Article of footwear with a knitted component

Abstract

Aspects herein are directed to, among other things, a knitted component for an article of footwear and a method of manufacturing a knitted component having a first knit zone in a heel region having a lower knit density than a second knit zone in the midfoot and/or forefoot regions. The first and second knit zones may be integrally knit and adjacent one another along a seamless boundary. In some examples, the boundary between the first and second knit zones is more rearward on the medial side of the upper than on the lateral side. The knitted component may also extend underfoot and combine with a thermoplastic film layer to form a composite structure to which a sole structure is secured.

What is claimed is: 
     
         1 . An article of footwear, comprising:
 an upper comprising a knitted component and including:
 a first knit zone in a heel region of the upper, the first knit zone having a first knit density; and 
 a second knit zone integrally knit with the first knit zone and in a midfoot region of the upper, the second knit zone having a second knit density that is greater than the first knit density. 
   
     
     
         2 . The article of footwear of  claim 1 , wherein the first knit zone extends from the midfoot region on a lateral side of the upper, through the heel region, and to the midfoot region on a medial side of the upper. 
     
     
         3 . The article of footwear of  claim 2 , further comprising a sole structure secured to the upper, wherein the first knit zone extends continuously from a collar to a biteline wherein the sole structure meets the upper. 
     
     
         4 . The article of footwear of  claim 1 , wherein the second knit zone is also within a forefoot region of the upper. 
     
     
         5 . The article of footwear of  claim 4 , wherein the second knit zone extends continuously from the midfoot region on a medial side of the upper, through the forefoot region, and to the midfoot region on a lateral side of the upper. 
     
     
         6 . The article of footwear of  claim 1 , wherein the first knit density is no more than half of the second knit density. 
     
     
         7 . The article of footwear of  claim 1 , wherein the knitted component comprises a single layer knit construction in the first knit zone and the second knit zone. 
     
     
         8 . The article of footwear of  claim 1 , wherein the first knit zone comprises a course of a first yarn comprising a tenacity of at least 5 grams per denier. 
     
     
         9 . The article of footwear of  claim 8 , wherein, in at least the first knit zone, the first yarn is plated with a second yarn having a lower melting temperature than the first yarn. 
     
     
         10 . The article of footwear of  claim 1 , wherein the first knit zone comprises a mesh structure having integrally knit openings having a width of at least two wales. 
     
     
         11 . An article of footwear, comprising:
 a sole structure; and   an upper secured to the sole structure, the upper comprising a composite structure extending underfoot and secured to the sole structure, the composite structure comprising:
 a knit mesh component on an outer-facing surface of the composite structure and having a plurality of integrally knit openings; and 
 a thermoplastic film layer on an inner-facing surface of the composite structure, the thermoplastic film layer extending partially to the outer-facing surface of the composite structure, 
   wherein the sole structure is bonded to the knit mesh component and the thermoplastic film layer of the composite structure.   
     
     
         12 . The article of footwear of  claim 11 , wherein the composite structure extends continuously through a forefoot region, a midfoot region, and a heel region of the upper. 
     
     
         13 . The article of footwear of  claim 12 , further comprising a biteline where the sole structure meets the upper, and wherein the composite structure extends above the biteline in at least part of the forefoot region and maintains below the biteline in the midfoot region and the heel region. 
     
     
         14 . The article of footwear of  claim 11 , wherein the upper comprises an integrally knitted component comprising a first knit zone having a first knit density and a second knit zone having a second knit density that is greater than the first knit density, wherein the composite structure comprises a portion of the integrally knitted component in the first knit zone and a portion of the integrally knitted component in the second knit zone, wherein the integrally knitted component in at least one of the first knit zone or the second knit zone comprises the knit mesh component of the composite structure. 
     
     
         15 . The article of footwear of  claim 14 , wherein the first knit zone extends around a heel region of the upper and the second knit zone abuts the first knit zone. 
     
     
         16 . An article of footwear, comprising:
 an upper comprising a knitted component and including:
 a first knit zone in a heel region of the upper, the first knit zone having a first knit density; 
 a second knit zone integrally knit with the first knit zone and in a midfoot region of the upper, the second knit zone having a second knit density different than the first knit density; and 
 a first boundary between the first knit zone and the second knit zone on a medial side of the upper and a second boundary between the first knit zone and the second knit zone on a lateral side of the upper, wherein the first boundary is closer to a heel end of the upper than the second boundary. 
   
     
     
         17 . The article of footwear of  claim 16 , further comprising a sole structure secured to the upper, a biteline being where the upper meets the sole structure. 
     
     
         18 . The article of footwear of  claim 17 , wherein the first boundary forms a first angle with the biteline along the second knit zone, and the second boundary forms a second angle with the biteline along the second knit zone, the first angle being less than the second angle. 
     
     
         19 . The article of footwear of  claim 17 , wherein the first boundary and the second boundary both extend continuously from the biteline to an eyestay area of the upper. 
     
     
         20 . The article of footwear of  claim 16 , further comprising a composite structure extending underfoot and comprising a thermoplastic film layer at least partially encapsulating a portion of the knitted component in the first knit zone and a portion of the knitted component in the second knit zone.