# US 11,109,641 B2 · Article of footwear having a skin layer between a knitted component and a sole structure > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,109,641 B2 - Document ID: US11109641B2 - Status: Granted - Kind: B2 - Application number: 16/361,978 - Filed: 2019-03-22 - Published: 2020-09-24 - Granted: 2021-09-07 - Earliest claimed: 2019-03-22 - Applicants: NIKE, Inc. - Inventors: Torrey J. Bell; Lauren X. Tyndall - Web page: https://patentgrep.com/patent/US11109641B2 ## CPC - A43B 13/125: {characterised by the midsole or middle layer} - A43B 13/04: Plastics, rubber or vulcanised fibre - A43B 13/12: Soles with several layers of different materials - A43B 13/32: by adhesives - A43B 23/0215: {Plastics or artificial leather} - A43B 23/0235: {Different layers of different material} - A43B 23/0255: {assembled by gluing or thermo bonding} - A43B 23/026: {Laminated layers} - A43B 23/0265: {having different properties in different directions} - D04B 1/16: synthetic threads - D10B 2401/041: thermoplastic; thermosetting - D10B 2403/0112: One smooth surface, e.g. laminated or coated - D10B 2403/0114: with one or more yarns appearing predominantly on one face, e.g. plated or paralleled yarns (for pile fabrics D03D27/00, D04B1/02, D04B21/02; for intarsia fabrics D04B1/126) - D10B 2501/043: Footwear - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - D04B: KNITTING - D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES ## Abstract An article of footwear may have a knitted component with an overfoot portion and an underfoot portion. At least one sole structure may be secured to the underfoot portion of the knitted component. A first surface of the underfoot portion, facing away from the at least one sole structure, may be formed as a first knit layer of the knitted component. A second layer of the knitted component, located between the first knit layer and the sole structure, may include a first thermoplastic material having a first melting temperature. A third layer, located between the second layer and the sole structure, may include a second thermoplastic material having a second melting temperature, where the second thermoplastic material is different than the first thermoplastic material. A transition region may be located between the second layer and the third layer. ## Claims ### Claim 1 An article of footwear, comprising: a knitted component having an overfoot portion and an underfoot portion collectively defining a void for receiving a foot; and at least one sole plate secured to the underfoot portion of the knitted component, the underfoot portion of the knitted component comprising a first knit layer and a second layer, the first knit layer forming a first surface of the underfoot portion facing away from the at least one sole plate, wherein the second layer of the underfoot portion, located between the first knit layer and the at least one sole plate, includes a first thermoplastic material having a first melting temperature, the first knit layer being located between the void and the second layer, wherein a third layer, located between the second layer and the at least one sole plate, includes a second thermoplastic material having a second melting temperature, wherein the second thermoplastic material is different than the first thermoplastic material, wherein a transition region is located between the second layer and the third layer, and wherein the transition region comprises a mixture of the first thermoplastic material and the second thermoplastic material and secures the second layer to the third layer. ### Claim 2 (depends on 1) The article of footwear of claim 1, wherein the first melting temperature of the first thermoplastic material is about 140 degrees Celsius or less. ### Claim 3 (depends on 1) The article of footwear of claim 1, wherein the second melting temperature of the second thermoplastic material is about 180 degrees Celsius or less, and wherein the second melting temperature is at least 30 degrees Celsius greater than the first melting temperature. ### Claim 4 (depends on 1) The article of footwear of claim 1, wherein the overfoot portion of the knitted component includes an exterior surface at least partially formed by a yarn that is also included in the first knit layer of the underfoot portion. ### Claim 5 (depends on 4) The article of footwear of claim 4, wherein the first knit layer substantially excludes the first thermoplastic material and the second thermoplastic material. ### Claim 6 (depends on 4) The article of footwear of claim 4, wherein at least two sole plates are included, and wherein the underfoot portion is exposed between the at least two sole plates. ### Claim 7 (depends on 4) The article of footwear of claim 4, wherein a skin component is included that at least partially covers the underfoot portion of the knitted component in a location corresponding with the at least one sole plate, and wherein the skin component forms the third layer. ### Claim 8 (depends on 1) The article of footwear of claim 1, wherein the transition region has a thickness of 0.1 mm or less. ### Claim 9 (depends on 8) The article of footwear of claim 8, wherein the mass ratio of the first thermoplastic material to the second thermoplastic material in the transition region is between 2:1 and 1:2. ### Claim 10 An article of footwear, comprising: a knitted component having an overfoot portion and an underfoot portion collectively defining a void for receiving a foot; a sole plate secured to the underfoot portion, wherein at least a portion of the underfoot portion of the knitted component includes a first knit surface and a second knit surface, wherein the first knit surface faces the void of the article of footwear and is located between the void and the second knit surface, and wherein the second knit surface faces the sole plate and is located between the first knit surface and the sole plate, and wherein the second knit surface includes a first thermoplastic material having a melting temperature of about 140 degrees Celsius or less; and a skin layer comprising a second thermoplastic material with a melting temperature of about 180 degrees Celsius or less, wherein the skin layer contacts the second knit surface, and wherein the skin layer is located between the second knit surface and the sole plate. ### Claim 11 (depends on 10) The article of footwear of claim 10, wherein the underfoot portion of the knitted component includes a multi-layer knit structure with a first knit layer and a second knit layer, wherein the first knit layer and the second knit layer respectively include a first yarn and a different second yarn, wherein the first knit layer defines the first knit surface, and wherein the second knit layer defines the second knit surface. ### Claim 12 (depends on 10) The article of footwear of claim 10, wherein the skin layer is secured to the second knit surface via a thermal bond. ### Claim 13 (depends on 10) The article of footwear of claim 10, wherein the overfoot portion of the knitted component includes an exterior surface at least partially formed by a first yarn, wherein the first yarn at least partially forms the first knit surface of the underfoot portion. ### Claim 14 (depends on 13) The article of footwear of claim 13, wherein the first yarn substantially excludes the first thermoplastic material and the second thermoplastic material. ### Claim 15 (depends on 10) The article of footwear of claim 10, wherein the first thermoplastic material is included in a yarn having a polyester core with a thermoplastic polymer sheath. ### Claim 16 (depends on 10) The article of footwear of claim 10, wherein the sole plate is secured to the skin layer via thermal bonding. ### Claim 17 An article of footwear, comprising: a knitted component having an overfoot portion and an underfoot portion collectively defining a void for receiving a foot, the underfoot portion of the knitted component including a first knit layer and a second layer, the second layer including a first thermoplastic material; a sole plate secured to the underfoot portion; and a skin layer located between the second layer of the underfoot portion and the sole plate and directly attached to the second layer and the sole plate, wherein the first knit layer is located between the void and the second layer and wherein the second layer is located between the first knit layer and the sole plate; wherein the second layer of the underfoot portion has a first thickness, wherein the skin layer has a second thickness, and wherein the first thickness is at least 100% greater than the second thickness. ### Claim 18 (depends on 17) The article of footwear of claim 17, wherein the first thickness is greater than about 0.7 mm, and wherein the second thickness is less than about 0.2 mm. ### Claim 19 (depends on 17) The article of footwear of claim 17, wherein the first knit layer substantially excludes the first thermoplastic material. ### Claim 20 (depends on 17) The article of footwear of claim 17, wherein the skin layer is attached to the sole plate via thermal bonding.