Interlaced knitted upper and methods of manufacture

Abstract

Aspects herein are direct to, among other things, a knitted component, which may be incorporated into an upper for an article of footwear. The knitted component includes two interconnected knit structures. A first knit structure may form loops on a first set of wales and float across a second set of wales. A second knit structure may float across the first set of wales and form knit loops, tuck stitches, and held loops on the second set of wales. The two structures are not interlooped together, but are interconnected where the first yarn alternatively passes in front of and behind the second yarn. The first structure may be formed from a first yarn and the second structure may be formed from a second yarn, where the first yarn and the second yarn have different tenacities. The knit structures may incorporate various yarn types, knit stitch patterns, and/or constructions.

1 . A knitted component comprising:
 a first knit structure comprising a first yarn forming knit loops on a first set of wales and floating across a second set of wales;   a second knit structure comprising a second yarn floating across the first set of wales and forming knit loops, tuck loops, and held loops on the second set of wales;   wherein the first yarn and second yard have different tenacities; and   wherein the first knit structure and the second knit structure are interconnected in at least a portion of the knitted component where the first yarn alternatively passes in front of and behind the second yarn, the first yarn and the second yarn are not interlooped together in at least the first and second sets of wales within the portion.   
     
     
         2 . The knitted component of  claim 1 , wherein the second set of wales includes a first subset of wales and a second subset of wales, wherein along a first set of courses of the second knit structure, the second yarn forms knit loops on the first subset of wales and forms tuck loops and held loops on the second subset of wales, wherein the second set of wales comprises the third set of wales and the fourth set of wales. 
     
     
         3 . The knitted component of  claim 2 , wherein along a second set of courses of the second knit structure, the second yarn forms tuck loops and held loops on the first subset of wales and knit loops on the second subset of wales. 
     
     
         4 . The knitted component of  claim 1 , wherein the second yarn has a greater tenacity than the first yarn. 
     
     
         5 . The knitted component of  claim 1 , wherein the second yarn has a tenacity greater than 5 g/denier. 
     
     
         6 . The knitted component of  claim 1 , wherein the first yarn has a tenacity less than 5 g/denier. 
     
     
         7 . The knitted component of  claim 1 , wherein the first yarn is a monofilament yarn and the second yarn is a multi-filament yarn. 
     
     
         8 . The knitted component of  claim 1 , wherein at least over the first and second sets of wales in the portion, the knitted component is a single knit jersey structure. 
     
     
         9 . The knitted component of  claim 1 , wherein the knitted component includes a tensile strand inlaid within a third knit structure. 
     
     
         10 . The knitted component of  claim 9 , wherein the third knit structure is a double knit structure where the tensile strand is inlaid. 
     
     
         11 . The knitted component of  claim 10 , wherein the third knit structure includes a yarn comprising elastane forming at least part of the double knit structure. 
     
     
         12 . An article of footwear comprising an upper with the knitted component of  claim 1 . 
     
     
         13 . A knitted component, comprising:
 a first yarn knitted into knit loops and floats extending in a first direction;   a second yarn knitted into knit loops and floats extending in a second direction that is different that the first direction;   the first yarn and the second yarn are knit along a plurality of courses comprising a plurality of adjacent wales, wherein each wale within the plurality of adjacent wales comprises at least one float that is formed by one of the first yarn or the second yarn;   wherein at least a portion of the floats of the second yarn traverse at least two courses; and   wherein the first yarn and second yard have different tenacities.   
     
     
         14 . The knitted component of  claim 13 , wherein a first set of floats of the second yarn each extend between two adjacent courses and a second set of floats of the second yarn each extend between two courses that are separated by a third course. 
     
     
         15 . The knitted component of  claim 14 , wherein the second yarn has a greater tenacity of the first yarn. 
     
     
         16 . The knitted component of  claim 13 , wherein the first direction of the floats of the first yarn is a course-wise direction, and the second direction of the floats of the second yarn is in a direction other than the course-wise direction or a wale-wise direction. 
     
     
         17 . The knitted component of  claim 13 , wherein the knitted component has a first side and a second side, the floats of the first yarn and the floats of the second yarn each positioned on the first side. 
     
     
         18 . An article of footwear comprising an upper with the knitted component of  claim 13 . 
     
     
         19 . A method for manufacturing a knitted component, the method comprising:
 knitting, on a single needle bed of a knitting machine, a plurality of courses each having a first yarn and a second yarn having a different tenacity than the first yarn, knitting the plurality of courses comprises:   knitting the first yarn to form knit loops over a first set of needles and floating the first yarn over a second set of needles that are interspersed with the first set of needles along the single needle bed,   knitting the second yarn to form knit loops on the second set of needles and floating over the first set of needles, wherein some of the knit loops of the second yarn that are knit on the second set of needles are released from the respective needle and some of the knit loops of the second yarn are held on the respective needle to be released in a subsequent course.   
     
     
         20 . The method of  claim 19 , wherein the first set of needles comprise every other needle on the single needle bed. 
     
     
         21 . The knitted component of  claim 19 , wherein the second yarn has a greater tenacity than the first yarn. 
     
     
         22 . The knitted component of  claim 19  wherein the first yarn follows a knit loop-float stitch pattern with each pass of a feeder of the first yarn, and the second yarn follows a tuck stitch-float pattern with each pass of a feeder of the second yarn. 
     
     
         23 . The knitted component of  claim 1 , wherein the first yarn is a monofilament yarn and the second yarn is an elasticated yarn. 
     
     
         24 . The knitted component of  claim 1 , wherein the first yarn is an ultra-high molecular weight polyethylene yarn and the second yarn is a thermoplastic yarn. 
     
     
         25 . The knitted component of  claim 1 , wherein the first yarn is a monofilament yarn and the second yarn is a chenille yarn.