Knitted article with raised structure and methods of manufacture

Abstract

A knitted article having a first layer and a second layer is described. The first layer is formed from a first yarn having a first shrinkage rate and the second layer is formed by a second yarn having a second shrinkage rate. The shrinkage rate of the first yarn is greater than the shrinkage rate of the second yarn when subjected to heat. Upon heat exposure, the second layer forms a raised structure. The raised structures have a length that is generally perpendicular to the lateral-to-medial course-wise direction of the knitted article.

What is claimed is: 
     
         1 . A textile, comprising:
 a first textile layer comprising a first yarn having a first shrinkage rate;   a second textile layer comprising a second yarn having a second shrinkage rate, wherein the first shrinkage rate and the second shrinkage rate are different from each other; and   a fused area forming part of the textile.   
     
     
         2 . The textile of  claim 1 , wherein the fused area comprises a thermoplastic polymer material. 
     
     
         3 . The textile of  claim 2 , wherein the textile is formed with a yarn comprising the thermoplastic polymer material. 
     
     
         4 . The textile of  claim 1 , wherein the first textile layer and the second textile layer form a plurality of shaped structures, each shaped structure having a geometry that is defined by the different shrinkage rate of the first yarn and the second yarn upon exposure to a stimulus. 
     
     
         5 . The textile of  claim 4 , wherein each shaped structure includes a pocket formed between the first textile layer and the second textile layer. 
     
     
         6 . The textile of  claim 4 , wherein each shaped structure is elongated. 
     
     
         7 . The textile of  claim 4 , wherein the plurality of shaped structures are separated by a plurality of valleys, each valley having a shorter thickness than the plurality of shaped structures. 
     
     
         8 . The textile of  claim 7 , wherein each valley comprises part of the fused area. 
     
     
         9 . The textile of  claim 7 , wherein each valley includes a third yarn that has a different shrinkage rate than the first yarn and the second yarn. 
     
     
         10 . The textile of  claim 1 , wherein the textile comprises a knitted textile. 
     
     
         11 . The textile of  claim 1 , wherein the textile comprises a woven textile. 
     
     
         12 . An article comprising the textile of  claim 1 . 
     
     
         13 . An article of footwear comprising the textile of  claim 1 . 
     
     
         14 . An article, comprising:
 a textile, comprising:   a first layer comprising a first yarn with a first shrinkage rate;   a second layer comprising a second yarn with a second shrinkage rate; and   a plurality of shaped structures each comprising a first side that is part of the first layer and a second side that is part of the second layer, wherein the first side and the second side are shaped differently due to the difference in the first shrinkage rate of the first yarn and the second shrinkage rate of the second yarn upon exposure to a stimulus, wherein a pocket is formed between the first side and the second side.   
     
     
         15 . The article of  claim 14 , wherein the pocket includes a filler material. 
     
     
         16 . The article of  claim 14 , wherein the first yarn is more elastic than the second yarn. 
     
     
         17 . The article of  claim 14 , wherein the textile comprises a fused area. 
     
     
         18 . The article of  claim 17 , wherein the fused area is located between the plurality of shaped structures. 
     
     
         19 . The article of  claim 18 , wherein the fused area comprises a thermoplastic polymer material that connects together the first layer and the second layer adjacent to the plurality of shaped structures. 
     
     
         20 . The article of  claim 14 , wherein the plurality of shaped structures each have a greater thickness than a plurality of valleys extending between the plurality of shaped structures. 
     
     
         21 . The article of  claim 14 , wherein the article is an article of footwear. 
     
     
         22 . The article of  claim 14 , wherein the article is an article of apparel. 
     
     
         23 . The article of  claim 14 , wherein the stimulus is heat. 
     
     
         24 . An article of footwear, comprising:
 an upper, comprising:   a textile, comprising:
 a first layer comprising a first yarn having a first shrinkage rate, and 
 a second layer comprising a second yarn having a second shrinkage rate, wherein the first layer and the second layer form a plurality of shaped structures based on a difference between the first shrinkage rate of the first yarn and the second shrinkage rate of the second yarn upon exposure to a stimulus, and 
 wherein the first layer and/or the second layer comprises a fused area; and 
   a sole structure attached to the upper.   
     
     
         25 . The article of footwear of  claim 24 , wherein the fused area at least partially surrounds the plurality of shaped structures. 
     
     
         26 . The article of footwear of  claim 24 , wherein the textile is formed with a yarn comprising a thermoplastic polymer material that is heat-processed to form the fused area. 
     
     
         27 . The article of footwear of  claim 24 , wherein each shaped structure includes a pocket enclosed between the first layer and the second layer. 
     
     
         28 . The article of footwear of  claim 24 , wherein the stimulus is heat.