Article with multiple layers and method of manufacture

Abstract

One general aspect of the present disclosure includes an article having a first zone, the first including a first region of a knitted base layer and a knitted second layer, where the second layer is disposed primarily on one side of the base layer. The article may further include a second zone that may include a second region of the base layer, where the second region of the base layer and the first region of the base layer have a common yarn, and where the second region of the base layer and the second layer have a common yarn. The first zone may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone may have a second degree of elasticity such that it has a second elongation when subjected to the tensile load.

What is claimed is: 
     
         1 . An article, comprising:
 a knitted component, comprising:
 a knitted base layer comprising at least a first yarn, the knitted base layer having a first stitch density; and 
 a knitted net layer comprising at least a second yarn, the knitted net layer having a second stitch density and a plurality of adjacent cells forming a pattern, each cell of the plurality of adjacent cells having a plurality of corners defined by portions of the second yarn being intertwined with one another; 
 wherein the first stitch density of the knitted base layer is greater than the second stitch density of the knitted net layer, 
 wherein the knitted net layer overlaps a first portion of a surface of the knitted base layer in a first zone of the knitted component, 
 wherein the knitted net layer is secured to the knitted base layer with a plurality of tie-down portions formed from the first yarn of the knitted base layer, and 
 wherein the plurality of tie-down portions are located at every corner of the plurality of corners of each cell of the plurality of adjacent cells of the knitted net layer. 
   
     
     
         2 . The article of  claim 1 , wherein the knitted net layer further overlaps a second portion of the surface of the knitted base layer in a second zone of the knitted component, wherein the second zone is knitted continuously with the first zone, and wherein the knitted net layer limits elongation of the knitted base layer when the article is subjected to a tensile load. 
     
     
         3 . The article of  claim 2 , wherein a second degree of elongation of the second zone of the knitted component is at least 5% greater than a first degree of elongation of the first zone of the knitted component. 
     
     
         4 . The article of  claim 3 , wherein the second degree of elongation of the second zone of the knitted component is at least 20% greater than the first degree of elongation of the first zone of the knitted component. 
     
     
         5 . The article of  claim 2 , wherein the knitted net layer further overlaps a third portion of the surface of the knitted base layer in a third zone of the knitted component, wherein the third zone is knitted continuously with the first zone on an opposite side of the first zone. 
     
     
         6 . The article of  claim 5 , wherein the third zone further includes an additional knitted net layer, wherein the additional knitted net layer limits elongation of the third zone of the knitted component. 
     
     
         7 . The article of  claim 1 , wherein the first yarn comprises a first characteristic different than a second characteristic of the second yarn. 
     
     
         8 . The article of  claim 1 , wherein the first yarn is primarily disposed on a first side of the knitted base layer in the first zone, and wherein the second yarn is primarily disposed on an opposite second side of the knitted base layer in the first zone. 
     
     
         9 . The article of  claim 1 , wherein the knitted net layer includes a first net region and a second net region in the first zone. 
     
     
         10 . The article of  claim 9 , wherein the first net region and the second net region of the knitted net layer are disposed primarily on the same side of the knitted base layer. 
     
     
         11 . The article of  claim 9 , wherein the first net region comprises one or more first cells of the plurality of adjacent cells of the knitted net layer, wherein the second net region comprises one or more second cells of the plurality of adjacent cells of the knitted net layer, wherein the one or more first cells in the first net region are larger than the one or more second cells in the second net region. 
     
     
         12 . The article of  claim 1 , wherein the article is an upper for an article of footwear, and wherein the knitted net layer extends from a bite line of the article of footwear to a throat area of the article of footwear. 
     
     
         13 . An article of footwear, comprising:
 a knitted component forming an upper of the article of footwear, the knitted component comprising:
 a knitted base layer comprising at least a first yarn, the knitted base layer having a first elasticity; and 
 a first knitted net layer comprising at least a second yarn, the first knitted net layer having a second elasticity and a first plurality of adjacent cells forming a pattern, each cell of the first plurality of adjacent cells having a plurality of corners defined by portions of the second yarn being intertwined with one another; 
 wherein the first elasticity of the knitted base layer is greater than the second elasticity of the first knitted net layer, 
 wherein the first knitted net layer overlaps a first portion of a surface of the knitted base layer in a first zone of the knitted component, 
 wherein the first knitted net layer is secured to the knitted base layer with a plurality of tie-down portions formed from the first yarn of the knitted base layer, and 
 wherein the plurality of tie-down portions are located at every corner of the plurality of corners of each cell of the plurality of adjacent cells of the first knitted net layer. 
   
     
     
         14 . The article of footwear of  claim 13 , wherein the first yarn comprises a first characteristic different than a second characteristic of the second yarn. 
     
     
         15 . The article of footwear of  claim 13 , wherein the first zone further comprises a second knitted net layer that overlaps the first knitted net layer, wherein a second plurality of adjacent cells of the second knitted net layer are offset from the first plurality of adjacent cells of the first knitted net layer. 
     
     
         16 . The article of footwear of  claim 13 , wherein the first knitted net layer further overlaps a second portion of the surface of the knitted base layer in a second zone of the knitted component, wherein the second zone is knitted continuously with the first zone on one side of the first zone. 
     
     
         17 . The article of footwear of  claim 16 , wherein a second degree of elongation of the second zone of the knitted component is at least 5% greater than a first degree of elongation of the first zone of the knitted component. 
     
     
         18 . The article of footwear of  claim 17 , wherein the knitted base layer comprises a third portion in a third zone of the knitted component, wherein the third zone is knitted continuously with the first zone on an opposite side of the first zone. 
     
     
         19 . The article of footwear of  claim 18 , wherein the third zone comprises a third degree of elongation, wherein the third degree of elongation is at least 20% greater than the first degree of elongation. 
     
     
         20 . An article comprising a knitted component, comprising:
 a knitted base layer; and   an open-meshed knitted layer that is coextensive with at least a portion of the knitted base layer,   wherein the open-meshed knitted layer is disposed on one side of the knitted base layer,   wherein the knitted base layer comprises a first stitch density, wherein the open-meshed knitted layer comprises a second stitch density,   wherein the first stitch density is greater than the second stitch density,   wherein the open-meshed knitted layer comprises a plurality of adjacent cells each having two or more corners defined by portions of a second yarn being intertwined with one another,   wherein the open-meshed knitted layer is secured to the knitted base layer with a plurality of tie-down portions, the plurality of tie-down portions comprising one or more knitted loops formed using a first yarn of the knitted base layer, and   wherein the plurality of tie-down portions are located at each corner of the two or more corners.