Knitted component with an inner layer having a thermoplastic material and related method
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.
1 . An upper for an article of footwear, the upper comprising:
a first knit layer located on a first side of the upper;
a second knit layer located on a second side of the upper that is opposite the first side, wherein the first knit layer and/or the second knit layer comprise at least one high melting-point yarn; and
a third layer formed between the first knit layer and the second knit layer, wherein the third layer includes one or more thermoplastic strands inlaid between the first knit layer and the second knit layer,
wherein a first region of the upper includes a first ratio of the one or more thermoplastic strands to the at least one high melting-point yarn by volume, and wherein a second region of the upper includes a second ratio of the one or more thermoplastic strands to the at least one high melting-point yarn by volume, wherein the first ratio is greater than the second ratio.
2 . The upper of claim 1 , wherein the first region has a greater degree of penetration of the one or more thermoplastic strands into the first and second knit layers than the second region.
3 . The upper of claim 1 , wherein, in the first region, the one or more thermoplastic strands occupy a greater percentage of space between yarns forming the first and second knit layers compared to the second region.
4 . The upper of claim 1 , wherein the first region includes a first low-melting point thermoplastic yarn having a first melting temperature and the second region includes a second low-melting point thermoplastic yarn having a second melting temperature, the first and second melting temperatures each being less than a melting temperature of high melting-point yarn forming the first knit layer and the second knit layer.
5 . The upper of claim 4 , wherein the first and second melting temperatures are each less than 150° C.
6 . The upper of claim 1 , wherein the one or more thermoplastic strands inlaid in the first region extend from a first edge of the upper to a second edge of the upper.
7 . The upper of claim 1 , wherein the one or more thermoplastic strands inlaid in the second region extends from a first edge of the upper and partway to a second edge of the upper.
8 . The upper of claim 1 , wherein the first region has complete penetration of the first and second knit layers by the one or more thermoplastic strands, and the second region has partial penetration of the first and second knit layers by the one or more thermoplastic strands.
9 . An article of footwear, comprising:
an upper having a first knit layer located on a first side of the upper;
a second knit layer located on a second side of the upper that is opposite the first side;
a third layer formed between the first knit layer and the second knit layer, wherein the third layer includes one or more thermoplastic strands inlaid between the first knit layer and the second knit layer,
wherein a first region of the upper includes a first ratio of the one or more thermoplastic strands to high-melting point yarn by volume, and wherein a second region of the upper includes a second ratio of the one or more thermoplastic strands to high-melting point yarn by volume, wherein the first ratio is greater than the second ratio; and
a sole structure secured to the upper.
10 . The article of footwear of claim 9 , wherein the third layer provides a waterproof barrier.
11 . The article of footwear of claim 9 , wherein the third layer provides a water-resistant barrier.
12 . The article of footwear of claim 9 , wherein the one or more thermoplastic strands comprise a first low-melting point yarn having a first melting temperature and being present in the first region and a second low-melting point yarn having a second melting temperature and being present in the second region, the first and second melting temperatures each being less than a melting temperature of yarn forming the first knit layer and the second knit layer.
13 . The article of footwear of claim 12 , wherein the first and second melting temperatures are each less than 150° C.
14 . The article of footwear of claim 9 , wherein the one or more thermoplastic strands inlaid in the first region extend from a first edge of the upper to a second edge of the upper.
15 . The article of footwear of claim 9 , wherein the one or more thermoplastic strands inlaid in the second region extend from a first edge of the upper and partway to a second edge of the upper.
16 . An article of footwear, comprising:
an upper, comprising:
a knitted component, comprising:
a first knit layer,
a second knit layer, and
a thermoplastic material incorporated between the first knit layer and the second knit layer,
wherein the thermoplastic material has been melted and re-solidified such that it penetrates through at least one of the first knit layer and the second knit layer and is exposed on an outer-facing surface of the upper.
17 . The article of footwear of claim 16 , wherein the re-solidified thermoplastic material forms a barrier between the first knit layer and the second knit layer, the barrier being water-resistant or waterproof.
18 . The article of footwear of claim 16 , wherein the thermoplastic material that is exposed on the outer-facing surface of the upper forms a smooth surface on the outer-facing surface of the upper.
19 . The article of footwear of claim 16 , wherein the thermoplastic material that is exposed on the outer-facing surface of the upper forms a flattened region on the outer-facing surface of the upper.