     
         8 . The article of footwear of  claim 7 , wherein the third layer forms a water-resistant or waterproof barrier between the first knit layer and the second knit layer. 
     
     
         9 . The article of footwear of  claim 7 , wherein the third layer comprises a non-linear cross-sectional shape. 
     
     
         10 . The article of footwear of  claim 1 , wherein the first knit layer and the second knit layer each comprise at least one yarn having a melting point that is higher than a melting point of the thermoplastic material. 
     
     
         11 . The article of footwear of  claim 1 , wherein the thermoplastic material that is exposed is located in at least a forefoot region of the article of footwear. 
     
     
         12 . The article of footwear of  claim 1 , wherein the thermoplastic material forms a micro-texture on the outer-facing surface of the upper. 
     
     
         13 . An article of footwear, comprising:
 an upper, comprising:   a knitted component, comprising:
 a first knit layer, 
 a second knit layer, wherein the first knit layer forms at least part of an outer-facing surface of the upper, and 
 a thermoplastic material inlaid between the first knit layer and the second knit layer, wherein the thermoplastic material is melted and re-solidified such that the thermoplastic material penetrates the first knit layer and is exposed on the outer-facing surface of the upper. 
   
     
     
         14 . The article of footwear of  claim 13 , wherein the thermoplastic material completely penetrates the first knit layer, and forms a smooth surface on the outer-facing surface of the upper. 
     
     
         15 . The article of footwear of  claim 13 , wherein one or more strands are inlaid between the first knit layer and the second knit layer, the one or more inlaid strands comprising the thermoplastic material. 
     
     
         16 . The article of footwear of  claim 13 , wherein the thermoplastic material forms a flattened region on the outer-facing surface of the upper. 
     
     
         17 . The article of footwear of  claim 13 , wherein a first region of the upper comprises a first stiffness from the thermoplastic material which is different from a second region of the upper that has a second stiffness. 
     
     
         18 . The article of footwear of  claim 13 , wherein the inlaid thermoplastic material forms a water-resistant barrier between the first knit layer and the second knit layer. 
     
     
         19 . The article of footwear of  claim 13 , wherein the inlaid thermoplastic material forms a waterproof barrier between the first knit layer and the second knit layer. 
     
     
         20 . An article of footwear, comprising:
 an upper, comprising:   a knitted component, comprising:
 a first layer forming at least part of an outer-facing surface of the upper; 
 a second layer; and 
 a third layer positioned between the first layer and the second layer, 
 wherein the third layer comprises a thermoplastic material, and 
 wherein the thermoplastic material is heat-processed such that a portion of the thermoplastic material has penetrated at least the first layer and is exposed on the outer-facing surface of the upper. 
   
     
     
         21 . The article of footwear of  claim 20 , wherein the thermoplastic material completely penetrates the first layer and is exposed in at least a forefoot region of the upper. 
     
     
         22 . The article of footwear of  claim 20 , wherein the third layer comprises a water-resistant or waterproof barrier between the first layer and the second layer. 
     
     
         23 . The article of footwear of  claim 20 , wherein the portion of the thermoplastic material exposed on the outer-facing surface of the upper forms a shiny region.